EIL Tender Doc For HPCL Lift PDF

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Table of Contents
Document Number Rev. Document Title Page
Number
A133-086-LZ-MR- 0 ENQUIRY DOCUMENT 2
4140-1005-RFQ
A133-086-LZ-MR- A COKE DRUM STRUCTURE ELEVA TOR (LIFT) (HAZARDOUS 322
4140 AREA)
A133-086-16-44-CL- A A133-086-16-44-CL-4140 327
4140
A133-086-16-44-SP- A JOB SPECIFICATIONS FOR COKE DRUM STRUCTURE 335
4140 ELEVATOR
44NC-4600-0086- A PMC'S JOB SPECIFICATION FOR LIFT 343
M02-0023-A4
A133-086-16-44-DS- A DATA SHEET FOR COKE DRUM STRUCTURE ELEVATOR 352
4140
A133-086-16-44-VR- A VENDOR DATA REQUIREMENTS 358
4140
Annexure-1 to A Annexure-1 to Vendor data requirement 361
Vendor data
requirement
PMC A PMC'S SPECIFICATION FOR SITE HSE 381
SPECIFICATION
FOR SITE HSE
44NC-4600-0000- 1 General Specification for Shop and Field painting 482
V.02-0111-A4
General Specification
for Painting
A133-086-16-50-SP- A JOB SPECIFICATION 527
4140
A133-086-16-50-DS- A DATA SHEET FOR MV MOTOR 536
4140
A133-086-16-50-DS- A DATA SHEET FOR VFD 540
4141
A133-086-16-50-DS- A ELECTRICAL LOAD DATA 545
4142
A133-086-16-50-VR- A VENDOR DATA REQUIREMENTS 547
4140
44NC4600ESS001A 0 LV INDUCTION MOTORS 551
44NC4600ESS008 0 MEDIUM AND HIGH VOLTAGE HEAVY DUTY CABLES 566
44NC4600ESS026 0 ELECTRICAL INSTALLATION 574
44NC4600ESS027 0 ELECTRICAL CONTENT OF PACKAGE UNIT 607
44NC4600ESS031 0 AC VARIABLE SPEED DRIVE SYSTEM 618
44NC4600ESS067 0 FLAMEPROOF DISTRIBUTION 633
PANEL,PLUGS,SOCKETS,LAMPS AND LIGHT FITTINGS FOR
HAZARDOUS LOCATIONS
44NC4600ITP001A 0 ITP FOR LV MOTORS 642
44NC4600ITP008 0 ITP FOR MV/HV HEAVY DUTY CABLES 644
44NC4600ITP031 0 ITP FOR AC/DC DRIVES 647
44NC- 4 VENDOR LIST 649
4600R010005A4
Page 1 of 674
0Regd. Office: Engineers India Bhawan, 1-Bhikaiji Cama Place, New Delhi-110066, India
Phone No. : 00 91 11 26762121 ; Fax No. : 00 91 11 26191714, 26167664
REQUEST FOR QUOTATION (RFQ)-(INDIGENOUS / FOREIGN / GLOBAL)
(e-Tendering)
* Ref.: RC/A133-086-LZ-MR-4140/1005 Date: 23-SEP-2013

M/s Client Chennai Petrochemical Corporation Limited
The Suppliers to whom this RFQ
is issued are only required to Project Coker Block of Resid Upgradation Project at Manali
quote. Refinery, Chennai
RFQ No. RC/A133-086-LZ-MR-4140/1005
Item COKE DRUM STRUCTURE ELEVATOR ( LIFT )
( HAZARDOUS AREA )
Category II
Due Date 17-Oct-2013 [Up to 1200 Hrs. (IST)]
UNPRICED / COMPOSITE BID At 1400 Hrs.(IST) on final bid due date
OPENING: (In case the bid due date happens to fall on Holiday, the next working
day shall be deemed to be due date)
PRE-BID MEETING At 1100 HRS. (IST) on 01-Oct-2013 (at Business Centre, EI

Bhawan, Bhikaiji Cama Place, R.K. Puram, New Delhi-110066).
PRICED BID OPENING : TIME & VENUE SHALL BE INTIMATED LATER
Gentlemen,
1. Chennai Petroleum Corporation Limited (CPCL), a subsidiary of Indian Oil Corporation Limited has
existing Refinery Facilities at Manali, Chennai, Tamilnadu (India). The present capacity of CPCL at Manali
Refinery is 9.5 MMTPA. CPCL is currently implementing a Revamp of existing units to increase the crude
processing capacity by 1 MMTPA to take the overall complex capacity to 10.5 MMTPA unit.
Chennai Petroleum Corporation Limited (CPCL) has awarded the work of Resid Upgradation Project-Coker
Block to Engineers India Limited (EIL) and EIL is the CONTRACTOR for this Project.
2. Bids are requested for the captioned item in complete accordance with enquiry documents/attachments.
3. The complete RFQ can be downloaded from the EIL website (http://tenders.eil.co.in or e-tender site of EIL's
ASP (Authorized service provider) https://www.tenderwizard.com/eil or from CPP portal
http://eprocure.gov.in/cppp.
4. Bidders are requested to submit e-bids in e-tendering portal (https://www.tenderwizard.com/eil) in

accordance with the instructions and terms & conditions enclosed with this RFQ Covering letter.
Bids should be submitted separately in two parts as follows:
Part-I: UNPRICED BID : The techno-commercial Part consisting of following:
i) Offer Covering letter (in bidders letter head)

ii) Techno-commercial compliance to the RFQ terms & Conditions.
RFQ NO. RC/A133-086-LZ-MR-4140/008 Page 1 of 8

Page 2 of 674
iii) Duly filled-in, signed & stamped Annexure I to Prefilled ATC giving basic details on
transportation charges, taxes/ duties etc.
iv) Bank Certified Mandate Form as per Annexure-II to Prefilled ATC, duly signed and
stamped with the Bankers certification alongwith cancelled cheque ( applicable for
Indigenous Supplier only )
v) Unpriced copy of Price Schedule format ( Format A, B, C1, C2, D1 & D2 ) ( Excel
file ) available on https://www.tenderwizard.com/eil (Indicating Q in place of prices).
Format A, C1 & D1 are applicable for Indigenous supply whereas,
Format B, C2 & D2 are applicable for Foreign supply.
vi) Latest Audited Balance Sheet.
vii) Fresh Solvency Certificate, Date of issue of this certificate should not be earlier than 1
year from the date of Opening of Techno-commercial part.
viii) Integrity Pact ( Refer Note (d) and Clause # 32 for Instructions )
ix) Concurrent Commitment, in the format enclosed with RFQ
x) Technical Compliance/ datasheets/ documents, required as per RFQ Document
Part-II: PRICED BID
Containing only prices filled in the prescribed price schedule excel format and other formats provided
in the RFQ Document, consisting of the following:
i) Prices in Price Schedule Format ( Format A, B, C1, C2, D1 & D2 ) ( Excel file )
available on https://www.tenderwizard.com/eil
Format A, C1 & D1 are applicable for Indigenous supply whereas,
Format B, C2 & D2 are applicable for Foreign supply.
Note:
a) Bidders are required to have a VALID digital signature of class III B issued by C.C.A. (Controller
of certifying authority, India) for participation in e-tendering.
b) A Ready Reckoner for e-tendering is available on e-tendering website

(https://www.tenderwizard.com/eil) under the Link Latest Format/Circular/Manual. Bidders to
click on the link to download the same. Bidders to follow the instructions given in the same for
uploading their e-bids in e-tendering website.
c) Deviations to terms and conditions, presumptions etc shall not be stipulated in Price part of bid
and price bids shall not contain any stapled slips. In case of any conditions stipulated in price
bids or the price bid containing any stapled slips, the bids of such bidders shall be summarily
rejected and shall not be considered for further evaluation. Evaluation shall be carried out
excluding such bidder(s.)
d) In addition to uploading the Integrity Pact on the e-tendering website, the same shall also be
submitted in Original physical form within the final bid due date & time indicated above.
In case the bidder fails to submit the Integrity Pact in original physical form within the
final bid due date & time, his bid shall be rejected, irrespective of their status/ ranking in
tender and notwithstanding the fact that a copy of the same was earlier uploaded by the
bidder.
5. Bids complete in all respects should be successfully Submitted online on or before the bid due date and
time specified above.

Page 3 of 674
6. Offers received through Fax / Telex / Telegraphic / E-Mail / hard form (other than the documents
specifically required in hard form) shall not be considered.
7. Technical specifications should be strictly as per the material requisition attached.
8. EIL will open the bids received online at their office, at the specified date and time given in the RFQ or
extended date, if any.
The bidders who have submitted their bid will be able to view online the name & status of all the bidders at
their respective windows, after unpriced bid opening by EIL.
Similarly, all technically and commercially acceptable bidders will be advised of date and time of online
priced bid opening. Aforesaid Bidders, will be able to view online the price sheets of other techno-
commercially acceptable bidders at their respective windows, after priced bid opening by EIL.
9. As Purchaser intends to contract directly with suppliers of the goods for which bids are invited, the bids
should be prepared by the suppliers and submitted directly. Purchaser reserves the right to reject offers
made by intermediaries.
10. Please furnish your response to our RFQ either through EILs website http://tenders.eil.co.in or by sending
email/fax to EIL as per Proforma of Reply/ Acknowledgement Letter enclosed, on or before the date of pre-bid
meeting/ at the pre-bid meeting.
If not bidding, please return/delete enquiry documents and as well as furnish regret letter with reason(s) of not
participating in the RFQ.
The bidders should respond to this enquiry either by submitting their bids or by explaining the reason for non-
submission of the offer. In case there is no response either way continuously, the bidder shall be liable
for suitable action including review of their enlistment with EIL for that particular item.
11. The bidder shall bear all costs associated with the preparation and submission of its bid, and the Purchaser
shall in no case be responsible or liable for these costs regardless of the conduct or outcome of the bidding
process.
12. Bidders who are enlisted with EIL are required to quote as per their capabilities registered with EIL.
13. EIL reserves the right to use in-house information for assessment of bidders capability for consideration of
bid.
14. EIL reserve the right to make any changes in the terms and conditions of purchase and to reject any or all
the bids.
15. The order, if placed will be issued by EIL.
16. Net Worth of the Bidder shall be positive as per the immediate preceding years Audited financial results.
Bidder is therefore requested to furnish the latest Audited Financial Statement including Profit & Loss
Account.
In case, the bidders Net Worth is negative, their bid shall not be evaluated further. However this
criteria will not be applicable for Indian Central Public Sector Undertaking/Enterprises.
17. Purchaser reserves the right to allow purchase preference to Central Public Sector
Undertakings/enterprises, as admissible under prevailing policy of Government of India.
18. Preference to MSEs

Deleted (Not Applicable)
19. In case any bidder is found to be involved in cartel formation, his bid will not be considered for evaluation /
placement of order. Such bidder will also be debarred from bidding in future.

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20. In case a supplier seeks any suo-moto price increase subsequent to the bid due date and which is not as a
result of any change in scope of supply or terms and conditions, the bid of such a supplier shall be rejected
for the items in which such suo-moto increase is sought.
21. FRAUDULENT PRACTICES
The Owner requires that Bidders/ Vendors/ Contractors observe the highest standard of ethics during the
award/ execution of Contract. "Fraudulent Practice" means a misrepresentation of facts in order to
influence the award of a Contract to the detriment of the Owner, and includes collusive practice among
bidders (prior to or after bid submission) designed to establish bid prices at artificial non-competitive levels
and to deprive the owner of the benefits of free and open competition.
a) The owner will reject a proposal for award if it determines that the bidder recommended for award has
engaged in fraudulent practices in competing for the Contract in question.
Bidder is required to furnish the complete and correct information/ documents required for evaluation
of their bids. If the information/ documents forming basis of evaluation is found to be false/ forged, the
same shall be considered adequate ground for rejection of bids and forfeiture of Earnest Money
Deposit.
b) In case, the information/ document furnished by the Bidder/ Vendor/ Contractor forming basis of
evaluation of his bid is found to be false/ forged after the award of the contract, Owner shall have full
right to terminate the contract and get the remaining job executed at the risk & cost of such Bidder/
Vendor/ Contractor without any prejudice to other rights available to Owner under the contract such as
forfeiture of CPBG/ Security Deposit, withholding of payment etc
c) Incase, this issue of submission of false documents comes to the notice after execution of work,
Owner shall have full right to forfeit any amount due to the Bidder/ Vendor/ Contractor along with
forfeiture of CPBG/ Security Deposit furnished by the bidder/vendor/ contractor.
d) Further, such bidder/ vendor/ contractor shall be put on Blacklist/ Holiday/ Negative List of owner
debarring them from future business with Owner for a time period, as per the prevailing policy in EIL.
22. Submission of authentic documents is the prime responsibility of the bidder. Wherever EIL has concern or
apprehension regarding the authenticity/correctness of any document, EIL reserves a right of getting the
document cross verified from the document issuing authority.
23. SPECIAL INSTRUCTIONS TO FOREIGN BIDDERS
a) The bidder must ascertain and confirm along with supporting documents in the bid, if any Customs
Duty exemption / waiver is applicable to the products being supplied by him under any multi-lateral /
bi-lateral trade agreement between India and bidder's country.
b) The bidder shall be liable to provide all documentation to ensure availment of the exemption / waiver.
In case' the bidder defaults on this due to any reason, whatsoever, he shall be liable to bear the
incremental Customs Duty applicable, if any.
c) Any Customs Duty applicability on account of any change in the bi-lateral / multi-lateral agreement
shall be to bidder's account.
d) Documentation to be furnished for availing the exemption / waiver of Customs Duty shall be
specifically listed in the Letter of Credit also as the pre-requisite for release of payment against
shipping documents and this documentation shall necessarily form a part of shipping documents

Page 5 of 674
e) COMPLIANCE TO REQUIREMENT OF PAN NO. , TAX RESIDENCY CERTIFICATE AND FORM
NO.10F
It is mandatory for the foreign supplier/contractor/consultant to furnish the following information in

case his receipts are subject to tax deduction at source in India:
i) PAN No.
As per the Indian Income Tax requirements failing which the Supplier/Contractor/Consultant
shall be responsible for any additional tax deduction at source as per the provisions of the Indian
Income Tax Act/Rules and the same shall be deducted from the payment made to
supplier/contractor/consultant
ii) Tax Residency Certificate (TRC)

TRC containing prescribed particulars as per the enclosed Annexure-A from the Government of
foreign country in order to claim the benefits of DTAA as per the Indian Income Tax
requirements failing which the relief under DTAA will not be available and consequently the
higher rate of withholding tax @25% will be applicable and deducted from the payment made to
supplier/contractor/consultant (i.e., non-resident taxpayer). The TRC shall be duly verified by the
Government of the country of which the assessee claims to be a resident for the purposes of tax.
iii) Form 10F

In additional to TRC, bidder in order to claim the benefits of DTAA shall also submit additional
information in form no. 10F (enclosed as Annexure-A). Form 10F has to be signed & verified by
the assessee himself.
If some information is already contained in TRC, the bidder shall not be required to provide that
information in Form no. 10F but even then Form no. 10F is required to be provided by the bidder.
However, the bidder may write Not Applicable in the relevant column in case that information is
already contained in TRC.
The above shall be furnished before release of any payment or within one month of the release
of Order, whichever is earlier.
Failing submission of the above information, any additional tax liability on purchaser, will be
deducted from the payment due to the supplier.
24. SHIFTING OF ORDER
25. CLARIFICATION REQUESTS FROM BIDDERS

A bidder may seek clarification regarding the bidding document provisions, bidding process and / or
rejection of his bid. EIL shall respond to such requests with in a reasonable time.
26. SETTLEMENT OF DISPUTE BETWEEN CPSEs OR CPSEs & GOVERNMENT DEPARTMENTS
27. PRE-BID MEETING

Bidders authorized representative(s), shall attend the Pre-Bid meeting on the prescribed day at the given
venue. During the Pre-Bid meeting, all the technical and commercial issues shall be discussed and
concluded to ensure that the bid received subsequent to Pre-Bid meeting shall be without any deviations to
terms and conditions. Hence, bidders shall treat the Pre-Bid meeting as utmost important and depute
competent & senior person capable of taking on the spot decision to sort out all the technical and
commercial issues.

Page 6 of 674
However, in case any bidder do not attend the Pre- Bid meeting, it shall be understood that the bidder has a
clear understanding of the scope & terms & conditions of the bidding document and does not have any
comments/ deviations to the requirements of the bidding document
In order to ensure fruitful discussions during pre bid meeting, the bidder is requested to submit any
Queries/clarification/information pertaining to Bidding document in writing delivered by hand or by fax/ email
as per format enclosed in the Bidding Document so as to reach two days prior to Pre-bid meeting.
These queries shall be replied during pre-bid meeting. The editable soft copies of the queries shall also
be e-mailed to enable EIL to prepare replies to the queries against each query in the same format
expeditiously.
The bidders are required to participate in the Pre-Bid meeting with the following essential documents, so
that the same can reviewed & discussed during the meeting to avoid any techno-commercial clarifications/
discussions post bid
a) Latest annual report including Profit & loss account

b) Solvency certificate from bank
c) Concurrent Commitment
d) Details of work experience meeting the BQC (if applicable)
e) Technical details, documents, design, filled datasheets as per MR.
f) Any other relevant document/ details.
Record notes of meeting, including the questions raised and the responses given will be furnished as
expeditiously as possible to all the bidders and shall also be uploaded on the website. After pre-bid
meeting, no further queries will be entertained from the bidders.
Any modification of the Bidding Document, which may become necessary as a result of the pre-bid
discussion shall be intimated to all bidders through the issue of an Addendum/Amendment.
Based on the pre-bid discussions, a no-deviation form/techno-commercial compliance shall be signed
and submitted by the bidders as part of their offer. After pre-bid meeting, no deviation shall be accepted
and if any deviation is found in the bid of such bidder, their offer shall be liable to be rejected without
raising any technical/ commercial queries.
Technical/ Commercial queries shall not be issued once the bid have been opened. However,
wherever CQ/ TQ are unavoidable, the same shall be raised only once and the cut-off date given for
CQ/ TQ replies shall be adhered to. Offers shall be evaluated based on the information available upto
cut-off date for CQ/ TQ replies.
Extension in bid due date shall not generally be granted.
28. REVERSE AUCTION

EIL reserves the right to go in for reverse auction among the technically and commercially acceptable
bidders. The decision to conduct reverse auction or not, will be conveyed to short listed bidders prior to
opening of price bid. In view of this, the bidders must quote most competitive prices in the first instance
itself.
The methodology and terms & conditions applicable for reverse auctioning shall be as per Appendix-A to
ITB, document titled Methodology and terms & conditions for Reverse Auction , enclosed with this RFQ.
29. OFFER VALIDITY

03 ( Three ) Months from the date final / extended bid due date.

Page 7 of 674
30. PAYMENT TERMS
Indigenous Supplier:
For Supply (excluding Mandatory Spares): As per clause No. 1.1.1 (v) of Instruction to Bidders
For Mandatory spares : As per clause No. 1.1.2 of Instruction to Bidders.
For Site Work : As per clause No. 1.1.3 of Instruction to Bidders.
For other scope: As per Instruction to Bidders
Foreign Supplier:
For Supply (excluding Mandatory Spares): As per clause No. 1.2.1 (v) of Instruction to Bidders.
For Mandatory spares : As per clause No. 1.2.2 of Instruction to Bidders.
For Site Work : As per clause No. 1.2.3 of Instruction to Bidders.
For other scope: As per Instruction to Bidders.
31. Delivery/Completion Period :
Supply :
Indigenous Supplier:
13 ( Thirteen ) Months on FOT Despatch point on freight to pay basis. The date of LR/GR shall be
considered as the date of delivery.
Foreign Supplier:
12 ( Twelve ) Months on FOB international sea port of exit basis. The Date of On Board Bill of Lading shall
be considered as date of Delivery.
Site Work:
( For both Indigenous & Foreign Suppliers )
Completion of site activities as per MR within 03 ( Three) months from the date of site readiness.
01 ( One) Month advance intimation regarding site readiness shall be given to bidder for Mobilization
purpose.
Date of handing over of the equipment at site after completion of site work as per MR/ PR shall be date of
completion period of site work
32. PRICE REDUCTION SCHEDULE
As per clause No. 12.2 & 12.3 of Instruction to Bidders.

Page 8 of 674
33. INTEGRITY PACT
The attached copy of the Integrity Pact shall be included in the Bid submitted by the bidder (to be executed
by the bidder for all RFQ of value Rs. 5 (Five) crore and above). In case a bidder does not sign the Integrity
Pact, his bid shall be liable for rejection.
INDEPENDENT EXTRNAL MONITORS (IEMS)
The following two Independent External Monitors (IEMs) have been appointed by EIL, in terms of Integrity
Pact (IP) which forms part of EIL Tenders / Contracts.
i) Dr. U. K. Sen
C-162, Belvedere Park,
DLF Phase 3, Gurgoan-122002
(email : uksen@hotmail.com)
ii) Shri P. R. Balasubramanian

th st
229, 9 A Main, 1 Block,
HRBR Layout, Kalyan Nagar,
Bangalore-560043
(email : prbalasubramanian@gmail.com)
34. Contact Persons for this RFQ are:
Ms. Rekha ChoudharyAsst.General Manager(C&P)Phone:91-11-26763457, r.choudhary@eil.co.in

Mr. Rachit Jain Sr. Engineer (C&P) Phone : 91-11-2676 2427, rachit.jain@eil.co.in
* Please specify Ref. No. (i.e. RFQ No.) in all correspondence
THIS IS NOT AN ORDER Very truly yours,
(REKHA CHOUDHARY)
Asst. General Manager (C&P)
Enclosures : Refer Page 8 of 8

Page 9 of 674
Enclosures :
Reply/ Acknowledgement letter

Proforma of Letter of Authority Rev.0
Instructions to Bidders for e-Tendering
Techno-commercial of RFQ Requirement
Exceptions and Deviations (Commercial)
Format for Present/ Concurrent Commitments
Format for Bidders Pre-bid Queries
Annexure A : Particulars required for Tax Residency Certificate (TRC) & Form 10F
Price Schedule Format available on e-tendering portal (www.tenderwizard.com/EIL) :
Format A ( for Indigenous Supply )
Format B ( for Foreign Supply )
Format C1 ( for Indigenous Supply of 2 Years O & M Spares)

Format C2 ( for Foreign Supply of 2 Years O & M Spares )
Format D1 ( for Indigenous Unit Rates for Addition / Deletion)

Format D2 ( for Foreign Unit Rates for Addition / Deletion)
Standard Commercial Documents Containing:

Instructions to Bidders (ITB)
Appendix-A to ITB : Methodology and terms & conditions for Reverse Auction
Agreed Terms & Conditions ( ATC) (Respectively for Indian and Foreign Bidder)
General Purchase Conditions (GPC) (Respectively for Indian and Foreign Bidder)
Packing, Marking, Shipping And Documentation Specification( Respectively for Indigenous &
Foreign materials : enclosed with respective GPC )
Proformae of Bank Guarantee for Advance. ( ABG) (attached with respective GPCs)
Proformae of Bank Guarantee for Performance. ( PBG ) (attached with respective GPCs)
Terms & Conditions For Installation/Site Work ( T & C Site Work)
Specification For Health, Safety & Environment (HSE) management at DCU,CPCL ,Chennai
(SPECIFICATION No. A133-00-6-82-0001 Rev. 0 ) ( enclosed with T & C Site Work)
Contractor Safety-OISD-Guidelines-207 ( enclosed with T & C Site Work)
Safety Practices During Construction-OISD- Guidelines-192 ( enclosed with T & C Site Work)
Special Conditions Of Contract - Safety Regulation - 44NC-4600- EPCC-1 Rev 0
( enclosed with T & C Site Work)
Integrity Pact format
Material Requisition
MR No. A133-086-LZ-MR-4140 Rev. B

Page 10 of 674
REPLY/ACKNOWLEDGEMENT LETTER
FAX Nos. : 00-91-11-26191714, 26167664

SELF ADDRESSED FAX
(PLEASE REFAX TO EIL WITHIN TEN DAYS OF RECEIPT OF RFQ)
Engineers India Limited

Engineers India Bhawan,
EI Annexe, 2nd Floor,
1-Bhikaiji Cama Place,
New Delhi 110066
Attn. : Ms. Rekha Choudhary Asst. General Manager (C&P)

RFQ No. : RC/A133-086-LZ-MR-4140/1005
Item : COKE DRUM STRUCTURE ELEVATOR ( LIFT ) ( HAZARDOUS AREA )
Bid Due Date : 17-Oct-2013 [Up to 1200 Hrs. (IST)]
Project : Coker Block of Resid Upgradation Project at Manali Refinery of M/s CPCL, Chennai
Dear Sirs,
We acknowledge with thanks receipt of your above cited RFQ alongwith enclosures. We undertake
that the contents of the above RFQ shall be kept confidential including all the drawings,
specifications and documents and the said documents shall be used only for the purpose, for which
they are intended.
Further, our response is as under:- (Bidders to put a tick , as applicable).
1. We will submit the bid within due date.
2. We regret to submit our offer/quote because of the following reasons:
a. _____________________________________________________
b. _____________________________________________________
Thanking you,
Very truly yours,

Name of Bidder :
Bidders Address :
Contact Person :
Bidders Phone No. :
Bidders Fax No. :
Bidders E-mail No. :
Bidders Ref. No. & Date
Page 1 of 1
Page 11 of 674
PROFORMA OF LETTER OF AUTHORITY FOR ATTENDING PRE-BID CONFERENCE /
UNPRICED BID OPENING / AND PRICED BID OPENING
No. Date:
To,
ENGINEERS INDIA LIMITED
1, Bhikaiji Cama Place
R.K. Puram,
New Delhi 110066(India)
Attn . Ms. Rekha Choudhary, Asst. General Manager (C&P)
Dear Sirs,
We..hereby authorise following representatives (s) to attend the Pre-

Bid Meeting against your RFQ No.: . for Item
.
1. Name & Designation Signature ..
2. Name & Designation Signature
We confirm that we shall be bound by all and whatsoever our representative (s) shall commit.
Yours faithfully,
Signature
Name & Designation .
For & on behalf of .
Note :
This Letter of Authority should be on the letter head of the bidder and should be signed by a
person competent and having the power of attorney to bind the bidder.
Page 1 of 1
Page 12 of 674
INSTRUCTIONS TO BIDDERS FOR E-TENDERING
Bidders who wish to participate for RFQs/ Tenders which are uploaded on EILs Authorised service
providers website (i.e. www.tenderwizard.com/eil) should follow the following instructions which shall
permit them to Search, View, Download and Submit their Electronic Bids online in a secure manner ensuring
confidentiality. These Instructions for E-Tendering shall be read in conjunction with various instructions,
wherever appearing with the RFQ/ Bidding Document. The conditions & instructions mentioned here in under
shall supersede and shall prevail over the conditions & instructions enumerated elsewhere in the RFQ/ Bidding
Document.
1) PARTICIPATION IN E-TENDERING, REQUEST FOR USER ID and PASSWORD:
To participate in E-Tendering, it is Mandatory to the Bidders have a user id and password on e-tendering
portal. Bidders are required to be registered on E-Tendering website to obtain user id & password
(password will be system generated). However for the tenders issued on limited basis, bidders are already
registered by EIL and after their registered, user id & password were communicated to bidders at their e-
mail id available in EIL. The bidders who are already registered may contact to concern person of EIL to get
their user id and password.
For tender issued on NIT/ Press advertisement basis, bidders are required to registered themselves by
using the link of registration provide on the home page of e-tendering website. The bidders are required to
fill the online registration form with all required details. The bidder should indicate correct information
including their e-mail since all system generated correspondences will be send on these e-mail ids. Digital
signature of class 3b individual or class 3 organization is a mandatory requirement for e-tendering, right
from log-in into the system. Hence, during registration, bidders shall fill the details of their digital Signature
(serial No.) to save time and avoid mapping of Digital Signature details to the bidders user ID at the bid
uploading stage. Otherwise, bidders are required to furnish their DC details to EIL for mapping the same to
their user id by Service provider. Once, the online registration form is submitted with all required field and
documents like pan card, registration or any other document of company, the system will generate the user
id and password for the bidder.
However, to use this user id, the bidders are required to get their user id enabled (activate) through
concerned engineer for the tender in EIL. Accordingly, after registration, bidder shall send a request to EIL
to activate their user id by providing user id and bid reference number.
Note : Bidders who are already registered in any earlier tender of EIL, need not to create new user id, as
the same user id can be used for all the tenders issued to them by EIL on this e-tendering portal.
User id and password are unique to each bidder and the bidder shall use the same to
view/download/participate in all e-tenders of EIL. Bidders are required to change the password during their
first login into the system. There will be single user id permission for each bidder in the system for their
company/Organization.
Bidders in their own interest are requested to register on e- tendering portal and upload/submit their bid
well in time. Bidders should avoid the last hour rush to the website for registration of user id & password,
enabling of user id and mapping of digital signature serial number etc. since this exercise require activities
from EIL & M/s Antares System (Service Provider) and needs time. In the event of failure in bidders
connectivity with EIL/Service Provider during the last few hours, bidder is likely to miss the deadline for bid
submission. Due date extension request due to above reason may not be entertained.
EIL/EILs ASP will not be responsible for any delay/ non-availability of USER ID or Password or any last
minute request for enabling /resetting the same by the Bidders.
Instructions To Bidders For E-Tendering Page 1 of 4

Page 13 of 674
2) TRAINING & FAMILIARIZATION WITH E-TENDERING SYSTEM
The bidder should familiarize themselves with the e-tendering system and understood all formalities related
to e-tendering including log-in, system settings, downloading & uploading procedures. The contact details
of the concerned representatives from ASP and other helpdesk no.
3) VIEW AND DO WNLOAD E-TENDER
Bidders must go to E-Tendering website www.tenderwizard.com/eil and log-in using their user-id, password
and digital signature.
However, the open tenders can be viewed/ downloaded from the link tender free view provided on the
home page the website, without being log-in into the system.
4) DIGITAL SIGNATURE
Bidders cannot submit e-bids without having valid Digital Signature. The Digital Signature shall be issued by
C.A. (Certifying Authority) in India, in the name of a person authorized for E- Tendering on behalf of his
Company.
FOREIGN BIDDERS SHALL ALSO HAVE TO OBTAIN DIGITAL SIGNATURE FROM CERTIFYING AUTHORITIES
IN INDIA AS APPROVED BY CCA. DIGITAL SIGNATURE OBTAINED FROM FOREIGN COUNTRIES ARE NOT
ACCEPTABLE.
Note: In terms of Indian I.T Act 2000, only a digitally signed document will be considered as a valid signed
document.
5) BID DOCUMENT FEE/ EARNEST MONEY DEPOSIT/ INTEGRITY PACT, IF APPLICABLE
Bidders are required to submit the Bid Document Fee, EMD (in the prescribed format), Integrity Pact, as
required as per RFQ in original as per the manner prescribed in the RFQ/ Bidding Document at the time of
bid submission in sealed envelope. However, bidders are required to upload the scanned copy of both Bid
Document fee as well as EMD on E- Tendering website along with the e-bid.
In case the bidder fails to submit the above in original physical form within the final bid due date & time,
his bid shall be rejected, irrespective of their status/ ranking in tender and notwithstanding the fact that a
copy of the same was earlier uploaded by the bidder.
Any bidder intends to modify their bid they should use MODIFY instead of WITHDRAW.
Caution : ONCE BID IS WITHDRAWN BY THE BIDDER WILLINGLY OR UNWILLINGLY , SYSTEM WILL
NOT ALLOW THEM TO RESUBMIT THEIR BID.
6) SUBMISSION OF BID :
Bidders are required to upload the bid along with all supporting documents & Priced part on the E-
Tendering website (www.tenderwizard.com/eil) only. However, documents required to be submitted
physically, viz., Bid Document Fee, EMD, etc., need to be submitted in a sealed envelope as per the
provisions of RFQ/ Bidding Document.
Bidders shall ensure that all the required documents are uploaded in time and failure to upload the same
before bid submission date & time is the sole responsibility of bidder. Under no circumstances, EIL shall
entertain any request for acceptance of bid documents in physical form or any other form, which are
required to be uploaded on E- Tendering Website.
Also bidders are suggested to check the uploaded documents to verify the uploaded documents are
opening correctly or not by clicking on the download link.

Page 14 of 674
The bidders needs to submit prices on-line strictly as per the Price Schedule format provided in our E-
Tender.
Bidders can submit their Bids on-line only after digitally signing the bid/documents with the Digital
Signatures used for log-in.
The Authenticity of above digital signatures may be verified through authorized CA after bid opening and in
case the digital signature is not authorized/valid, the bid will be rejected. Bidder shall be responsible for
ensuring the validity of digital signatures and proper usage of the same by responsible persons.
No Late Bids after due date & time shall be permitted in E-Tendering website. The system time (IST) being
displayed on the E-Tendering website shall be final and binding on bidder and bids have to be submitted by
bidders considering this time only and not the time as per their location / country. Bidder who intends to
change the bid already submitted may change/revise the same on or before the closing date & time of bid
submission.
No Manual Bids shall be permitted. The offers submitted through E-tendering website shall only be
considered for evaluation.
Note:
i. Bidders are advised in their own interest to ensure that bids are uploaded in E- tendering website
well before the closing date and time of bid submission.
ii. No bid can be modified after the dead line for submission of bids.
iii. EIL shall not be responsible for any failure on the part of the bidder to follow the instructions.
iv. Inadvertently, if a document is uploaded in E- tendering website by the bidders, such document
can be deleted/detach by the Bidder and a new/modified document can be uploaded digitally
signed within the bid due date & time.
v. Bidders are requested to upload small sized documents preferably (upto 5 MB) at a time to
facilitate easy uploading into E- Tendering website. EIL does not take any responsibility in case of
failure of the bidder to upload the documents within specified time of Bid submission. Bidder can
upload any number of documents each below 5 MB in size.
vi. Wherever, the bidders are asked to upload the required document in Mandatory folders, the
bidders must upload the required document only in the Mandatory folders and other documents
can be attached in general documents section.
vii. Any bidder intends to modify their bid they should use MODIFY instead of WITHDRAW.
viii. Caution : ONCE BID IS WITHDRAWN BY THE BIDDER WILLINGLY OR UNWILLINGLY , SYSTEM
WILL NOT ALLOW THEM TO RESUBMIT THEIR BID.
7) OPENING OF BIDS:
The unpriced bids shall be opened online, at the specified date and time given in the RFQ document or
extended otherwise. The price bids shall also be opened online on the date & time which will be informed
to all the techno-commercially qualified/ acceptable bidders in advance.
The bidders who have submitted their bid will be able to view online the name & status of all the bidders at
their respective windows, after unpriced bid opening by buyer. Similarly, the techno-commercially
acceptable bidders will be able to view online the price sheets of other techno-commercially acceptable
bidders (who qualify for the price bid only) at their respective windows, after priced bid opening by buyer.
Wherever the composite bids are invited, the composite bids shall be opened accordingly.

Page 15 of 674
8) LAST DATE FOR SUBMISSION / RECEIPT OF BIDS:
System does not allow for submission of bids beyond the deadline for bid submission. The system time
displayed on EILs ASP E-Tendering website shall be final and binding on the bidders for all purposes
pertaining to various events of the subject RFQ/ Bidding Document and no other time shall be taken into
cognizance.
9) GENERAL
i. The bidders may quote from their own offices/ place of their choice. Internet connectivity shall be
ensured by bidders on its own.
ii. Bidders agree to non-disclosure of trade information regarding the purchase, identity of EIL, bid
process, bid technology, bid documentation and bid details.
iii. EIL shall not have any liability to bidders for any interruption or delay in access to the site
irrespective of the cause.
iv. EIL shall not be responsible for any indirect / consequential losses / damages, including but not
limited to systems problems, inability to use the system, loss of electronic information, etc.
v. EIL decision on award of Contract shall be final and binding on all the Bidders.
vi. EIL reserves the right to prescribe different Security Devices for accessing and/or using E-
Tendering System or any part thereof, including but not limited to prescribing different Security
Device(s) for accessing and/or using different parts of E-Tendering System.
vii. EIL reserves the right to prescribe password(s) and Login ID(s) for the bidders and its
representatives as well as any combination and/or sequence of letters and/or numerals for the
password(s) and Login ID(s).
viii. The actions, failures, omissions and defaults of the bidder's representative(s) shall be construed
and be given legal effect as if they are the actions, failures, omissions and defaults of the bidder
and the bidder shall be fully responsible for all such matters.
ix. The bidder shall bear all costs and expenses in relation to its access and use of E-Tendering
System, including but not limited to the costs and expenses incurred in ensuring its continued
access and use of E-Tendering System.
x. EIL shall not be responsible or held liable under these Terms and Conditions for any loss or
damage that is caused to any party due to use or misuse of the E-Tendering System or breach, by
any party, of the Terms and Conditions mentioned herein.
xi. All Clarification/ correspondences including enabling of user ids, password re-set request, mapping
of DC details, etc, if any, will only be entertained from 0900 Hrs. (IST) to 1600 Hrs. (IST) only,
during the office working hours.
NOTE: A Ready Reckoner for e-tendering is available on e-tendering website (www.tenderwizard.com/eil)

under the Link Vendor Help. Bidders to click on the link Vendor Help- Detailed Help to downloading
the same. Bidders to follow the instructions given in the same for uploading their e-bids in e-tendering
website.

Page 16 of 674
Annexure-I to ITB for E-Tendering
Contact details of Authorized Service Provide (ASP)
ASP Name: M/s Antares Systems Limited, Bangalore
Address: # 24, 1st Floor, Sudha Complex

Near Havanoor Circle, 3rd Stage
4th Block, Basaveshwara Nagar
Bangalore - 560 079
Ph: 080-40482000
Fax No: +91-80-40482114
New Delhi Help Desk:

C-9, 1st Floor (Back Side)
New Krishna Park, Najafgarh Road, Vikaspuri
Near Janakpuri West Metro Station
New Delhi-110018
Ph No: 011-49424365
Fax No: +91-11-25618721
Contact Persons:
1. Mr. Santosh Srivastava
Contact no: 08800591739
Email: santoshkumar.s@antaressystems.com
2. Mr. Sachin
Contact no: 8401982112
Email: sachin.t@antaressystems.com
Help Desk Numbers:

1. Bangalore : 080-40482000
2. New Delhi : 011-49424365
08800 991865
3. Gujarat : 08401982112
Page 1 of 1
Page 17 of 674
TECHNO-COMMERCIAL COMPLIANCE TO BID REQUIREMENT
RFQ No. : RC/A133-086-LZ-MR-4140/1005

Item : COKE DRUM STRUCTURE ELEVATOR ( LIFT ) ( HAZARDOUS AREA )
Project : Coker Block of Resid Upgradation Project at Manali Refinery of M/s CPCL, Chennai
1. We hereby agree to fully comply with, abide by and accept without variation, deviation or
reservation all technical, commercial and other conditions whatsoever of the RFQ
documents and Amendment/ Addendum to the RFQ Documents, if any, for subject work
issued by Engineers India Limited.
2. We hereby further confirm that any terms and conditions other than required, if mentioned in our
bid, shall not be recognised and shall be treated as null and void.
3. Compliance to requirement Of PAN No. , Tax Residency Certificate(TRC) & Form No.10F
(APPLICABLE FOR FOREIGN SUPPLIERS ONLY)
In compliance to clause # 23.(e) of RFQ covering letter above, We hereby confirm to furnish the
following information in case his receipts are subject to tax deduction at source in India :
(i) PAN No.
(ii) Tax Residency Certificate (TRC)
(iii) Form 10F
The above information shall be furnished before release of any payment or within one month of the
release of Order, whichever is earlier. Failing submission of the above information, any additional tax
liability on purchaser, will be deducted from the payment due to the supplier.
SIGNATURE OF BIDDER : _______________________
NAME OF BIDDER : _______________________
COMPANY SEAL : _______________________
Page 1 of 1
Page 18 of 674
Page 19 of 674
Page 20 of 674
Page 21 of 674
ANNEXURE A DOC NO. A133-1841-WT REV 0
23.09.2013
( APPLICABLE FOR FOREIGN BIDDERS ONLY)
Particulars required for Tax Residency Certificate (TRC) & Form 10F
1. Particulars required for Tax Residency Certificate (TRC)
TRC containing prescribed particulars from the Government of foreign country is required to
be submitted in order to claim the benefits of DTAA as per the Indian Income Tax
requirements failing which the relief under DTAA will not be available and consequently the
higher rate of withholding tax @25% will be applicable and deducted from the payment made
to supplier/contractor/consultant (i.e., non-resident taxpayer). The TRC shall be duly verified
by the Government of the country of which the assessee claims to be a resident for the
purposes of tax.
TRC obtained by the Non-resident from Government of foreign country shall contain the
following particulars:
a. Name of the assessee;

b. Status (individual, company, firm etc.) of the assessee;
c. Nationality (in case of individual);
d. Country or specified territory of incorporation or registration (in case of others);
e. Assessee's tax identification number in the country or specified territory of residence
or in case no such number, then, a unique number on the basis of which the person
is identified by the Government of the country or the specified territory;
f. Residential status for the purposes of tax;
g. Period for which the certificate is applicable; and
h. Address of the applicant for the period for which the certificate is applicable.
2. Form 10F
In additional to TRC, bidder in order to claim the benefits of DTAA shall also submit additional
information in form no. 10F (enclosed). Form 10F has to be signed & verified by the assessee
himself.
If some information is already contained in TRC, the bidder shall not be required to provide
that information in Form no. 10F but even then Form no. 10F is required to be provided by
the bidder.
However, the bidder may write Not Applicable in the relevant column in case that information
is already contained in TRC.
Page 1 of 2
Page 22 of 674
ANNEXURE A DOC NO. A133-1841-WT REV 0
23.09.2013
( APPLICABLE FOR FOREIGN BIDDERS ONLY)
"FORM NO. 10F

[See sub-rule (1) of rule 21AB]
Information to be provided under sub-section (5) of section 90 or sub-section (5) of section 90A of the Income-
tax Act, 1961
1. ..................................... *son/daughter of Shri............................................... in the capacity of.....................................
. . . . (designation) do provide the following information, relevant to the previous year......................................................
. . . . *in my case/in the case of .................................................... for the purposes of sub-section (5) of * section
90/section 90A:
SI.No. Nature of information Details#

(i) Status (individual; company, firm etc.) of the assessee
(ii) Permanent Account Number (PAN) of the assessee if allotted
(iii) Nationality (in the case of an individual) or Country or specified territory of incorporation or
registration (in the case of others)
(iv) Assessee's tax identification number in the country or specified territory of residence and if
there is no such number, then, a unique number on the basis of which the person is identified by
the Government of the country or the specified territory of which the assessee claims to be a
resident
(v) Period for which the residential status as mentioned in the certificate referred to in sub-section
(4) of section 90 or sub-section (4) of section 90A is applicable
(vi) Address of the assessee in the country or territory outside India during the period for which the
certificate, mentioned in (v) above, is applicable
2. I have obtained a certificate to in sub-section (4) of section 90 of sub-section (4) of section 90A from the
Government of. (name of country or specified territory outside India)
Signature: ..........................................
Name: .........................................
Address: ..........................................
Permanent Account Number: ...............................................
Verification
I ......................................... do hereby declare that to the best of my knowledge and belief what is stated above is
correct complete and is truly stated.
Verified today the............................................. day of .............................
Signature of the person providing the information

Place: . .......................................
Notes :
1. *Delete whichever is not applicable.
2. #Write N.A. if the relevant information forms part of the certificate referred to in sub-section (4) of
section 90 or sub-section (4) of section 90A.
Page 2 of 2
Page 23 of 674
Document No.
INSTRUCTION TO BIDDERS (ITB) A133-01- ITB Rev. 0
[ CPCL LSTK ] 12.09.2013
Page 1
1 PAYMENT TERMS
1.1 FOR INDIGENOUS BIDDERS:
1.1.1 Supply:
(i) Where the MR is for supply of materials and there is no Vendor Data
requirement (VDR) specified in the MR:
- 90% against despatch documents directly to EIL on pro-rata basis together
with full taxes, duties and transportation charges and on submission of
Performance Bank Guarantee valid for the 3 (Three) Months beyond
guarantee period.
- 10% on receipt and acceptance of last consignment of materials at site and
and on submission of E1/E2 Form (wherever applicable).
(ii) Where the MR is for supply of materials and calls for Vendor Data
requirement: (Without site work):
- 5% against approval of drawings, wherever required (identified in
Purchase Requisition) at least in Code-2 and manufacturing Schedule.
.
- 80% (85% in cases where drawing approval is not required) against
despatch documents directly to EIL on prorate basis together with full
taxes, duties and transportation charges and on submission of Performance
Bank Guarantee valid for the 3 (Three) Months beyond guarantee period.
- 5% on receipt of Final/As built Drawings/Documents/Data/Manual in requisite

number of copies/sets/CDs as per VDR specified in Purchase Requisition.
- 10% on receipt and acceptance of goods/ materials at Site and on

submission of E1/E2 Form (wherever applicable).
(iii) Where the MR is for supply of materials and calls for Vendor Data
requirement: (With site work)
- 5% against approval of drawings, wherever required (identified in
Purchase Requisition) at least in Code-2 and manufacturing Schedule.
- 80% against dispatch documents directly to EIL on prorate basis together

guarantee period.
- 5% on receipt of Final/As built Drawings/Documents/Data/Manual in

requisite number of copies/sets/CDs as per VDR specified in Purchase
Requisition.
T&C FOR ED COMMITTEE APPL- LSTK-A133
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL- All rights reserved
Page 24 of 674
Document No.
[ CPCL LSTK ] 12.09.2013
Page 2
- 10%. on successful completion of Site Work and on submission of E1/E2

Form (wherever applicable).
Note: In case site is not available upto 6 (Six) months after receipt of all
supplies at site, the last 10% payment shall be released against submission
of additional Bank Guarantee of equivalent amount valid for 1 (One) year or
such extended period as may required.
(iv) Where the MR is for Packages (with significant Bought out item) and
calls for Vendor Data requirement: (Without site work)
- 5% on approval of drawings, wherever required (identified in Purchase
Requisition), in at least Code-2 and manufacturing schedule.
-10% against placement of sub-order for specified major raw material (to be
identified by PEM and PM before issue of enquiry) against submission of
equivalent Bank Guarantee.
- 70% against dispatch documents directly to EIL on prorate basis together with
full taxes, duties and transportation charges and on submission of
guarantee period.
- 5% on receipt of Final/As built Drawings/Documents/Data/Manual in requisite number

of copies/sets/CDs as per VDR specified in Purchase Requisition.
- 10% on receipt and acceptance of goods/ materials at Site and on

submission of E1/E2 Form (wherever applicable).
(v) Where the MR is for Packages (with significant Bought out item) and
calls for Vendor Data requirement: (With site work)
.
-10% against placement of sub-order for specified major raw material (to be
identified by PEM and PM before issue of enquiry) against submission of
equivalent Bank Guarantee.
full taxes, duties and transportation charges and on submission of Performance
Bank Guarantee valid for the 3 (Three) Months beyond guarantee period and
on submission of Performance Bank Guarantee valid for the 3 (Three) Months
beyond guarantee period.
Page 25 of 674
Document No.
[ CPCL LSTK ] 12.09.2013
Page 3
- 10% on successful completion of Site Work and on submission of E1/E2

Form (wherever applicable).
Note: In case site is not available up to 6 (Six) months after receipt of all
(vi) For Pumps, Compressors, Heat Exchangers, Columns and Vessels:

(Without site work)
- 15% against receipt and identification of specified major raw materials and
against submission of equivalent BG.
- 65% against dispatch documents directly to EIL on prorate basis together
Performance Bank Guarantee valid for 3 months beyond guarantee period
- 5% on receipt of Final/As built Drawings/Documents/Data/Manual in
Requisition.
- 10% on receipt and acceptance of goods/ materials at Site on submission of
E1/E2 Form (wherever applicable).
Major Raw Material for payment against receipt & identification of raw
materials:
Columns and Vessels Plates and Forgings
Heat Exchangers : Plates, Forgings and Tubes
Pumps : Castings
Compressors : Castings / Forgings
(vii) For Pumps, Compressors, Heat Exchangers, Columns and Vessels:

(With site work)
- 15% against receipt and identification of specified major raw materials and
against submission of equivalent BG..
full taxes, duties and transportation charges and on submission of Performance
Page 26 of 674
Document No.
[ CPCL LSTK ] 12.09.2013
Page 4
Bank Guarantee valid for 3 months beyond guarantee period

- 10% on successful completion of Site Work on submission of E1/E2 Form

(wherever applicable).
Note: In case site is not available upto 6 (Six) months after receipt of all supplies at
site, the last 10% payment shall be released against submission of additional Bank
Guarantee of equivalent amount valid for 1 (One) year or such extended period as
may required.
Major Raw Material for payment against receipt & identification of raw materials:
Columns and Vessels : Plates and Forgings
Heat Exchangers: Plates, Forgings and Tubes
Pumps : Castings
(viii) For all Site Fabricated Columns:

- 5% on approval of drawings, manufacturing schedule & QAP by TPIA.
- 15% after receipt of identified raw materials at fabrication yard and against
certification by TPIA against Hypothecation Bond.
- 50% on completion of fabrication in all respect, Third party inspection and

making completed column ready for hydro-testing.
- 10% after hydro-testing of completed column and against submission of

Performance Bank Guarantee for 10% of total order value valid for the
guarantee period plus 3 (Three) Months claim period.
- 20% after receipt of tax invoice along with taxes & duties and after submission of
final technical documentation and drawings as per Purchase Requisition and on
transportation of completed column from fabrication yard/ assembly yard to
erection site, delivery of column up to equipment foundation and handing over
to Engineer-in-charge at site.
Terms of Delivery shall be delivery of column up to equipment foundation and
handing over to Engineer-in-charge at site.
1.1.2 For supply of Mandatory Spares:

- 90% on dispatch of spares against direct delivery of dispatch documents to
PURCHASER.
- 10% on receipt and acceptance of materials at site and on submission of
EI/E2 FORM (wherever applicable).
1.1.3 Site Work:

Page 27 of 674
Document No.
[ CPCL LSTK ] 12.09.2013
Page 5
- 90% against monthly progressive bills (based on agreed billing schedule) duly
certified by Engineer-in-charge.
- 10% on successful completion of site work and handing over of

goods/equipment at site.
1.1.4 Supervision of Erection, Testing & Commissioning

- 100% prorate against monthly bills to be submitted by seller duly certified by
Engineer-in-Charge.
1.1.5 Training
- 100 % on successful completion of Training duly certified by PURCHASER,
as per Purchase Requisition.
1.1.6 Annual Maintenance Contract (AMC):

- 100% payment shall be paid at the end of each half year of the contractual
year against quarterly progressive bills to be submitted by seller duly certified
by Site-in-Charge.
1.2 FOR FOREIGN BIDDERS

1.2.1 Supply:
(i) Where the MR is for supply of materials and there is no Vendor Data
requirement (VDR) specified in the MR (Without Site Work):
- 100% against shipping documents through irrevocable Letter of Credit
(ii) Where the MR is for supply of materials and calls for Vendor Data
requirement: (Without site work)
- 5% against approval of Drawings, wherever required (identified in Purchase
Requisition) in at least in Code-2 & manufacturing schedule through Wire
Transfer.
- 90% (95% in cases where drawing approval is not required) against shipping
documents through irrevocable Letter of Credit .
- 5% on receipt of Final/ As built Drawings/Documents/Data/Manual in

Requisition through wire transfer. .
(iii) Where the MR is for supply of materials and calls for Vendor Data
requirement: (With site work)

Requisition) at least in Code-2 & manufacturing schedule through Wire
Transfer.
- 80% against shipping documents through irrevocable Letter of Credit .
Page 28 of 674
Document No.
[ CPCL LSTK ] 12.09.2013
Page 6
- 5% on receipt of Final/ As built Drawings/Documents/Data/Manual in requisite

number of copies/sets/CDs as per VDR specified in Purchase Requisition
through wire transfer.
- 10% on successful completion of Site Work through wire transfer.
Note: In case site is not available upto 6 (Six) months after receipt of all supplies
at site, the last 10% payment shall be released against submission of additional
Bank Guarantee of equivalent amount valid for 1 (One) year or such extended
period as may required.
(iv) Where the MR is for Packages (with significant Boughtout item) and
calls for Vendor Data Requirement: (Without site work)

Transfer.
- 10% against placement of sub orders for specified major raw materials, against
submission of equivalent bank guarantee through wire transfer.
- 80% against shipping documents through irrevocable Letter of Credit.

(v) Where the MR is for supply Packages (with significant Boughtout item)
and calls for Vendor Data Requirement: (With site work)

Transfer.
- 10% against placement of sub orders for specified major raw materials, against
submission of equivalent bank guarantee through wire transfer.
- 70% against shipping documents through irrevocable Letter of Credit.

Note: In case site is not available upto 6 (Six) months after receipt of all
Page 29 of 674
Document No.
[ CPCL LSTK ] 12.09.2013
Page 7
(vi) For Pumps, Compressors, Heat Exchangers, Columns and Vessels:

(Without site work)
Transfer.
- 15% against receipt and identification of specified major raw materials against
submission of equivalent BG through wire transfer.
documents through irrevocable Letter of Credit.

Pumps : Castings
(vii) For Pumps, Compressors, Heat Exchangers, Columns and Vessels:

(With site work)
Transfer.
- 15% against receipt and identification of specified major raw materials against
submission of equivalent BG through wire transfer.
documents through irrevocable Letter of Credit.

Note: In case site is not available upto 6 (Six) months after receipt of all supplies at
site, the last 10% payment shall be released against submission of additional Bank
Guarantee of equivalent amount valid for 1 (One) year or such extended period as
may required.
Page 30 of 674
Document No.
[ CPCL LSTK ] 12.09.2013
Page 8
Pumps : Castings
1.2.2 For supply of Mandatory Spares:

- 100% against shipping documents through Bank through irrevocable Letter
of Credit
1.2.3 Site Work:

- 90% against monthly progressive bills (based on agreed billing schedule)
duly certified by Engineer-in-charge.
- 10% on successful completion and handing over of goods/equipment at site..
1.2.4 Supervision of Erection, Testing & Commissioning:

- 100% prorate against monthly bills to be submitted by seller duly certified by
Engineer-in-Charge.
1.2.5 Training:
- 100% through Wire Transfer on successful completion of Training duly
certified by PURCHASER, as per Purchase Requisition (PR).
1.2.6 Annual Maintenance Contract (AMC):

-
100% payment shall be paid at the end of each half year of the contractual
year against quarterly progressive bills to be submitted by seller duly certified
by Site-in-Charge.
NOTES :
(i) Total Order value shall be as indicated in the Purchase Order.
(ii) All bidders are required to submit their acknowledgement of FOA and/or PO.
(iii) PRS, if applicable, shall be deducted from payment milestone subsequent to
dispatch of material. In case of clause no. 1.1.1 ( Viii) , i.e, Fabricated column
at site , PRS , if applicable, shall be deducted from milestone payment of
20%.
(iv) All foreign vendors having service components in their purchase order are
required to submit PAN (Indian I. Tax) and to provide TRC (Tax Residency
Certificate) from the Govt. of vendors country in order to claim the benefit of
DTAA, wherever applicable.
(v) In case of indigenous SUPPLIERs, wherever taxes/duties are separately
indicated, the order value shall be exclusive of taxes/duties. 100% payment
of taxes/duties shall be paid alongwith the payment released against
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dispatch documents on receipt of Cenvatable (Duplicate Copy of Excise

Invoice)/vattable documents (wherever applicable).
Payment to indigenous SUPPLIERs shall be released through Electronic
Clearing System (ECS). In view of this, necessary details, such as name of
bank, bank account no. etc., duly attested by BIDDERs bank must be
submitted along with the offer.
(vi) Status of bills after submission can be viewed on our website
http://www.engineersindia.com.
(vii) Foreign bidders are required to submit contract cum Performance Bank
Guarantee within 30 days of FOA/PO.
(viii) Irrevocable Letter of Credit for payment to Foreign SUPPLIERs shall be
established in favour of the supplier in a bank in his country, for an
appropriate amount (in line with Payment Terms). L/C shall be opened
within 45 days of receipt of acknowledgement of FOA/PO along with PBG
(wherever applicable). In case confirmed L/C is insisted by supplier, L/C
confirmation charges shall be to suppliers account.
(ix) Payment to foreign SUPPLIERs against Site Work and Supervision/Training
shall be through wire transfer.
(x) All payments (other than through L/C) shall be released within 30 days of
receipt of invoice and all requisite documents, complete in all respects.
(xi) All bank charges of respective bankers shall be to respective account.
(xii) Seller shall submit Billing Schedule within three weeks after placement of
FOA/PO ( whichever is issued earlier ) for PURCHASERs approval
(wherever applicable).
(xiii) Sellers requiring multiple despatches will restrict the number of despatches to
maximum three, unless agreed otherwise by Project Manager.
(xiv) All progressive advances to foreign as well as Indian bidders (except the
milestone payment against drawing approval) shall be against equivalent
bank guarantees. The progressive advances shall be paid through wire
transfer to foreign bidder.
(xv) Other than the payment terms given above, no other advance payments shall
generally be payable. However, if any Seller insists on advance payments, such
advance payment (other than the payment terms given in RFQ) shall be interest
bearing @ SBI PLR + 2% per annum (simple interest) on reducing balance, up to
delivery period and shall be released only against equivalent Bank Guarantee,
which shall be valid up to contractual delivery date plus three months. Interest shall
be adjusted while releasing the payment against despatch documents.
2 TERMS OF DELIVERY
2.1 INDIGENIOUS ENQUIRIES: Terms of delivery are FOT Project site on freight
prepaid & door delivery basis. The date of receipt of material at site shall be
considered as the date of delivery.
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2.2 FOREIGN ENQUIRIES: Terms of delivery are FOB international sea port of exit
basis. The Date of On Board Bill of Lading shall be considered as date of
Delivery.
2.3 GLOBAL ENQUIRIES:
2.3.1 For Indigenous Suppliers: Terms of delivery are FOT Despatch point on
freight to pay basis. The date of LR/GR shall be considered as the date of delivery.
2.3.2 For Foreign Suppliers: Terms of delivery are FOB international sea port of
exit basis. The Date of On Board Bill of Lading shall be considered as date of
Delivery.
3 TRANSPORTATION
3.1 INDIGENOUS SUPPLIERS

Indigenous SUPPLIERs are required to dispatch the goods on door delivery basis
through any of the bank approved Transporters. Any deviation shall be subject to
prior approval of Project Manager.
3.2 FOREIGN SUPPLIERS

In case order is placed on FOB International port of exit basis, ocean transportation
from FOB Port of Exit to the designated Indian Port (CHENNAI) shall be arranged
through PURCHASER nominated freight forwarder. BIDDER shall arrange handing
over the material to nominated freight forwarder at the designated Port of Exit. The
BIDDER will be required to furnish firm cargo details containing weight, dimensions,
no. of packages, no. & type of containers required & Port of shipment. In case the
actual cargo dispatched exceeds the cargo details furnished, the extra freight
incurred by PURCHASER will be to SUPPLIERs account.The marine freight
quoted should be kept valid for a period one month lesser to delivery period.
However, Vendor shall furnish the shipping details viz. Net/ Gross weight, Volume
of consignment, number of packages with dimensions at least two month before the
expiry of validity of Ocean Freight. In the event of any delay by Vendor, the quoted
Ocean Freight charges shall remain valid further for one month from the date of
furnishing the above details. EIL reserves the option to ask the bidder to arrange
shipment at the quoted freight rates.
4 CURRENCY OF QUOTE
4.1 FOREIGN SUPPLIERS
Foreign SUPPLIERs are required to submit prices only in USD. In case a foreign
SUPPLIER is sourcing part of equipment/ services from India, prices of such
equipment/ services shall be quoted in Indian Rupees only and terms & conditions
applicable to Indian portion shall be same as applicable to Indian Bidders.
4.2 INDIGENOUS SUPPLIERS
Indigenous SUPPLIERs are required to submit price in Indian Rupees.
5 ANNUAL MAINTENANCE CONTRCT (AMC)
The prices shall be asked for AMC, if required as per Material Requisition.
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6 SINGLE POINT RESPONSIBILITY OF THE SUPPLIER
In case of MRs containing supplies as well site work, a single order, covering the
supply part as well site work, shall be placed. Split ordering will not be permitted.
In case, a foreign SUPPLIER requests for a separate order on his Indian sub-
SUPPLIER, the same shall not be accepted. However, payment to Indian sub-
SUPPLIER shall be released directly in Indian Rupees against invoices duly
certified by the Foreign SUPPLIER.
For this purpose, the Indian sub-SUPPLIERs name, material and corresponding
price in Indian Rupees, shall be clearly spelt out in the purchase order on foreign
SUPPLIER.. In case a Foreign supplier sources supplies/ services within India, the
applicable terms & conditions shall be modified to the extent as per Annexure-1
enclosed.
7 GUARANTEE PERIOD
GUARANTEE PERIOD:
For all items having CDD up to Dec 2014 :
18 Months from the date of successful Commissioning or 36 Months from the
date of shipment, whichever is earlier.
For all items having CDD beyond Dec 2014 :
18 Months from the date of successful Commissioning or 30 Months from the
date of shipment, whichever is earlier.
8 PERFORMANCE BANK GUARANTEE (PBG)/(CPBG)

8.1 PBG shall be required @ 10% of total order value. However, PBG shall not be
required for orders upto Rs. Twenty Five (25) Lakhs (equivalent Foreign
currency in case of Foreign SUPPLIERs) in case of Pipes, Fittings, Flanges,
Gaskets and Fasteners in Limited enquiries. For all other cases, PBG shall not
be required for Orders upto Rs. Five (5) lakh (equivalent Foreign currency in
case of Foreign SUPPLIERs).
8.2 PURCHASER shall get all bank guarantees verified for authenticity from the
regional / controlling / branch office of the issuing bank before the same are
accepted.
8.3 In limited enquiries for purchasing, Indigenous suppliers shall be required to
submit the PBG while claiming the dispatch payment.
8.4 In all other cases, the PBG shall be required to be submitted within four weeks
of issue of FOA.
8.5 Performance Bank Guarantees shall be valid till expiry of guarantee period
plus 3 (Three) Months claim period after which the PBG shall be released.
8.6 Bank Guarantee(s) shall be issued through Indian Nationalised Bank/ Indian
Scheduled bank (other than Co-operative Banks) / Indian branches of foreign
banks registered with Reserve Bank of India as a scheduled foreign bank.
Bank Guarantee from Foreign banks will only be accepted if same is counter
signed by their Indian branch or by any scheduled Indian bank.
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8.7 Bank Guarantee shall have a claim period of 3 (Three) Months after its expiry.
9 INDIAN TAXES/DUTIES
9.1 The prices shall be exclusive of all Indian taxes/duties applicable on finished
goods/services supplied directly to PURCHASER. The excluded taxes/duties
shall be payable extra at actuals against documentary evidence. Where
Purchase Order includes supply and site work, Purchase Order will be divided
into supply and service portion separately , no VAT on work contracts is
envisaged, however VAT on work contract on site work portion if applicable
shall be included in the bidders quoted price & no statuary variation is payable
on the same.
9.2 Entry Tax and Terminal taxes are presently not applicable. If applicable at a
later date, same shall be payable extra at actual on production of necessary
Documentary evidence. Road permit shall be issued to supplier by CPCL for
material consigned to CPCL.
9.3 All payments on account of Excise Duty, Service Tax, TNVAT on finished
goods shall be released on receipt of CENVATABLE ( Duplicate Copy of
Excise Invoice) /VATTABLE copy of corresponding invoice and documents
valid for availing CENVAT / VAT credit.
9.4 PURCHASER shall be able to avail 100% credit against TNVAT(i.e. VAT on
sale of finished goods). PURCHASER will not issue any concessional form for
TNVAT.
TN VAT on sale of goods shall not be loaded for evaluation.
9.5 EIL shall issue concessional form-C for central sales tax.
CST against inter state sale shall be loaded during evaluation at the applicable
rates.
9.6 Since Cenvat Credit shall be available against Excise Duty and Service Tax
(excluding service tax on freight) & the same shall not be considered for
comparison purpose.
9.7 Indigenous SUPPLIERs shall issue E1/E2 form on quarterly basis within 60
days after completion of each quarter based on C form no. provided by
PURCHASER. PURCHASER will provide original C form in exchange of
original E1/E2 form.
Statutory Variations are eligible only on Service Tax, cenvatable excise duty,
and VAT amount for which input tax credit is available to the OWNER under
TNVAT Act subject to SUPPLIER producing documentary evidence for the
above . Statutory Variations are eligible on CST also.
Statutory variations on non-cenvatable excise duty and VAT amount for which
input tax credit is not available to the OWNER/PURCHASER under TN VAT
Act shall be to SUPPLIERs account.
9.9 All non-cenvatable /non-vattable taxes/duties shall be considered for
evaluation.
9.10 All new taxes/duties/cess/levies notified after the last date of submission of
final price bid/price implication, but within contractual delivery /completion
period, shall be to EILs account. These shall be reimbursed against
documentary evidence.
However, in case of delay on account of supplier, any new or additional taxes
and duties imposed after contractual delivery shall be to suppliers account.
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10 CUSTOMS DUTY/EPCG LICENSE

10.1 OWNER is obtaining an EPCG license for this project. In view of this
concessional rate of Custom Duty shall be applicable to imports from foreign
BIDDERs for the goods directly consigned to CPCL.
10.2 Indigenous BIDDERs will be required to quote price considering only merit
rate of duty, for their built in import content, in their bid and evaluation shall be
done accordingly. No PAC/EC/INVALIDATION LETTER shall be issued to
Indigenous BIDDERs.
11 FIRM PRICES
11.1 The prices shall be firm and fixed and not subject to any variation,
whatsoever. In case of Cables, variation in prices shall be admissible as per
IEEMA Price Variation Clause.
11.2 For 2 years O&M spares, prices shall be kept valid for a period of 2 years
from the date of order of main equipment along with annual % escalation ( to
be indicated by the bidder) for subsequent two years.
12 PRICE REDUCTION SCHEDULE
12.1 In case of MRs other than packages, Price Reduction Schedule shall be
@1/2% of value of delayed equipment/ item per week of delay or part thereof
subject to a maximum of 5% of total order value.
12.2 For packages and critical items, with or without site work, the Price Reduction
Schedule shall be @1/2% of total order value per week of delay or part
thereof subject to a maximum of 7.5% of total order value.
12.3 Wherever the supply period and site work are indicated as two separate
periods and notice of site readiness is required for site work, intervening
period, if any, shall be excluded, while calculating the price reduction for
delay.
Note : it shall be endeavor to split the period ,i,e., a separate period for supply
and site work.
12.4 Price reduction shall be effected in the Invoice value before presenting for
payment. The Purchaser reserves the right to cancel the Purchase Order for
any delay exceeding the period of maximum reduction and the Seller shall be
liable to all consequences thereof.
13 INSPECTION
All items shall be inspected by a Third Party Inspection agency as follows:
13.1 INDIGENOUS BIDDERs: CEIL shall be appointed as Third Party Inspection
for the indigenous materials & accordingly the charges for the same shall be borne
by EIL. The quoted price of Bidder shall be exclusive of TPI charges.
13.2 FOREIGN BIDDERs: The quoted price shall be inclusive of TPI charges
(out of M/s.Lloyds Register (Country of origin), M/s.Bureau Veritas(BV) and
M/s.TUV Nord)
Suppliers will be informed the following:
a) QAP will be approved by Third Party Inspection agency incorporating
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requirements of ITP, Technical specifications and approved documents. Approval of

QAP will not be carried out by EIL.
b) The Inspection release note issued by the Third party inspection agency shall
clearly stipulate that materials/equipment have been inspected as per Code-1
approved drawings, wherever applicable and approved QAP.
c) Certification of final documents, wherever applicable, for release of final payment,

shall be carried out by Third Party Inspection Authority issuing the final inspection
certificate.
14 GENERAL PURCHASE CONDITIONS
General Purchase Conditions including formats for advance bank guarantee and
Performance Bank Guarantee shall be as approved earlier by ED Committee for
LSTK Projects with modification based on these terms and conditions.
15 COMPREHENSIVE MARINE-CUM-ERECTION INSURANCE
Comprehensive Insurance (Transit/Marine cum storage, erection, till handing over
of equipment) shall be arranged by PURCHASER.
16 BASIS OF EVALUATION
16.1 WHERE ONLY INDIAN BIDS ARE UNDER COMPARISON
16.1.0 Bids shall be evaluated on the basis of landed cost at Site, including site
work, if any, all duties, taxes, transportation charges less Cenvatable Excise
duty, Cenvatable Service tax, Cenvatable Educational cess & Vattable
TNVAT (100% of TNVAT).
16.1.1 Cost of mandatory spares, if identified in the Material Requisition,
commissioning spares and special tools & tackles will be included for price
evaluation of bids, but cost of Spares for two years operation shall be
excluded.
16.1.2 AMC charges shall be considered for evaluation wherever AMC is required.
16.1.3 Supervision and Training charges shall be considered for evaluation
wherever supervision and training are required.
16.1.4 Commercial loading shall be considered for evaluation of bids.
16.1.5 Technical loading, if any, shall be considered for evaluation of bids.
NOTE :
- Site Work, wherever applicable, shall be considered for evaluation.
- In case freight charges are not quoted, estimated freight shall be taken from
EIL shipping dept. and loading shall be done with the same. In case of
ordering , bidder shall be asked to absorb the freight first. In case bidder
does not agree to absorb then negotiation shall be done with the bidder to
agree upto maximum of the freight with which loading has been done. If
bidder does not agree with this also, then refloating of MR shall be done.
16.2 WHERE ONLY FOREIGN BIDS ARE UNDER COMPARISON
16.2.1 Bids shall be evaluated on the basis of CFR (CHENNAI) prices including
third party inspection charges, stowage charges wherever applicable (as
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quoted by BIDDERs), and considering sea freight as under:

(i) Packages/equipments/pipes & plates :
- Firm freight as quoted by BIDDERs
(ii) Bulk items piping (other than pipes) / instruments :
- Firm freight as quoted by BIDDERs.
In case, firm freight is not quoted by BIDDER ( For Bulk Items as well
as Packages/equipments/pipes & plates), freight shall be taken from
Transchart through shipping Dept. and loading shall be done with the
same. In case of ordering, transportation shall be done by the
Transchart only.
16.2.2 Cost of mandatory spares identified in the Material Requisition,
Commissioning Spares and special tools & tackles will be included for
evaluation of bids, but costs of Spares for two years operation shall be
excluded.
16.2.3 AMC charges shall be considered for evaluation wherever AMC is required.
16.2.4 Supervision (man days as indicated in MR as well as TBA ) and Training
charges shall be considered for evaluation, wherever, supervision and
training are required.
16.2.4 (i) Service tax on Reverse charge and withholding tax ( in case it is not
included in bidders price) basis, wherever applicable shall be added for bid
evaluation purpose only.
16.2.5 Commercial loading shall be considered for evaluation of bids.
16.2.6 Technical loading, if any, shall be considered for evaluation of bids.
16.2.7 For global enquiries, evaluation of offer shall be done considering foreign
exchange rate, i.e., 1 USD = Rs. 56.13.
Payment shall be made based on the Foreign Exchange Rate prevailing on

the date of making payment.
NOTE :
16.3 WHERE INDIAN AS WELL AS FOREIGN BIDS ARE UNDER

COMPARISON
16.3.1 INDIGENOUS BIDDERS:
(i) The evaluated price of indigenous BIDDERs shall be carried out on the
basis of landed cost at Site, as per clause 16.1 above.
(ii) Notional Loading of 1% for TPI charges shall be considered for
evaluation.
16.3.2 FOREIGN BIDDERS :
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The evaluated price of foreign BIDDERs shall be on the basis of landed cost
at Site, including the following:
(i) Evaluation shall be done as per clause 16.2 above plus marine
insurance @ 1% of FOB Price.
(ii) L/C charges @ 1% of FOB price.
(iii) Landing Charges @ 1% of CIF Value i.e S.No. (i).
(iv) Custom clearance, Port Handling and Inland Freight (from Port of Entry
(CHENNAI) to CPCL project site) charges @ 3% of CIF value including
L/C Charges, i.e., S. No. (i) plus (ii).
(v) Landed Cost = S.No. (i) to (iv).
NOTE :
- Transit insurance for Indigenous and Foreign BIDDERs, will not be loaded..
16.4 GENERAL
16.4.1 Taxes and duties will be cost loaded as quoted by the bidder. However, if a
SUPPLIER states that taxes/duties are not applicable at present and will be
charged as applicable at the time of delivery then his bid shall be loaded by
the maximum rate of taxes/duties applicable at the time of evaluation of
Bids.
16.4.2 In case of pipes, if a foreign BIDDER has not quoted or not included
stowage charges, the same shall be loaded @ 10% of BIDDERs quoted
Ocean Freight.
17 LOADING/REJECTION CRITERIA
Cost loading on account of deviations to commercial terms & conditions shall be

calculated on FOT Despatch Point price/ FOB price as under :
17.1 PERFORMANCE BANK GUARANTEE (PBG)
In case, Foreign SUPPLIER takes any deviation with respect to the amount or
period or validity of the performance bank guarantee, the offer shall be rejected.
Any other type of bond (e.g. indemnity bond ) is not acceptable in lieu of
Performance Bank Guarantee (PBG).
In case foreign bidder submit stand by Letter of Credit in lieu of CPBG, same shall
be accepted. Confirmation charges for the stand by Letter of Credit shall be to
sellers account.
In case, Indian Supplier takes any deviation with respect to the amount or period or
validity of the performance bank guarantee, loading shall be done for the differential
amount and /or the differential period.
For differential period/amount loading, the following example will amplify the
methodology :
For differential period:
10% for differential period : 10% * differential period /total period ,i.e,
(guarantee period + claim period)
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In case of Differential Amount
Amount offered by the Bidder : Loading

a) 10% : Nil
b) Less than 10% : Differential between the offered percentage
and 10%
17.2 PRICE REDUCTION SCHEDULE (PRS)
17.2.1 PRICE REDUCTION SCHEDULE (APPLICABLE AS 1/2% DOV ~ 5% TOV)

FOR DELAYED DELIVERY:
(i) 1/2% of DOV up to maximum of 5% of No loading
TOV
(ii) 1/2% of DOV up to maximum of 5% of 2.5%
DOV
(iii) Other than the above 5%
17.2.2 PRICE REDUCTION SCHEDULE ( APPLICABLE AS 1/2% TOV ~ 7.5%

TOV FOR PACKAGES & CRITICAL ITEMS ONLY )
(i) 1/2% of TOV up to maximum of 7.5% of No loading
TOV
(ii) 1/2% of TOV to x% of TOV (7.5-x)%
(iii) Other than the above 7.5%
NOTE: TOV Total Order Value (FOT Despatch Pt. Price); DOV Delayed Order
Value (FOT Despatch Pt. Price).
17.4 PRICE VARIATION

(i) Firm Prices : No Loading
(ii) In case of Price Variation : Loading by ceiling %age
Formula with ceiling offered
(iii) No formula and no ceiling : Offer shall be rejected
specified by the BIDDER
Note : In case the enquiry itself provides for price variation on account of
certain variables, offers seeking such variation shall not be loaded.
17.5 PAYMENT TERMS

Payment terms at variance with RFQ (which are not interest bearing), will not be
permitted. However, if a BIDDER insists on the same, these shall be loaded @ SBI
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PLR+ 2% per annum (simple interest) for the relevant period as under:
(i) Advance against FOA / PO : 100% of the delivery period
(ii) Drawing approval : 80% of the delivery period
(iii) Order on sub Vendors : 75% of the delivery period
(iv) Receipt of raw material at Vendors works : 50% of the delivery period
(v) %age payment against dispatch : Interest for Three month
Documents instead receipt & acceptance
at Site (Specified in RFQ)
(vi) % age payment against dispatch : Interest for One month
document instead of Final document
as per Purchase Requisition
(Specified in RFQ)
(vii) %age payment against : Interest for Three month

receipt of material
at site instead acceptance of
material at site
(Specified in RFQ)
Notes to S. No. (vii) :

- Shall be applicable to indigenous bidders.
- Shall be against Additional BG of equivalent amount valid initially for 3
months plus claim period.
PBG shall be required along with the Dispatch documents, in cases where there is
no further milestone payment of 10% or more left.
17.6 DELIVERY
17.6.1 FOR IDENTIFIED CRITICAL EQUIPMENTS (TO BE IDENTIFIED BY THE
PROJECT):
Delivery/Completion period longer than required in enquiry shall be liable for
rejection..
17.6.2 FOR BALANCE ITEMS/EQUIPMENTS (OTHER THAN CRITICAL
EQUIPMENTS) :
(i) FOR ENQUIRIES WITH DELIVERY/COMPLETION PERIOD UPTO 6
MONTHS
Delivery/Completion period longer than required in enquiry shall be loaded
@ 1/2% per week up to a maximum of four (4) weeks. In case, a SUPPLIER
quotes delivery longer than four (4) weeks from required, the bid shall be
rejected. One (1) month shall be construed as equal to four (4) weeks for the
purpose of such evaluation.
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(ii) FOR ENQUIRIES WITH DELIVERY /COMPLETION PERIOD BEYOND 6

MONTHS
Delivery/Completion period longer than required in enquiry shall be loaded
@ 1/2% per week upto a maximum of six (6) weeks. In case, a SUPPLIER
quotes delivery longer than six (6) weeks from required, the bid shall be
rejected. One (1) month shall be construed as equal to four (4) weeks for the
purpose of such evaluation.
NOTE: In case under clause no. 2.1, indigenous bidder offers a deviation
against the terms of delivery basis, their bid shall be rejected.
17.7 OFFER VALIDITY:
In case a SUPPLIER offers shorter validity of the bid against RFQ requirement, the
bid shall be rejected.
18 INVOICING INSTRUCTIONS
For imported goods, The Invoices shall be billed to CPCL a/c EIL. Consignee on
the invoices and bill of lading issued by the foreign supplier shall be in the name of
CPCL.
For Indigenous Goods, the invoices shall be billed to EIL a/c CPCL. However , the
consignee in the tax invoices shall be CPCL a/c EIL to avail input credit of Excise
duty by CPCL
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Annexure I
TERMS & CONDITIONS FOR INDIAN SOURCED COMPONENTS / SERVICES BY FOREIGN BIDDER
Foreign bidder may source components / sub-supplies and services from India, if allowed as
per Material Requisition. For such sub-supplies / services ,Commercial Terms & Conditions of
the RFQ shall stand modified to the following extent:
1. PRICING:
1.1 Unit and total price on FOT Despatch Point basis including packing and forwarding
charges.
1.2 Details of Taxes and duties (rates) payable extra on the finished goods, applicable on
Indian sub-suppliers. Purchaser shall issue C form for Concessional rate of Central sales
tax.
1.3 Separate and clear break-up of charges for inland transportation excluding Entry Tax &
Terminal Tax. Entry Tax and Terminal Tax, if applicable, shall be reimbursed at actuals by
EIL on submission of documentary evidence.
1.4 Materials if ordered against the RFQ/Bidding Document are required to be dispatched
on door delivery basis through a reliable bank approved Road Transport Company.
1.5 Transit insurance of Indian sub supplies shall be borne and arranged by the EIL.
2. CURRENCY OF QUOTE:
The quoted price of sub-supplies / services shall be in Indian Rupees only.
3. AWARD OF ORDER:
Foreign Principal shall be the single point responsible Vendor and separate order on
Foreign supplier and Indian sub-supplier / sub-contractor is not acceptable. Single
Purchase order shall be issued on the Foreign principal clearly indicating the sub-
suppliers / sub-contractors name, material and corresponding price in Indian Rupees.
4. DELIVERY:
The delivery period for sub-supplies shall be on FOT site basis within specified delivery
period for Foreign bidder as per Terms of RFQ/Bidding document.
5. PRICE REDUCTION SCHEDULE:

PRS shall be applicable in totality on Foreign scope + Indian sourced component / Service
for delay in supply of goods/services either by Foreign principals or Indian counterpart.
6. PAYMENT TERMS:
6.1 Indian sub-supplies:
90% through E-Payment with taxes and duties will be paid against receipt of Indian
sourced goods/material at project site.
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10% against receipt & Acceptance on delivery of main equipments by Foreign

principal and as well as Indian supplies at site as per Terms of bidding document.
Payment of Indian sub supplies/Services shall be released directly to Indian counterpart
against Invoices raised by Indian counterpart duly certified by Foreign principal.
6.2 Foreign principals: Payment terms of Foreign bidder shall be modified and 5% payment
out of payment against shipping documents through L/c shall be released after receipt
on delivery of main equipments by Foreign principal as well as Indian supplies at site as
per Terms of bidding document through wire transfer.
6.3 The payments shall be made after Adjustment of Price Reduction Schedule.
7. PERFORMANCE BANK GUARANTEE:

Foreign principal shall submit the performance bank guarantee for 10% of total order
value including value of Foreign portion and Indian sourced components / services
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AppendixAtoITB

TermsandconditionsforReverseAuction
1 Owner / Purchaser reserves the right to go in for reverse auction among the
technically and commercially acceptable bidders. The decision to conduct reverse
auctionornot,willbeconveyedtoshortlistedbidderspriortoopeningofpricebid.
Inviewofthis,thebiddersmustquotemostcompetitivepricesinthefirstinstance
itself.
2 OncethedecisiontoconductReverseAuctionisconveyedtothebidders,itwillbe
mandatory for the bidders to participate in Reverse Auction, failing which, the
bidder shall be liable for punitive action including but not limited to rejection of
offer,encashmentofbidsecurity,whereverapplicable,etc.Forthispurpose,even
logintothesystemshallbeconstruedasparticipation.
3 ScheduleforReverseAuction

The Reverse Auction shall be scheduled for a duration of two hours. If a bidder
placesaBidinthelast5minutesofscheduledclosingtimeoftheAuction,the
Auctiontimeshallgetextendedautomaticallyforanother5minutesfromthetime
ofthelastBidplaced.Incase,thereisnoBidinthelast5minutesofclosingofthe
Auction,theAuctionshallbeclosedautomaticallywithoutanyextension.

Theaboveprovisionshallapplytothebidsinextendedtimealso.
4 Auctionprocess

- EachBiddershallbeassignedaUniqueUserName&Password.TheBiddersare
requestedtochangethePasswordandedittheinformationintheRegistration
Page after the receipt of initial Password. All bids using the Login ID given to
thebidderwillbedeemedtohavebeensubmittedbythebidders.Duringthe
auction,bidderswillbereferredbyproxynamesasB1,B2, B3, etc.andidentity
willnotbedisclosed.
- The Reverse Auction shall be conducted based on the lowest evaluated price
out of all the technocommercially acceptable bidders, based on the prices
submittedalongwiththebid,astheopeningprice.TheBiddershallbeableto
bid lower than the opening price in multiples of the decrement, but a Bidder
mustalwaysbidlowerthantheLowestBid.
- Onlyonebiddershallbeataparticularposition/rank,whichmeansonlyone
L1.
Page 1 of 4
Page 45 of 674
- The Bidder shall be able to view the following on his screen along with the
necessaryfields:

i) OpeningPrice.
ii) LeadingBidintheAuction,i.e.,thelowestbid.
iii) Bidplacedbyhim.
At no point of time will any bidder see the names of other bidders, or the
pricesofbiddersotherthanthelowestbid.

- A bidder can continue to revise his bid till the auction ends. However, the
Biddercannotquote/BidequaltotheLeading/LowestBid.Hemustalways
quotelowerthantheLeading/LowestBid.
- The evaluation criteria is based on Price alone. The Bidder who quotes the
lowestevaluatedPriceisdeterminedasthelowestbidder.
- However,ifReverseAuctiondoesnotleadtoanybid,EILshallreservetheright
toawardthejobbasedonthelowestpricesquotedinsealedenvelope.
- Apartfromtheparticipatingbidders,theReverseAuctionshallbevisible,while
in progress to authorized officials of Owner / Purchaser, who are monitoring
theprocess.
5 BidPrice

The price shall be based on the scope, technical specifications and commercial
terms & conditions and other part of Bidding document agreed upto the date of
reverseauction.

TheOpeningPriceandtheBidDecrementshallbedisplayedontheauctionsiteat
the start of the auction. However, the bidders shall be able to view the auction
details,generally,15to30minutesbeforethestartofactualauction.

6 BidDecrement

Shallbe0.1%oftheOpeningPrice.Thebiddertolowerthebidinmultiplesofthe
biddecrement.

7 BiddingCurrency

BiddingwillbeconductedinIndianRupees(INR).

Page 2 of 4
Page 46 of 674
8 BidValidity

The Bid Price submitted in the reverse auction shall be firm and valid for
acceptanceforaperiodof15daysfromthedateofreverseauctionandshallnotbe
subjecttoanychangewhatsoever.
9 Bidsonceplaced,bindingontheBidder

Thebidofthebidderwillbetakentobeanoffertosell.Bidsoncesubmittedby
thebiddercannotbecancelled.Thebidderisboundtosellthematerial/servicesat
thepricethattheybid.Shouldanybidderbackoutandnotaccepttheorderasper
theratesquoted,Owner/Purchaserreservestherighttotakeactionasconsidered
appropriate, including encashment of bid security and placement on Holiday /
Negativelistetc.
10 LowestbidofaBidder

Duringtheprocessofreverseauction,thebiddermaysubmitseveralbids.Incase
the bidder submits such multiple bids, the lowest bid will be considered as the
biddersfinaloffertosell.
11 Submissionoffinalpricesbysuccessfulbidder
Successful bidder shall be required to submit the final prices, quoted during the
Reverse Auction in an appropriate format within two days of the completion of
AuctiontoEIL,dulysignedandstampedastokenofacceptancewithoutanynew
condition.However,incasethereverseauctionisforapackage,within2working
daysaftercompletionoftheonlineeventofReverseAuction,thesuccessfulbidder
would submit their cost break down as per the price format for the final price
arrivedatafterreverseauction.

12 General
- The bidders may quote from their own offices/ place of their choice. Internet
connectivity shall have to be ensured by each agency on its own. In extreme
caseoffailureofinternetconnectivity,(duetounforeseencircumstancesother
thanpowerfailure),communicationshallhavetobesentbyfax/Email/phone
immediately.Owner/Purchasershallextendthebiddingtime,insuchacase,
appropriately(generallybyhalfanhour)butnotmorethanonceperbidder.
- The Bidder, himself or any of his representatives, shall not involve in Price
manipulation of any kind directly or indirectly by communicating with other
bidder.

Page 3 of 4
Page 47 of 674
- The Bidder shall not divulge either his Bids or any other exclusive details of
Owner/Purchasertoanyotherparty.

- Bidders agree to nondisclosure of trade information regarding the purchase,
identityofEIL,bidprocess,bidtechnology,biddocumentationandbiddetails.
- Owner/Purchasercandecidetoextend,rescheduleorcancelanyAuction.No
biddercanclaimanykindofcompensationonaccountofthesame.
- Owner/PurchasershallnothaveanyliabilitytoBiddersforanyinterruptionor
delayinaccesstothesiteirrespectiveofthecause.

- Owner / Purchaser shall not be responsible for any direct / indirect /
consequential losses / damages, on account of systems problems, inability to
usethesystem,lossofelectronicinformationetc.

- Owner / Purchaser shall be at liberty to cancel the reverse auction process /
tenderatanytime,beforeordering,withoutassigninganyreason.

- Owner/PurchasersdecisiononawardofContractshallbefinalandbindingon
alltheBidders.

Page 4 of 4
Page 48 of 674
JOB NO. A133
RESID UPGRADATION PROJECT COKER BLOCK OF CPCL, CHENNAI
PRE-FILLED AGREED TERMS & CONDITIONS (FOR INDIGENOUS SUPPIERS)
BIDDERs NAME : M/s._____________________________________________________________________________
RFQ No.: ________________________________________________________________________________________
Bidders Offer Ref. No. :____________________________________________________________________________
Tel No. : ____________________________________ Fax No.:_____________________________________________
Contact Person :________________________E-Mail:______________________Mobile No:_____________________
1. Duly signed & stamped copies of this pre-filled Questionnaire shall be enclosed with each and every set of
bidders unpriced quotation.
2. Failure on the part of bidder in not returning this duly filled-up Questionnaire with all the sets of unpriced
quotation and/or submitting incomplete replies may lead to rejection of bidders quotation.
S. No. DESCRIPTION BIDDERS CONFIRMATION

Quoted prices are on FOT despatch point basis inclusive of Packing &
a) Confirmed
Forwarding (P&F) charges.
Indicated
b) Specify Despatch Point in the enclosed Annexure I
(Refer ANNEXURE I)
Confirm that firm freight charges for transportation by road upto the
c) Project site including Service Tax & Education Cess, have been quoted in Confirmed
the price bid.
1 Confirm the freight charges for Recommended Spares for two years
d) normal operation & maintenance, if any, have been quoted extra in the Confirmed
Price Schedule separately.
Confirm the freight for all other supplies like mandatory spares
e) commissioning spares, tools and tackles etc., are included in freight for Confirmed
main equipment.
Marine-cum-erection insurance (MCE policy) shall be arranged by EIL and
f) Confirmed
therefore, the same shall not be included in the quoted prices.
Excise Duty + Education Cess: Indicated
a)
Tarrif sub heading no. (Refer ANNEXURE I)
Present rate of Excise Duty + Education Cess payable extra against Indicated
b)
documentary evidence on finished products (including spares). (Refer ANNEXURE I
Indicated
c) Maximum rate applicable (If present rate is nil or concessional)
2 (Refer ANNEXURE I)
Clarify whether Excise Duty + Education Cess will be applicable on freight Indicated
d)
charges also. (Refer ANNEXURE I)
Please indicate following break-up
Indicated
e) I) Cenvatable [Excise Duty + Educational Cess]
(Refer ANNEXURE I)
II) Non Cenvatable
Sales Tax:
Indicated
a) Sales tax payable extra Specify CST/ Tamilnadu VAT (TN VAT) on sale of
(Refer ANNEXURE I)
goods.
3 *In case of CST, C form shall be provided.
b)
In case of TN VAT, no concessional form shall be provided. TN VAT shall be Confirmed
reimbursed to bidder subject to submission of requisite documents
enabling owner to avail INPUT CREDIT for the same.
A133 ATC (IND)-REV 0 AUG13 PAGE 1 OF 7
Page 49 of 674
EIL/CPCL shall avail credit of 100% of TN VAT on sale of goods. However,
for price evaluation TN VAT on sale of goods shall not be loaded. TN VAT
c) Confirmed
shall be reimbursed to bidder subject to submission of requisite
documents enabling EIL/IOCL to avail INPUT CREDIT for the same.
Clarify whether CST / TN VAT on sale of goods will be applicable on freight Indicated
d)
charges also. (Refer ANNEXURE I)
Indigenous suppliers shall issue E1/E2 form on quarterly basis within 60
days after completion of each quarter based on C form no. provided by
e) Confirmed
PURCHASER. PURCHASER will provide original C form in exchange of
original E1/E2 form.
In case Excise Duty / CST / TN VAT are stated as not applicable on freight
charges presently, and if they are applicable at the time of delivery due to
4 Confirmed
any reasons other than statutory, the same will be borne by the Bidder.
Confirm compliance.
Only statutory variations, if any, in the present rate of Service Tax,
cenvatable excise duty, Central Sales Tax and VAT amount for which input
a) Confirmed
tax credit is available to the EIL under TN VAT Act etc. shall be to EILs
account subject to documentary evidence to be furnished by the bidder.
5 Statutory variations on non-cenvatable excise duty shall be to SUPPLIERs
b) Confirmed
account.
However, any variation in Excise duty + Ed. Cess at the time of supplies for
c) any reasons, other than statutory, including variations due to turnover, Confirmed
shall be borne by bidder.
VAT on Works Contract:
Confirmed
a) Wherever site job is involved, bidders to quote their prices inclusive of TN
VAT on work contracts (if applicable).
Only single order covering complete scope of supply & services will be
6 b) issued (indicating supply and services portion separately). Order for supply Confirmed
and services shall not be split.
Any statutory variation on TN VAT on work contracts or change in rate of
c) TN VAT due to wrong assessment by supplier shall be to suppliers Confirmed
account.
Service Tax:
a) Service Tax on freight charges shall be included in the quoted Freight Confirmed
Charges.
Percentage of Cenvatable Service Tax applicable extra on Site Work Indicated (Refer Annexure I)
Charges, , if applicable as per MR.
b)
Service tax shall be paid only against a cenvatable invoice issued in Confirmed
accordance with Service Tax rules.
7 Percentage of Cenvatable Service Tax applicable extra on Supervision Indicated (Refer Annexure I)
Charges, if applicable as per MR.
c)
Percentage of Cenvatable Service Tax applicable extra on AMC Charges, if Indicated (Refer Annexure I)
applicable as per MR.
d)
Page 50 of 674
Percentage of Cenvatable Service Tax applicable extra on Training Indicated (Refer Annexure I)
Charges, if applicable as per MR.
Entry Tax and Octroi:
Entry Tax / Octroi and Terminal Taxes are presently not applicable. If
8 a) applicable at a later date, same shall be payable extra at actual on Confirmed
production of necessary Documents/Invoices and information. Confirm
Compliance.
All new taxes/duties/cess/levies notified after the last date of submission
of final price bid/price implication, but within contractual delivery
/completion period, shall be to EILs account. These shall be reimbursed
a) against documentary evidence. Confirmed
9 However, in case of delay on account of supplier, any new or additional
taxes and duties imposed after contractual delivery shall be to suppliers
account. Confirm compliance.
Any errors of interpretation of applicability of taxes/duties by bidders shall
b) Confirmed
be to bidders account.
Price Reduction Schedule:
a) Acceptance of applicable Price Reduction Schedule for delayed delivery as Confirmed
10 specified in RFQ/SIB.
In case of delay in delivery, bills shall be submitted after deducting price
b) Confirmed
reduction for delay.
Delivery Period / Completion Period:
11 Please confirm delivery/completion period as specified in RFQ Covering Confirmed
Letter.
Payment Terms:
a) Confirmed
Acceptance of applicable Payment terms as specified in RFQ /SIB.
Payment shall be released through Electronic Clearing System (ECS).
12 Furnished
In view of this, confirm that necessary details such as name of bank, bank
b) account no. etc. as per Mandate Form enclosed with RFQ, has been
furnished duly attested by your bank alongwith a cancel cheque, along (Refer ANNEXURE II)
with your offer (as per Annexure-II to ATC) .
Part Order:
a) Confirmed
Acceptance of Part Order as per GPC (Indigenous).
13
Any charges quoted extra as lumpsum shall be applicable prorata on value
b) Confirmed
basis in the event of part order.
Repeat Order:
14 Confirmed
Acceptance of repeat order as per the clause specified in GPC (Indigenous).
Performance Bank Guarantee:
a) Submission of Performance Bank Guarantee for 10% of total order value as Confirmed
15 per General Purchase Conditions (GPC)/ Instructions to Bidders.
Indemnity Bond/Corporate Guarantee in lieu of PBG shall not be
b) Confirmed
considered.
Page 51 of 674
Guarantee :
16 Confirm acceptance of Guarantee period & terms as per referred Clause of Confirmed
Instruction to Bidders/General Purchase Conditions (Indigenous) in RFQ
Covering Letter.
Firmness of prices:
17 The prices shall be firm and fixed and not subject to any variation, Confirmed
whatsoever. However, in case of Cables, variation in prices shall be
admissible as per IEEMA Price Variation Clause.
CIF Value of Built in Import Content and Import Duties:
a) In case of any Built-in import content considered in your offer, details of Confirmed
items to be furnished in Annexure-I.
Confirm that quoted prices are based on Merit rate of Customs duty, CVD,
b) Confirmed
Educational Cess and SAD as applicable.
18
Quoted prices shall remain firm and fixed on account of FE variation and
c) Confirmed
Custom Duty Variation, till complete execution of the order.
d) EIL shall not provide any import license. Noted
Quoted prices are after considering the benefit of CENVAT on CVD
e) Confirmed
including Edu. Cess.
Testing charges:
19 Confirm that quoted prices are inclusive of all testing including IBR/ IGC/ Confirmed
Radiography/ NACE charges (if applicable) as per Material Requisition
attached.
Third Party Inspection charges:
a) Goods and services shall be subject to stagewise and final inspection by Confirmed
CEIL.
The TPI charges for Certification Engineers India Ltd. (CEIL) as TPI agency
20 b) Confirmed
shall be borne by EIL.
All built in import content shall be subject to inspection by TPI (out of M/s.
Lloyds Register (Country of origin), M/s.Bureau Veritas(BV) and M/s.TUV
c) Confirmed
Nord) for which charges are included in quoted price and no additional
charges shall be paid by EIL.
Validity:
a) Confirm that the Offer is valid for period as mentioned in RFQ covering Confirmed
letter from the bid due date/ extended due date.
21 For 2 years O&M spares, prices shall be kept valid for a period of 2 years
b) Confirmed
from the date of order of main equipment.
Confirm that Annual % escalation for subsequent two years beyod the
c) validity of 2 years for O&M spares have been quoted in format for prices Confirmed
for O&M spares.
Page 52 of 674
Confirm acceptance in totality to the following :
General Purchase Conditions (GPC) indigenous Confirmed
Instructions to Bidders / SIB Confirmed
Terms & Conditions for supervision of Erection, Testing & Confirmed
22
Commissioning (if applicable).
Terms & Conditions for site work (if applicable). Confirmed
Terms & Conditions for Annual Maintenance Contract (if applicable). Confirmed
All other terms & conditions of RFQ covering letter. Confirmed
Confirm that you have furnished the following documents in the offer:
a) Original Integrity Pact Furnished
23
b) Solvency Certificate Furnished
c) Concurrent / Present Commitment Furnished
Confirm the list, wherever required as per MR, has been submitted for
following :
a) Mandatory Spares (if specified in MR) Confirmed
b) Commissioning Spares (as included in main item) Confirmed
24
c) Special tools & tackles (if required) Confirmed
d) Recommended Spares for two years normal operation & maintenance (if Confirmed
required)
e) First fill of consumables, lubricant, etc Confirmed
Confirm that you have quoted strictly for items based on your registration
25 Confirmed
/ approval with EIL on the date of issue of RFQ.
Furnish Annual Report containing Balance Sheet & Profit & Loss Statement
26 Enclosed
for last one (01) years along with your unpriced offer.
Confirm that net worth of your company (bidder) during the last financial
27 Confirmed
year is positive.
Whether any of the Directors of Bidder is a relative of any Director of EIL
or the Bidder is a firm in which any Director of EIL or his relative is a
28 No
partner of the Bidder or a private company in which any Director of EIL is a
Director.
Please confirm you have not been banned or delisted by any Government
29 or Quasi Government agencies or PSUs. If you have been banned, then this Confirmed
fact must be clearly stated.
Deviations to Terms & Conditions shall lead to loading of prices or
30 Confirmed
rejection of offer as per Instructions to Bidders. Please confirm.
Printed terms and conditions, if any, appearing in quotation, shall not be
applicable in the event of order. In case of contradiction between the
31 Confirmed
confirmations given above and terms & conditions mentioned elsewhere
in the offer, the confirmation given herein above shall prevail.
BIDDERS SIGNATURE & DATE : _______________________________

SEAL/ STAMP
Page 53 of 674
ANNEXURE I TO PRE-FILLED AGREED TERMS & CONDITIONS (FOR INDIGENOUS SUPPIERS)
NAME OF BIDDER : _______________________________________________________________________
OFFER REFERANCE: ________________________________________________ DATED ________________
RFQ NO.: _______________________________________________________________________________
ITEM : ________________________________________________________________________________
PROJECT : RESID UPGRADATION PROJECT COKER BLOCK OF CPCL, CHENNAI
1. Bidder confirms the following : DESPATCH POINT ________________________________

2. Service Tax & Education Cess on Supervision Charges, if applicable. _________________________% EXTRA
3. Service Tax & Education Cess on Site Work Charges, if applicable. _________________________% EXTRA
4. Service Tax & Education Cess on AMC, if applicable.
5. Service Tax & Education Cess on Training, if applicable.

6. Rate of Excise Duty : Tariff Sub Heading No. ________________________________
7. Excise Duty + Education Cess _________________________% EXTRA
8. Maximum rate of Excise Duty applicable (If present rate is nil or
concessional) _________________________% EXTRA
9. Please indicate following break-up
a) Cenvatable [Excise Duty + Educational Cess] a) Cenvatable [ED+ Edu. Cess]________%
b) Non Cenvatable b) Non Cenvatable [ED+ Edu. Cess]____%
10. Excise Duty on freight charges (Tick one whichever is applicable). APPLICABLE
(In case no option is selected, ED on Freight Charges shall be
NOT APPLICABLE
considered to be not applicable)
11. Central Sales Tax against form C
_________________________% EXTRA
12. Tamilnadu VAT without concessional form.
(Applicable for supplies from TN State) _________________________% EXTRA
13. CST/TN VAT on freight charges (Tick one whichever is applicable). APPLICABLE
(In case no option is selected, CST/TN VAT on Freight Charges shall be
NOT APPLICABLE
considered to be not applicable)
14. Built-in import content in the offer (Tick one whichever is applicable).
APPLICABLE
(In case no option is selected, Buit-in import content shall be
considered to be not applicable) NOT APPLICABLE
15. Item detail of CIF Content
16.
(a) The bidder is a Micro or Small Enterprise under the Micro, Small & YES NO
Medium Enterprises Development Act, 2006.
(b) Documentary evidence required as per RFQ to avail preference to FURNISHED
MSEs.
(c) The MSEs is owned by SC/ST Entrepreneurs. YES NO

\
(d) Supporting documentary evidence with respect to MSEs is owned FURNISHED

by SC/ST Entrepreneurs as per RFQ to avail preference to MSEs
owned by SC/ST.
BIDDERS SIGNATURE & DATE : _______________________________WITH SEAL/STAMP
Page 54 of 674
ANNEXURE - II TO AGREED TERMS & CONDITONS (INDIGINEOUS)
MANDATE FORM
1. Bidder Name :
2. Bidder Code: :
3. Address of the Bidder :

4. Particulars of Bank Account of Bidder :
a. Name of the Bank :

b. Name of the Branch and Address of the Branch :
c. Branch Code :
d. 9 Digit MICR code Number of the Bank & Branch :

(As appearing in the MICR Cheque issued by the bank)
(Please do not give multicity cheque book code Number)
e. Type of account (Saving Bank, Current or Cash Credit) :

f. Account Number :
g. RGTS/ IFSC Code (11 digit) :

h. NEFT Code No. :
5. E-mail address of the Bidder :

6. Contact Person(s) of the Bidder :
I/ we declare that the particulars given above are correct and complete and I/ we accord our consent for
receiving all our payments through Electronic Mechanism.
____________________________________________________
(Signature and designation of the Authorised person(s) of Bidder)
Official seal of the Bidder

Place :
Date :
BANK CERTIFICATION
Certified that the particulars furnished above are correct as per our records.
Place :
Date :
______________________________________
Signature of the Authorised Official of the Bank
Banks Stamp
Page 55 of 674
JOB NO. A133
PRE-FILLED AGREED TERMS & CONDITIONS (FOR IMPORTS)
BIDDERs NAME : M/s._____________________________________________________________________________
RFQ No.: ________________________________________________________________________________________
Bidders Offer Ref. No. :____________________________________________________________________________
Tel No. : ____________________________________ Fax No.:_____________________________________________
Contact Person :________________________E-Mail:______________________Mobile No:_____________________
1. Duly signed & stamped copies of this pre-filled Questionnaire shall be enclosed with each and every set of
bidders unpriced quotation.
2. Failure on the part of bidder in not returning this duly filled-up Questionnaire with all the sets of unpriced
quotation and/or submitting incomplete replies may lead to rejection of bidders quotation.

Confirm that the offer contains firm unit and total prices separately on
a) FOB International Seaport of Exit basis (including stowage charges, if Confirmed
applicable) as per INCOTERMS 2010.
Indicated
b) Indicate name of International Seaport of Exit.
(Refer Annexure-I)
Please Confirm that Firm Ocean Freight charges up to Port of Entry in Confirmed
1. c)
India (Chennai) have been quoted in the Price Bid.
Validity of Ocean Freight shall be kept valid for a period one month
d) Confirmed
lesser to delivery Period.
EIL reserves to place order on FOB Port of Exit or on CFR Port of Entry
basis. In case, order is placed on FOB basis, EIL reserves the right to
e) Confirmed
convert the order on CFR Port of Entry basis 01 month prior to
Contractual Date of Delivery (CDD). Confirm acceptance.
Delivery Period:
2. Confirmed
Please confirm delivery/completion period as per RFQ/SIB.
Currency of Quote: Currency of quote is in USD. Change in currency
3. Confirmed
quoted / any other currency will not be allowed. Confirm Compliance.
Marine-cum-erection insurance (MCE policy):
Prices quoted must exclude marine insurance charges from FOB
4. International Port of Exit as the same shall be arranged by the
Confirmed
Purchaser. However, all transit insurance charges for inland transit upto
FOB International Port of Exit must be included in your prices.
Taxes & Duties:
a) All taxes, duties and levies of any kind payable upto FOB International Confirmed
Seaport of Exit basis shall be borne by you.
5.
Export permit/license if required shall be Bidders responsibility & any
b) expenditure towards the same will be borne by you. Confirm Confirmed
acceptance.
Testing charges:
6.
Confirm that quoted prices are inclusive of all testing including IBR/ IGC/
Radiography/ NACE charges (if applicable) as per Material Requisition Confirmed
attached.
A133-ATC (IMP)-REV 0 AUG13 Page 1 of 5
Page 56 of 674
Third Party Inspection charges:
Goods and services shall be subject to stagewise and final inspection (as
7. a) required in the MR) by a third party inspection agency (out of Confirmed
M/s.Lloyds Register (Counry of origin), M/s.Bureau Veritas(BV) and
M/s.TUV Nord and the prices must be inclusive of the same.
Validity:
a) Confirmed
Confirm validity of offer shall be as per SIB / RFQ Covering Letter.
For 2 years O&M spares, prices shall be kept valid for a period of 2 years
8.
b) Confirmed
from the date of order of main equipment.
Confirm that Annual % escalation for subsequent two years beyod the
c) validity of 2 years for O&M spares have been quoted in format for prices Confirmed
for O&M spares.
Indicated
9. Manufacturers name and address
(Refer Annexure-I)
Country of Origin: Indicated
10.
Country of origin from where the goods have been offered. (Refer Annexure-I)
Confirm documentation charges as per MR are inclusive in quoted
11. Confirmed
prices.
Confirm customer references list for the item/ model quoted by you, is
12. Confirmed
given in offer.
Confirm complete technical literature/catalogue are submitted along
13. Confirmed
with each copy of the offer.
Indicated
14. Indicate shipping weight (net and gross) & volume of the consignment.
(Refer Annexure-I)
Performance Bank Guarantee:
a)
Submission of Contract cum Performance Bank Guarantee (CPBG) for Confirmed
10% of total order value as per General Purchase Conditions (GPC) and
15.
Instructions to Bidders.
Indemnity Bond/Corporate Guarantee in lieu of CPBG shall not be
b) Confirmed
considered.
Firmness of prices:
16. Confirm quoted prices shall remain firm and fixed till complete Confirmed
execution of order. However, in case of Cables, variation in prices shall
be admissible as per IEEMA Price Variation Clause.
Part Order:
a) Confirmed
Confirm acceptance to part order.
17.
In case of part order, confirm all lumpsum charges quoted extra if any
b) viz. Documentation, testing, third party, packing, crating, handling, FOB, Confirmed
IBR etc., can be considered on prorata value basis.
Repeat Order:
18. Confirm acceptance of repeat order as per the clause specified in GPC Confirmed
(Imports).
Price Reduction on delay in delivery:
19. a) Confirm acceptance of applicable Price Reduction Schedule for delayed Confirmed
delivery as per RFQ/SIB.
Page 57 of 674
In case of delay, bidder will reduce the invoice amount by applicable
b) Confirmed
reduction.
Payment Term:
20. Confirmed
Acceptance of applicable Payment terms as per RFQ/SIB.
Letter of Credit shall be established within 45 days of receipt of

acknowledgement of Fax of acceptance (FOA) / Purchase Order (PO) and
a) Confirmed
submission of requisite Contract cum Performance Bank Guarantee
within 30 days of FOA/ PO. Confirm acceptance.
Letter of Credit shall be opened through a Govt. of India Bank and hence
b) Confirmed
need not be confirmed. Confirm acceptance.
However, if you still insist for confirmed L/C, confirmation charges shall
21. c) Confirmed
be borne by you. Confirm acceptance.
It is noted that in the event of delays in delivery, payment shall be
d) released after making such price reduction from Sellers bills and Confirmed
relevant clause in this respect shall be inserted in L/C.
All Bank charges and stamp duties payable outside India in connection
with payments to be made under the Purchase Order, if placed, shall be
e) Confirmed
borne by you. All bank charges and stamp duties payable in India shall
be borne by the Purchaser. Confirm acceptance.
Confirm acceptance in totality to the following :
General Purchase Conditions (GPC) imports Confirmed
Instructions to Bidders Confirmed
Special Instruction of Bidders (SIB). Confirmed
22. Terms & Conditions for supervision of Erection, Testing & Confirmed
Commissioning (if applicable).
Terms & Conditions for site work (if applicable). Confirmed
Terms & Conditions for Annual Maintenance Contract (if applicable). Confirmed
All other terms & conditions of RFQ covering letter. Confirmed
Direct offer without the intermediary of an Indian Agent will only be
23. Confirmed
considered.
No correspondence with Indian Agent will be entertained. However, if
Indian Agent is involved, the bidder shall provide reason/ justification.
Further it should be ensured by bidder that the agents get themselves
registered with Reserve Bank of India (RBI). Payments to Indian Agent Confirmed
a)
shall only be remitted after getting proof of registration with RBI, New
Delhi. The payments to overseas suppliers (i.e. the principals) shall be
released through L/C after deducting the Indian agents commission
24. from the quoted prices. Confirm acceptance.
Indicate the name of the Indian Agent, with his full address and Indicated
b)
percentage of commission included in your offer. (Refer Annexure-I)
Indian Agent Commission will be paid directly by Purchaser to Indian
Agent in equivalent Indian Rupees (on conversion rate as applicable on
c) Confirmed
the date of payment to BIDDER) after satisfactory completion of the
order. Confirm acceptance.
Please indicate name and address of your Bankers for L/C opening, Indicated
25.
telephone/E-mail address. (Refer Annexure-I)
Page 58 of 674
26. All correspondence must be in ENGLISH language only. Noted
Please confirm you have not been banned or delisted by any

27. Government or Quasi Government agencies or PSUs. If you have been Confirmed
banned, then this fact must be clearly stated.
Confirm the list, wherever required as per MR, with item wise prices
have been submitted for following :
a) Mandatory Spares (if specified in MR) Confirmed
28.
b) Commissioning Spares (as included in main item) Confirmed
c) Special tools & tackles (if required) Confirmed
d) Recommended Spares for two years normal operation & maintenance Confirmed
Confirm that you have furnished the following documents in the offer:
a) Original Integrity Pact Furnished
29.
b) Solvency Certificate Furnished
c) Concurrent / Present Commitment Furnished
Furnish Annual Report containing Balance Sheet & Profit & Loss
30. Furnished
Statement of last one (01) year along with your unpriced offer:
Confirm that net worth of your company (bidder) during the last
31. Confirmed
financial year is positive.
Deviations to Terms & Conditions shall lead to loading/rejection of
32. Confirmed
prices as per Instructions to Bidders or rejection of offer.
Printed terms and conditions, if any, appearing in quotation, shall not be
applicable in the event of order. In case of contradiction between the
33. confirmations given above and terms & conditions mentioned Confirmed
elsewhere in the offer, the confirmation given herein above shall
prevail.
SEAL/ STAMP
Page 59 of 674
ANNEXURE I TO PRE-FILLED AGREED TERMS & CONDITIONS (FOR IMPORTS)
NAME OF BIDDER : _______________________________________________________________________
OFFER REFERANCE: ________________________________________________ DATED ________________
RFQ NO.: _______________________________________________________________________________
ITEM : ________________________________________________________________________________
PROJECT : RESID UPGRADATION PROJECT COKER BLOCK OF CPCL, CHENNAI
Bidder confirms the following :
1. International Seaport of Exit _________________________________
2. Manufacturers name & address

_________________________________
3. Country of Origin from where the goods have been offered _________________________________
4. Indicate shipping weight (net & gross) & volume of the
consignment.
5. Indicate Indian Income Tax as currently applicable, if

______________________%
any on supervision charges.
6. Indicate Permanent Account Number (PAN)
7. Clarify the applicability of Indian Agent in the offer. APPLICABLE

NOT APPLICABLE
If applicable, Indicate the name of the Indian Agent, with his
full address and percentage of commission included in your
offer. _________________________________
8. Indicate name & address of your Bankers for L/C opening,

telephone/E-mail address.
WITH SEAL/STAMP
Page 60 of 674
COKER BLOCK OF RESID UPGRADATION PROJECT
GENERAL PURCHASE CONDITIONS

(INDIGENOUS)
INDEX
PART A: GENERAL PURCHASE CONDITIONS (INDIGENOUS)
1. DEFINITIONS 18. RECOVERY OF SUMS DUE

2. REFERENCE FOR DOCUMENTATION 19. CHANGES
3. CONFIRMATION OF ORDER 20. CANCELLATION
4. SALES CONDITIONS 21. PATENTS AND ROYALTY
5. COMPLETE AGREEMENT 22. CONTROL REGULATION
6. INSPECTION - CHECKING - TESTING 23. PERFORMANCE GUARANTEE
7. OFFICIAL INSTITUTIONAL TESTING 24. NON-WAIVER
8. OILS & LUBRICANTS 25. NON-ASSIGNMENT
9. SPARE PARTS 26. PART ORDER/REPEAT ORDER
10. TRANSIT RISK INSURANCE 27. SELLERS DRAWINGS AND DATA REQUIREMENT
11.RESPECT FOR DELIVERY DATES 28. TECHNICAL INFORMATION
12. DELAYED DELIVERY 29 PROGRESS CHART AND EXPEDITING
13. DELAYS DUE TO FORCE MAJEURE 30. SERVICES OF SELLERS PERSONNEL
14. REJECTION, REMOVAL OF REJECTED GOODS AND 31. SELLERS LIABILITIES
REPLACEMENT 32. PURCHASERS MATERIAL
15. TRANSFER OF PROPERTY FROM THE 33. HEADINGS
SELLER TO THE PURCHASER 34. ARBITRATION
16. PRICE 35. JURISDICTION
17. TERMS OF PAYMENT
PART B: PACKING, MARKING, SHIPPING AND

DOCUMENTATION SPECIFICATION FOR INDIGENOUS
MATERIAL (Document No. 8-1843-0002 Rev. No. 0)
PARTC: PROFORMA OF BANK GUARANTEE

(PERFORMANCE)
PARTD: PROFORMA OF BANK GUARANTEE

ADVANCE (INDIGENOUS)
A133-01-GPC (Ind.)-R0
Page 61 of 674 Page 1 of 7
PART A: GENERAL PURCHASE CONDITIONS (INDIGENOUS)
1. DEFINITIONS: Purchase Order / Purchase Requisition number must

appear on order confirmation, correspondence,
The following expressions used in these General drawings, invoices, shipping notes, packing and/ or any
Purchase Conditions (GPC) and the Purchase shall documents or paper connected with the Order.
have the meaning indicated against each of these:
3. CONFIRMATION OF ORDER:
The PURCHASER / OWNER means Engineers India
Limited, a company incorporated in India having its The Seller shall acknowledge the receipt of the Fax of
registered office at Engineers India Bhawan, 1, Bhikaiji Acceptance (FOA) / Purchase Order (PO) within seven
Cama Place, RK Puram, New Delhi-110066 and shall days following the date of the FOA / Purchase Order
include its successors and assignees. and shall thereby confirm his acceptance of the FOA /
Purchase Order without any exceptions. This
GOODS/MATERIALS: Goods and/or materials shall acknowledgment will bear on both FOA / Purchase
mean any of the Articles, Materials, Machinery, Order and General Purchase Conditions
Equipment, Supplies, Drawings, Data and other
property and all services including but not limited to 4. SALES CONDITIONS:
design, delivery, installation, inspection, testing and
commissioning specified to complete the order. With Sellers acceptance of provision of the Purchase
Order, he waives and considers as cancelled any of his
SELLER: Seller shall mean the Person, Firm or general sales conditions.
Corporation to whom the Fax of Acceptance / Purchase
Order is issued. 5. COMPLETE AGREEMENT:
Contractual Delivery Date: Contractual Delivery The terms and conditions of the Purchase Order shall
Date is the date on which goods shall be delivered constitute the entire Agreement between the parties
F.O.T dispatching point/destination in accordance with hereto. Changes will be binding only if the amendments
the terms of the Purchase Order. The contractual are made in writing and signed by an authorized
delivery date/period is inclusive of all the lead time for representative of the Purchaser.
engineering, procurement of raw materials,
manufacturing, inspection, testing packing and any 6. INSPECTION-CHECKING-TESTING:
other activities whatsoever required to be accomplished
for effecting the delivery at the agreed delivery point. The equipment, materials and workmanship covered by
the Purchase Order are subject to inspection and
Procurement co-coordinators /Managers: testing at any time prior to shipment and/or despatch
Purchasers authorized representative appointed as and to final inspection within a reasonable time after
procurement co-ordinators/ manager. arrival at the place of delivery. Inspectors shall have the
right to carry out the inspection and testing which will
INSPECTORS: Inspectors Inspectors deputed / include the raw materials at manufacturers shop, at
authorized by Purchaser including Third Party fabricators shop and at the time of actual despatch
Inspection Agency. before and after completion of packing.
CLIENT: client means Chennai Petroleum Corporation All tests, mechanical and others as specified in the
Limited. Purchase Requisition and particularly those required by
codes will be performed at Sellers expenses and in
PROJECT: Resid Upgradation Project- Coker Block accordance with Inspectors instructions. The Seller will
at Manali Refinery of Chennai Petroleum Corporation also bear the expenses concerning preparation and
Limited. rendering of tests required by Boiler Inspectorate or
such other statutory testing agencies or by Lloyds
PROJECT MANAGEMENT CONSULTANT or Register of Shipping and Industrial Services as may be
PMC or CONSULTANT shall mean any person(s) required.
nominated by the OWNER as the Project
Management Consultant for the Project. The words The salaries and fees of Inspectors and their travelling,
PROJECT MANAGEMENT CONSULTANT, PMC& lodging and boarding expenses will not be borne by the
CONSULTANT are synonymous. M/s Jacobs Seller unless inspection becomes anfractuous due to
Engineering India Private Limited is the PMC for this any omission or commission on the part of the Seller.
Project. Before shipping or despatch, the equipment and/or
materials will have to be checked and stamped by
2. REFERENCE FOR DOCUMENTATION: Inspectors who are authorized also to forbid the use
A133-01-GPC (Ind.)-R0
and despatch of any equipment and/or materials which Inspectors to maintain Schedule and delay, if any, in
during tests and inspection fail to comply with the this process will not be taken into consideration as a
specification, codes and testing requirements. cause of Force Majeure.
The Seller shall: 8. OILS & LUBRICANTS:
- Inform Procurement Coordinator/Managers at The first filling of oils and lubricants, if any, required for
least eight days in advance of the exact place, every equipment shall be supplied inline with MR. The
date and time of rendering the equipment or Seller shall also recommend the quality / quantity of oils
materials for required inspection. and lubricants required for one-year continuous
operation.
- Provide free access as required to Inspectors
during normal and / or extended working hours 9. SPARE PARTS:
to Sellers or his/its sub-Suppliers works and
place at their disposal all useful means of The Seller must furnish item wise and priced list of
performing, checking, marking, testing, spare parts required for two years normal operation and
inspection and final stamping. maintenance of the equipment and prime movers also.
Even if the Inspections and tests are fully carried out, The Seller shall provide the necessary cross - sectional
Seller would not be absolved to any degree from his drawing to identify the spare parts numbers and their
responsibilities to ensure that all equipment and location as well as an inter-changeability chart.
material supplied comply strictly with requirements as
per agreement both during manufacturing, at the time of 10. TRANSIT RISK INSURANCE:
delivery, inspection, on arrival at site and after its
erection or start-up and guarantee period as stipulated The Purchaser against its/ Clients Open General Policy
in Clause 23 herein. (The name of the Insurance Co. will be conveyed
subsequently) shall cover transit Risk Insurance. The
The Sellers responsibility will not be lessened to any Seller shall advise the dispatch particulars to the
degree due to any comments made by Procurement Insurance Company under advice to the Procurement
Coordinators/Managers and Inspectors on the Sellers Coordinators / Managers before shipment.
drawings or specifications or by inspectors witnessing
any chemical or physical tests. In any case, the 11. RESPECT FOR DELIVERY DATES:
equipment must be in strict accordance with the
Purchase Order and/or its attachments failing which the Time of delivery as mentioned in the Purchase Order
Purchaser shall have the right to reject the goods and shall be the essence of the agreement and no variation
hold the Seller liable for non-performance of contract. shall be permitted except with prior authorization in
writing from the Purchaser. Goods should be delivered
7. OFFICIAL INSTITUTIONAL TESTING: securely packed and in good order and condition at the
place and within the time specified in the Purchase
In addition to testing and inspection by Inspectors Order for their delivery. The Purchaser reserves the
mentioned above, Lloyds register Industrial services or right to defer the period of delivery in writing.
similar institutional agencies like Boiler-Inspectorate
may be assigned for official testing of all coded 12. DELAYED DELIVERY:
equipment. The Seller shall ensure that all Procedures
for preparation and Performance of test prescribed by The time and date of delivery of materials / equipment
such institution shall be complied scrupulously. as stipulated in the Order shall be deemed to be the
essence of the contract. In case of delay in execution
The Seller is required to send to such institutions as of the order beyond the date of delivery stipulated in the
may be designed by the Purchaser at least three sets of order or any extensions sanctioned, the Purchaser may
fabricated / manufactured drawings for each equipment at his option either:
and calculations. All manufacturers mill test certificates
and analytical reports from material laboratories in (i) Accept delayed delivery at prices reduced by as per
respect of all raw material and components employed Price Reduction Schedule Clause of RFQ.
shall have to be presented to such Institutions
Inspectors in the number of copies required. Seller (ii) Cancel the order in part or full and purchase such
shall be responsible for any delay in submission of cancelled quantities from elsewhere on account and at
necessary certificates. The Seller shall maintain close risk and cost of the Seller, without prejudice to its right
liaison with Procurement Co-ordinators and Institutions under (i) above in respect to goods delivered.
A133-01-GPC (Ind.)-R0
13. DELAYS DUE TO FORCE MAJEURE: The transfer of property shall be deemed to have taken
place as follows subject to the provisions herein
In the event of causes of Force Majeure occurring within contained:
the agreed delivery terms, the delivery dates can be
15.1 F.O.T. despatch point: On handing over the
extended by the Purchaser on receipt of application
equipment to the carrier against receipt and
from the Seller without imposition of penalty. Only
such receipt having been passed over to the
those causes which depend on natural calamities, wars
Purchaser.
and national strikes which have duration of more than
seven consecutive calendar days and Government Acts 15.2 Equipment sent freight/ carriage paid to the
and other direct legislative enforcement are considered
Refinery site: On receipt of goods at site.
the causes of Force Majeure.
15.3 Equipment erected by the Seller; on
The Seller must advise the Purchaser by a registered acceptance at job site.
letter duly certified by a local Chamber of Commerce or
15.4 Equipment commissioned by the Seller: On
statutory authorities, the beginning and the end of such
taking over by the Purchaser for regular
causes of delay immediately, but in no case later than
operation after test run at maximum capacity
10 days from the beginning and end of each cause of
for specified period satisfactorily performed.
such Force Majeure condition defined above.
16. PRICE:
The extension of time for completion of the work or any
part of the work or any operation(s) involved therein Unless otherwise agreed to in the terms of the
shall be the sole remedy of the Seller for any cause or Purchase Order, the price shall be:
event of delay and the Seller shall not be entitled in
addition to or in lieu of such extension to claim any a) Firm and not subject to escalation for any reasons
damages or compensation for extended stay or whatsoever till the execution of entire order even though
otherwise whether under the law governing contracts or it might be necessary for the order execution to take
quasi-Seller or any other relationship, and the Seller longer than the delivery period specified in the order.
hereby waives and disclaims any and all contrary rights.
b) Inclusive of adequate road worthy packing and
14. REJECTION, REMOVAL OF REJECTED forwarding charges upto effecting delivery at F.O.T.
GOODS AND REPLACEMENT: despatch point in all cases whenever F.O.T destination
delivery terms are agreed to but exclusive of transit
In case the testing and inspection at any stage by insurance.
Inspectors reveal that the equipment, material and
workmanship do not comply with the specification and c) Exclusive of Central/State Sales Tax, Excise Duty
requirements, the Seller at his/its own expense and risk and or such imposts which are leviable by law on sales
shall remove the same within the time allowed by the of finished goods to Purchaser and/or Octroi duty, if
Purchaser. The Purchaser shall be at liberty to dispose any, leviable at destination/ project site. The nature and
of such rejected goods in such a manner, as he may extent of such levies shall be shown separately.
think appropriate. In the event the Seller fails to remove
the rejected goods within the period as aforesaid, all 17. TERMS OF PAYMENT:
expenses incurred by the Purchaser for such disposal
shall be to the account of the Seller. The freight paid by Payment terms shall be as specified in the Inquiry /
the Purchaser, if any, on the inward journey of the Purchase Order.
rejected materials shall be reimbursed by the Seller to
the Purchaser before the rejected materials are Seller shall claim their invoice excluding Excise Duty.
removed by the Seller. The Excise Duty shall be released separately on receipt
of documents including Transporters copy of Invoice,
The Seller shall have to proceed with the replacement valid for availing CENVAT. In the event CPCL is not
of that equipment or part of the equipment at able to claim CENVAT, the amount of Excise Duty to
Purchasers stores / site, if so required by the that extent shall be recovered from the Seller.
Purchaser, without claiming any extra payment. The
time taken for replacement in such event will not be Seller shall ensure submission of proper documents for
added to the contractual delivery period. availing CENVAT/ VAT benefits of Service Tax/ VAT. In
case the documents are not found to be in order,
15. TRANSFER OF PROPERTY FROM THE amount of Service Tax/ VAT will be recovered from the
SELLER TO THE PURCHASER. Seller.
A133-01-GPC (Ind.)-R0
The Seller shall furnish to the Purchaser bank owned by the Seller.
guarantee / Cash Security. Bank Guarantee shall be
from a Scheduled/ Nationalized Bank in a form Upon receipt of the cancellation notice the Seller shall
approved by the Purchaser for an amount of 10% of the discontinue all work on the Purchase Order and matters
contract value as security for the due performance of all connected with it.
the Sellers liability in terms of and/or in connection with
the contract. This security will be released after the The Purchaser in that event will be entitled to procure
expiry of the period of performance guarantee. the requirement in the open market and recover the
excess payment over the Venders agreed price, if any,
The financial settlement of Sellers Invoice is liable to be from the Seller, reserving to itself the right to forfeit the
withheld in the event the Seller has not complied with security deposit, if any, made by the Seller against the
submission of drawing, data and such documentation contract. The Seller is aware that the said goods are
as called for in Purchase Order and/or as required required by the Purchaser for the ultimate purpose of
otherwise. material production and that non delivery may cause
loss of production and consequently loss or profit to the
18. RECOVERY OF SUMS DUE: Purchaser. In this event of the Purchaser exercising the
option to claim damages for non-delivery other than by
Whenever any claim against the Seller for payment of way of difference between the market price and the
sum of money arises out of or under the contract, the contract price, the Seller shall pay to the Purchaser, the
Purchaser shall be entitled to recover such sums from fair compensation to be agreed upon between the
any sum then due or which at any time thereafter may Purchaser and the Seller.
become due from the Seller under this or any other
contract with the Purchaser including right to encash the The provision of this clause shall not prejudice the right
PBG. In the event of encashment of PBG, the same of the Purchaser from invoking the provisions of clause
shall be re-stored to its original amount by the Seller Delayed Delivery as aforesaid.
and should this sum be not sufficient to cover the
recoverable amount, the Seller shall pay to the 21. PATENTS AND ROYALTIES:
Purchaser on demand the balance remaining due.
On acceptance of this order, the Seller will be deemed
19. CHANGES to have entirely indemnified the Purchaser and
Procurement Coordinators/Managers from any legal
The Purchaser has the option at any time to make action or claims regarding compensation for breach of
changes in quantities ordered or in specifications and patent rights which the Seller deems necessary to apply
drawings. If such changes cause an increase or for manufacturing the ordered equipment and/or
decrease in the price or in the time required for supply, materials or which can in any way be connected in the
an equitable, adjustment under this provision must be manufacture.
finalized within 10 days from the date when the change
is ordered. 22. CONTROL REGUALTIONS:
20. CANCELLATION: The supply, despatch and delivery of goods shall be

arranged by the Seller in strict conformity with the
The Purchaser reserves the right to cancel the statutory regulations including provision of Industries
Purchase Order or any part thereof and shall be entitled (Development and Regulation) Act, 1951 and any
to rescind the contract wholly or in part in a written amendment thereof as applicable from time to time.
notice to the Seller if: The Purchaser disowns any responsibility for any
irregularity or contravention of any of the statutory
i) The Seller fails to comply with the terms of this regulations in manufacture or supply of his stores
Purchase Order. covered by this order.
ii) The Seller fails to deliver the goods on time

23. PERFORMANCE GUARANTEE:
and/or replace the rejected goods promptly.
iii) The Seller becomes bankrupt or goes into The Seller shall guarantee that any and all materials
liquidation. used in execution of the Purchase Order shall be in
strict compliance with characteristics, requirements and
iv) The Seller makes a general assignment for specifications agreed upon and that the same shall be
the benefit of creditors. free from any defects. Checking of the Sellers drawings
by Procurement Co-coordinators/ Managers and their
v) A receiver is appointed for any of the property approval and permission to ship or despatch the
A133-01-GPC (Ind.)-R0
equipment and materials guaranteed by Inspectors 27. SELLERS DRAWING AND DATA
shall not relieve the Seller from any part of his/its REQUIREMENT:
responsibilities of proper fulfillment of the requirement.
The Seller will guarantee that all materials and The Seller shall submit drawings, data and
equipment shall be repaired or replaced as the case documentation in accordance with but not limited to
may be, at his own expense in case the same have what is specified in the requisition and/or in the Seller
been found to be defective in respect of materials, drawings and data form attached to the Purchase
workmanship or smooth and rated operation within Requisition and as called for in Clause 8, viz. Expediting
Guarantee Period as stipulated in the RFQ document. above. Types, quantities and time limits of submitting
this must be respected in its entirety failing which the
The guarantee period for the replaced parts shall be 18 Purchase Order shall not be deemed to have been
months starting from the date on which the executed for all purposes including settlement of
replacements are put in service or period as specified payment since the said submission is an integral part of
above in case of critical items, whichever is later. Purchase Order execution.
Acceptance by the Purchaser or Inspectors of any
equipment and materials or their replacement will not 28. TECHNICAL INFORMATION:
relieve the Seller of his/its responsibility concerning the
above guarantee. Drawings, specifications and details shall be the
property of the Purchaser and shall be returned by the
The Seller shall furnish a Bank Guarantee for 10% of Seller on demand. The Seller shall not make use of
total of total order value (as per proforma hereunder) to drawings and specifications for any purpose at any time
support Sellers performance. This bank guarantee save and except for the purpose of the Purchaser.
shall remain in force for the entire period covered in
Performance Guarantee plus three months. The Seller shall not disclose the technical information
furnished to or gained by the Seller under or by virtue of
24. NON-WAIVER: or as a result of the implementation of the Purchase
Order to any person, firm or body or Corporate authority
Failure of the Purchaser / Procurement Coordinators/ and shall make all endeavours to ensure that the
Managers to insist upon any of the terms or conditions technical information is kept CONFIDENTIAL. The
incorporated in the Purchase Order or failure or delay to technical information imparted and supplied to the
exercise any rights or remedies herein or by law or Seller by the Purchaser shall at all times remain the
failure to properly notify Seller in the event of breach, or absolute property of the Purchaser.
the acceptance of or payment of any goods hereunder
or approval of design shall not release the Seller and 29. PROGRESS CHART AND EXPEDITING:
shall not be deemed a waiver of any right of the
Purchaser / Procurement Coordinators/Managers to The Seller shall submit to EIL within four (4) weeks from
insist upon the strict performance thereof or any of his the date of Fax Of Acceptance a BAR CHART showing
or their rights or remedies as to any such goods start and finish dates for various activities forming part
regardless of when goods are shipped received or of the execution of the order and identifying the delivery
accepted nor shall any purported oral modification or dates to this activity schedule. Seller shall update this
revisions of the order by Purchaser/ Procurement bar chart every fortnight showing the actual
Coordinators/Managers act as waiver of the terms performance of the activities and if and how the delivery
hereof. date has been affected thereby. Copies of the updated
bar chart will also be submitted for review of the
25. NON ASSIGNMENT: progress of the order.
The Seller without obtaining prior written consent of the Procurement Coordinator/Managers have been
Purchaser shall not assign the Purchase Order to any assigned to expedite both manufacture and shipment of
other agency. equipment and materials covered by the Purchase
Order. The Procurement Co-coordinator/ Managers
26. PART ORDER/ REPEAT ORDER shall have free access to Sellers shop and/or sub-
Suppliers shop at any time and they shall be provided
Seller hereby agrees to accept part order at Purchasers all the necessary assistance and information to help
option without any limitation whatsoever and also them perform their job.
accept repeat order(s) during a period of 6 months from
the date of original purchase order on same unit prices, In order to facilitate over-all execution of the order within
terms and conditions. the contractual delivery date, Seller shall furnish to
Procurement Coordinator / Manager within 4 weeks of
A133-01-GPC (Ind.)-R0
receipt of Purchase Order in required number of copies c) The Seller shall give a firm and binding list of
of documents / detailed drawings such as but not Purchasers issue of materials which shall be duly
limited to schedule/PERT chart, unpriced copies of sub reviewed & approved by EIL and the desired schedule
orders/sub contracts, phased program of itemize of its delivery to shop floor strictly in accordance with
manufacturing, testing and delivery and any other the sequence of fabrication vis-a-vis the contractual
information/documentation as may be called for by the delivery period.
Procurement Coordinators/Managers. All post order
correspondence shall be addressed to the DGM d) Unused materials or scrap from material supplied by
(Inspection), with a copy to the Project Manager, the Purchaser to the Seller shall be returned by the
Engineers India Ltd., New Delhi. Seller to the Purchaser or if the Purchaser so directs the
Seller may dispose of the same by sale or otherwise on
30. SERVICES OF SELLERS PERSONNEL: such terms and conditions as the Purchaser may
stipulate and the Seller shall pay to the Purchaser the
Upon three week advance notice, the Seller shall sale proceeds of the material so disposed off by sale
depute the necessary personnel along with required deducting there from expenses incurred by the Seller on
Tools & Tackles to site for supervision of erection and such sale, the quantum of such deduction to be
start up of the equipment and train a few of the IOCL/ mutually agreed upon in advance between the
EILs personnel for the operation and maintenance of Purchaser and the Seller.
the equipment, if required by the Purchaser. The terms
and conditions for the services of the Seller shall be 33. HEADINGS:
mutually settled.
The headings of the conditions hereof shall not affect
31. SELLERS LIABILITIES construction thereof.
The Sellers workmen or employees shall under no 34. ARBITRATION:

circumstances be deemed to be in Purchasers
employment and the Seller shall hold himself Any dispute or difference between the parties hereof
responsible for any claims which they or their heirs, arising out of any notified claim of the SELLER included
dependents or personal representatives may have or in his final bill and /or arising out of any amount claimed
make for damages or compensation for anything done by the OWNER (whether or not the amount claimed by
or committed to be done in the course of carrying out of the OWNER or any part thereof shall have been
the work covered by this Purchase Order, whether deducted from the Final bill of the supplier or any
arising on Purchasers premises or elsewhere and amount paid by the OWNER to the SELLER in respect
agrees to Indemnify the Purchaser against any such of the work) shall be referred to arbitration in
claim or claims if made against the Purchaser and all accordance with the UNCITRAL Rules as adopted in
cost (as between attorney and client) of proceedings, India by the Arbitration & Conciliation Act, 1996.
suits or action which the Purchaser may incur or sustain
in respect of the same. The Seller shall also procure The venue of the arbitration shall be New Delhi.
and keep in force at his own cost comprehensive
automobile Liability insurance for adequate coverage in Notwithstanding the existence of any dispute or
respect of all his vehicle/s visiting or plying in project arbitration in terms hereof or otherwise, the Seller shall
premises. The Seller shall also be responsible for continue and be bound to continue and perform the
compliance of existing laws in respect of their workmen works to completion in all respects according to the
and employees.
Contract (unless the Contract or works be determined
32. PURCHASERS MATERIAL by the Owner or by the Seller under the provisions of
the Contract), and the Seller shall remain liable and
a) Purchasers materials shall be delivered to the Seller bound in all respects under the Contract.
after the Seller submits the Bank Guarantee for
Indemnifying the full value thereof strictly in the manner 35. JURISDICTION
and as per Performa of Bank Guarantee approved by
the Purchaser. The Seller hereby agrees that the Court situated at New
Delhi alone shall have the jurisdiction to hear and
b) Wherever possible, the material shall be consigned determine all action and proceedings arising out of this
to goods depot to be specifically confirmed by Seller. contract.
The Seller at his responsibility and cost shall arrange
Loading/Unloading and any handling from the
destination.
A133-01-GPC (Ind.)-R0
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PROFORMA OF BANK GUARANTEE
(PERFORMANCE)
(On non-judicial stamp paper of appropriate value)
(For Indigenous Suppliers)
To
Engineers India Bhawan
1 Bhikaiji Cama Place
R.K. Puram
New Delhi 110 066
Kind Att.: Head (LSTK-Finance)
RFQ NO.: _______________________
Dear Sirs,
In consideration of the Engineers India Limited, 1 Bhikaiji Cama Place, R.K. Puram, New Delhi-110066 (hereinafter
called the Purchaser which expression shall include its successors and assigns having awarded
________________________________ work to M/s (Name) _______________________________________
(Constitution) ___________________________ (Address) _____________________________ (hereinafter referred
to as the Supplier which expression shall wherever the subject or context so permits include its successors and
assigns) a supply contract in terms inter-alia, of the Purchasers Letter No. ______________________ dated
__________ hereinafter referred to as the Contract and the general purchase conditions of the purchaser and upon
the condition of Suppliers furnishing security for the Performance of the Suppliers obligations and/or discharge of the
Suppliers liabilities under and/or in connection with the said supply contract for a sum of Rs.
_______________________ only amounting to 10% (ten percent) of the total contract value.
We _______________________________________ (name) a body / corporate registered/constituted under the laws

of ___________________________ and having a Branch at ______________________ (Indian Branch Address)
(hereinafter called the Bank which expression shall include its successors and assigns) with the intent to bind the
Bank and its successors and assigns, hereby undertake to pay the Purchaser at __________________ (place) on
first demand in writing without protest or demur or proof or satisfaction or condition and without reference to supplier
any and all amounts from time to time demanded by the Purchaser from the Bank with reference to this
Guarantee/Undertaking upto an aggregate limit of Rs. _________________ (Rupees
___________________________ only).
AND THE BANK DOTH HEREBY FURTHER AGREE AS FOLLOWS:-
1. This Guarantee/Undertaking shall be a continuing Guarantee/Undertaking and shall remain valid and
irrevocable for all claims of the Purchaser and liabilities of the Supplier arising upto and until ___________
plus claim period of 3 months.
2. This Guarantee/Undertaking shall be in addition to any other guarantee or security whatsoever that the
Purchaser may now or at any time have in relation to the Suppliers obligations liabilities under and/or in
connection with the said supply contract and the Purchaser shall have full authority to take recourse to or
reinforce this security in preference to the other security(ies) at its sole discretion, and no failure on the part
of the Purchaser in enforcing or requiring enforcement of any other security shall have the effect of releasing
the Bank from its full liability hereunder.
3. The Purchaser shall be at liberty without reference to the Bank and without affecting the full liability of the
Bank hereunder to take an other security in respect of the Suppliers obligation and/or liabilities under or in
connection with the said supply contract and to vary the terms vis--vis the Supplier of the said supply
contract or to grant time and/or indulgence to the Supplier or to reduce or to increase or otherwise vary the
prices of the total contract value or to release or to forebear from enforcement of all or any of the obligations
of the Supplier under the said supply contract and/or the remedies of the Purchaser under any other
Guarantee(s) or Security(ies) now or hereafter held by the Purchaser and no such dealing(s), variation(s),
reduction(s) or other indulgence(s) or arrangement(s) with the Supplier or release or forbearance whatsoever
shall have the effect of releasing the Bank from its full liability to the Purchaser hereunder or of prejudicing
rights of the Purchaser against the Bank.
4. This Guarantee/Undertaking shall not be determined or affected by the liquidation or winding up, dissolution,
or change of constitution or insolvency of the Supplier or any change in the legal constitution of the Bank or
of the Purchaser.
A133-01-GPC (Ind.)-R0 Page 1 of 2
Page 75 of 674
5. Bank hereby waives all rights at any time inconsistent with the terms of this Guarantee/Undertaking and the
obligations of the Bank in terms hereof shall not be anywise affected or suspended by reasons of any dispute
or disputes having been raised by the Supplier (whether or not pending before any Arbitrator, Officer,
Tribunal or Court) or any denial of liability by the Supplier or any other order for Communication whatsoever
by the Supplier stopping or preventing or purporting to stop or prevent any payment by the Bank to the
Purchaser in terms hereof.
6. Notwithstanding anything contained herein:
(a) The Banks liability under this Guarantee/Undertaking shall not exceed Rs._____________ (In
figures) ______________________ (In words) ____________________________ only).
(b) This Guarantee/Undertaking shall remain in force upto _____________ and any extension(s)
thereof, if any; and
(c) The Bank shall be released and discharged from all liability under this Guarantee/Undertaking
unless a written claim or demand is issued to the Bank on or before _____________ plus 3 months
period or the date of expiry of any extension(s) thereof if this guarantee/undertaking has been
extended.
7. The Bank doth hereby declares that Shri ______________________ (name & designation of the person
authorized to sign on behalf of the Bank) is authorized to sign this Guarantee/Undertaking on behalf of the
Bank and to bind the Bank thereby.
Yours faithfully,
(Signature)
NAME & DESIGNATION

NAME OF THE BANK
NOTE
1. This Guarantee is required to be stamped as an agreement according to the Stamp Duty Act.
2. The Performance Bank Guarantee shall be strictly as per above proforma and shall be through Indian or
Foreign Branches of Indian Scheduled Banks (other than Cooperative Bank)/Nationalized Bank or Indian
Branches of Foreign Banks.
3. The bank shall provide details viz contact person, telephone number, fax number, e-mail address and
address of the Controlling/Regional Office of issuing bank for verification of authenticity of Bank Guarantee.
4. This Guarantee is required to be sent by Sellers Bankers directly to the Head (LSTK-Finance), Engineers
rd
India Limited, EI Bhawan, 3 Floor, 1, Bhikaiji Cama Place, New Delhi-110066.
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ADVANCE (INDIGENOUS)
To
New Delhi 110 066
Attn.: Head (LSTK-Finance)
Project ______________________
RFQ No. _____________________
Dear Sirs,
Engineers India Limited, 1, Bhikaiji Cama Place, New Delhi-110066 (hereinafter called the Purchaser which
expression shall include its successors and assigns) has awarded M/s ____________________________________
(hereinafter called The Supplier which expression shall include its successors and assigns) the work of designing,
manufacturing, fabricating and supply of ______________________ in terms of a contract as constituted by Purchase
Order No. ____________________ dated _________________ issued by the Purchaser to the Supplier (hereinafter
called The Contract which expression include all the amendments and/or modifications of the Purchase Oder).
AND WHEREAS the Purchaser has agreed to advance the Supplier a sum of Rs._________________ (Rupees
_________________________________________________) hereinafter called The Advance as financial
assistance to the Supplier under the Contract on the condition, inter alia, that the advance shall be secured by a Bank
Guarantee as hereinafter appearing:
We ______________________________ Bank _____________________ a Bank incorporated/ constituted under the

laws of _____________________ and having it registered/principal office at _________________________________
(hereinafter called The Bank which expression shall include our successors and assigns) in consideration of the
aforesaid promises and at the request of the Supplier DO HEREBY bind ourselves and our successors and assigns,
and irrevocable undertake to pay the Purchaser on first demand in writing without protest or demur or proof or
condition and without reference to the Supplier any and all amounts at any time and from time to time claimed by you,
as due to you under or in respect of the said advance, and demanded by you from us, with reference to this
undertaking for an aggregate limit of Rs. _____________ (Rupees
___________________________________________).
AND, we, the Bank DO HEREBY further agree as follows:
(i) The Purchaser shall have the fullest liberty without reference to the Bank and without affecting in any way the
liability of the Bank under this Guarantee/Undertaking, at any time and/or from time to time to anywise vary
the Contract and/or any of terms and conditions thereof or of or relative to the advance and to extend time for
the performance of the Contract and/or repayment of the advance or to postpone for any time or from time to
time the obligations of the Supplier and to waive or postpone exercise of any of the rights available to the
Purchaser against the Supplier or to forebear from enforcing any of the terms or conditions of the Contract
and/or the advance or any security(ies) available to the Purchaser, AND the liability of the Bank shall remain
in full force and effect notwithstanding any exercise by the Purchaser of the liberty with reference to any or all
the matters aforesaid or by reason of time being given to the Supplier or any forbearance, waiver, act or
omission on the part of the Purchaser or any indulgence by the Purchaser to the Supplier or any other act,
matter or thing whatsoever which under the law relating to sureties would have the effect of releasing the
Bank from its liability hereunder or any part thereof, AND the BANK DOTH HEREBY waive all rights at any
time inconsistent with the terms of this Guarantee/Undertaking.
(ii) It shall not be necessary for the Purchaser to proceed against the Supplier before proceeding against the
Bank and this guarantee/undertaking shall be enforceable against the Bank as principal debtor
notwithstanding the existence of any other security for any indebtedness of the Supplier to the Purchaser
(including relative to the advance) and notwithstanding that any such security shall at the time when claim is
made against the Bank or proceedings taken against the Bank be outstanding or unrealized.
(iii) As between the Bank and the Purchaser for the purpose of this guarantee/undertaking the amount claimed
by the Purchaser from the Bank with reference to this guarantee/ undertaking shall be final and binding upon
the bank as to the amount payable by the Bank to the Purchaser hereunder.
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(iv) The liability of the Bank to the Purchaser under this guarantee/undertaking shall remain in full force and
effect notwithstanding the existence of any difference or dispute between the Supplier and the Purchaser,
the Supplier and the Bank and/or the Bank and the Purchaser, or otherwise howsoever touching or affecting
these presents or the liability of the Supplier to the Purchaser, and notwithstanding the existence of any
instructions or purported instructions of the Supplier or any other person(s) to the Bank not to pay or for any
cause withhold or defer payment to the Purchaser under these presents with the intent that notwithstanding
the existence of such difference, dispute or instruction, the Bank shall be and remain liable to make payment
to the Purchaser.
(v) This guarantee/undertaking shall not be affected by any change in the constitution of the Bank or that of the
Supplier or the Purchaser, or any irregularity in the exercise of borrowing powers by or on behalf of the
Supplier.
(vi) This guarantee/undertaking shall be valid for all claims/demands made by the Purchaser to or upon us upto
____________________ provided always that if for any reasons, the Supplier is unable to complete supplies
under the Contract, the Bank shall at the request of the Purchaser and without recourse to the Supplier
extend the validity of this guarantee/undertaking for a further period of six months. For the purpose of this
clause, the Purchasers statement that the Supplier is unable to complete supplies under the contract shall
be conclusive and final binding on us.
(vii) Notwithstanding anything contained herein:
(a) The Banks liability under this Guarantee/Undertaking shall not exceed Rs. _______ (Rupees
__________________________________only).
(b) This Guarantee/Undertaking shall remain in force upto ______________ and any extension(s)
thereof; and
(c) The Bank shall be released and discharged from all liability under this Guarantee/ Undertaking
unless a written claim or demand is issued to the Bank on or before ________ plus 3 months claim
period, or the date of expiry of any extension(s) thereof if this guarantee/undertaking has been
extended.
(viii) The Bank DOTH HEREBY declare that Mr. ______________ (name of the person signing on behalf of the
Bank) who is _____________ (his designation), is authorized to sign this guarantee/undertaking on behalf of
the Bank and to bind the Bank thereby.
Dated this ________________________ day of ______________
Yours faithfully,
For _____________________________________________
Signature ________________________________________
Name & Designation ________________________________
Name of the Branch ________________________________
NOTE
2. The Performance Bank Guarantee shall be strictly as per above proforma and shall be through Indian or
Foreign Branches of Indian Scheduled Banks (other than Cooperative Bank)/Nationalized Bank or Indian
Branches of Foreign Banks.
3. The bank shall provide details viz contact person, telephone number, fax number, e-mail address and
address of the Controlling/Regional Office of issuing bank for verification of authenticity of Bank Guarantee.
4. This Guarantee is required to be sent by Sellers Bankers directly to the Head (LSTK-Finance), Engineers
rd
India Limited, EI Bhawan, 3 Floor, 1, Bhikaiji Cama Place, New Delhi-110066.
Page 78 of 674
COKER BLOCK OF RESID UPGRADATION PROJECT
GENERAL PURCHASE CONDITIONS

(IMPORTS)
INDEX
PART-A: GENERAL PURCHASE CONDITIONS (IMPORTS)
1. DEFINITIONS 18. RECOVERY OF SUMS DUE

2. REFERENCE FOR DOCUMENTATION 19. MODIFICATIONS
3. IMPORT LICENCE 20. CANCELLATION
4. CONFIRMATION OF ORDER 21. PATENTS AND ROYALTY
5. SALES CONDITIONS 22. PERFORMANCE GUARANTEE
6. COMPLETE AGREEMENT 23. NON-WAIVER
7. INSPECTION - CHECKING - TESTING 24. NON ASSIGNMENT
8. EXPEDITING 25. SELLERS DRAWINGS AND DATA
9. OILS & LUBRICANTS REQUIREMENT
10. SPARE PARTS 26. TECHNICAL INFORMATION
11. RESPECT FOR DELIVERY DATES 27. SERVICES OF SELLERS PERSONNEL
12. DELAYED DELIVERY 28. HEADINGS
13. DELAYS DUE TO FORCE MAJEURE 29. ARBITRATION
14. REJECTION, REMOVAL OF REJECTED 30. FOREIGN LIABILITY CLAUSE IN COTRACTS
GOODS AND REPLACEMENT 31. ADDRESSES
15. PRICE 32. JURISDICTION:
16. TERMS OF PAYMENT
17. PART ORDER/ REPEAT ORDER
PART-B : PACKING, MARKING, SHIPPING AND DOCUMENTATION SPECIFICATION FOR INDIGENOUS

MATERIAL (Document No. 8-1843-0001 Rev. No. 0)
PARTC : PROFORMA OF BANK GUARANTEE (PERFORMANCE)
PARTD : PROFORMA OF BANK GUARANTEE ADVANCE (FOREIGN)
A133-02-GPC (Imp.)-R0 Page 1 of 6

Page 79 of 674
PART- A: GENERAL PURCHASE CONDITIONS (IMPORTS)
1. DEFINITIONS:
The following expressions used in these General Purchase Conditions (GPC) and the Purchase Order shall have the
meaning indicated against each of them:
PURCHASER/ OWNER: The Purchaser means Engineers India Limited a company incorporated in India having its
registered office at Engineers India Bhawan, 1, Bhikaiji Cama Place, RK Puram, New Delhi-110066, India and shall
include its successors and assignees.
GOODS/MATERIALS: Goods and/or materials shall mean any of the articles, materials, Machinery, Equipments,
Supplies, drawing, data and other property and all services including but not limited to design, delivery, installation,
inspection, testing and commissioning specified or required to complete the order.
SELLER: Seller shall mean the Person, firm or Corporation to whom the Fax of Acceptance / Purchase Order is issued.
INSPECTORS: Inspectors deputed / authorized by Purchaser including Third Party Inspection Agency.
PROJECT: Coker Block of Resid Upgradation Project at Manali Refinery of Chennai Petroleum Corporation Limited.
CLIENT: client means Chennai Petroleum Corporation Limited.
PMC: PROJECT MANAGEMENT CONSULTANT or PMC or CONSULTANT shall mean any person(s) nominated
by the OWNER as the Project Management Consultant for the Project. The words PROJECT MANAGEMENT
CONSULTANT, PMC& CONSULTANT are synonymous. M/s Jacobs Engineering India Private Limited is the PMC for
this Project.
2. REFERENCE FOR DOCUMENTATION:
Purchase Order / Purchase Requisition number must appear on correspondence, drawings, invoices, shipping notes,
packing and on any document or paper connected with the Order.
3. IMPORT LICENCE: If any, shall not be the sellers responsibility.
4. CONFIRMATION OF ORDER:
The Seller shall acknowledge the Fax / Letter of Acceptance (FOA/LOA) / Purchase Order within seven days following
the date of FOA / Purchase Order and shall there by confirm acceptance of FOA(LOA) / Purchase Order without any
exception. This acknowledgment will be on FOA (LOA)/ Purchase Order and General Purchase Conditions. Seller shall
also submit along with order acceptance a Contract cum Bank Guarantee as per Clause 22 hereunder.
5. SALES CONDITIONS:
With Sellers acceptance of provisions of the Purchase Order he waives and considers as cancelled any of his general
sales conditions.
6. COMPLETE AGREEMENT:
The terms and conditions of the Purchase Order constitute the entire Agreement between the parties hereto. Changes
will be binding only if the amendments are made in writing and signed by an authorized representative of the Purchaser.
7. INSPECTION-CHECKING-TESTING:
The equipment, materials and workmanship covered by the Purchase Order are subject to inspection and testing at any
time prior to shipment and/or despatch and to final inspection within a reasonable time after arrival at site. Inspectors
shall have the right to carry out the inspection and testing which will include the raw materials at manufacturers shop, at
fabricators shop and at the time of actual despatch before and after completion of packing.
7.1 All tests, mechanical and others and particularly those required by relevant codes will be performed at the Sellers
expenses and in accordance with Inspectors instructions. The Seller will also bear the expenses concerning preparation
and rendering of tests required by Boiler Inspectorate or such other statutory testing agencies or by Lloyds Register of
Shipping as may be required.
A133-02-GPC (Imp.)-R0
7.2 Before shipping or despatch, the equipment and/or materials will have to be checked and stamped by Inspectors who
are authorized also to forbid the use and despatch of any equipment and/or materials which during tests and inspection
fail to comply with the specification, codes and testing requirements.
7.3 The Seller will have to: -
- Inform Purchaser at least two weeks in advance of the exact place, date and time of rendering the equipment or
materials for required inspection.
- Provide free access to Inspectors during normal working hours to Sellers or his/its sub-Sellers works and place
at their disposal all useful means of performing, checking, marking, testing, inspection and final stamping with
prior intimation.
7.4 Even if the inspection and tests are fully carried out, Seller is not absolved to any degree from his responsibilities to
ensure that all equipments and materials supplied comply strictly with requirements as per agreement both during
manufacturing, at the time of delivery, inspection, on arrival at site and after its erection or start-up and guarantee period
as stipulated in Clause 22 hereof.
7.5 The Sellers responsibility will not be lessened to any degree due to any comments made by Purchaser/Purchasers
representative and Inspectors on the Sellers drawings or specifications or by inspectors witnessing any chemical or
physical tests. In any case, the equipment must be in strict accordance with the Purchase Order and/or its attachments
failing which the Purchaser shall have the right to reject the goods and hold the Seller liable for non-performance of
contract.
8. EXPEDITING:
Purchaser/Purchasers representatives shall expedite both manufacture and shipment of equipment and materials
covered by the Purchase Order. The Purchaser/Purchasers representatives shall have free access to Sellers shop
and/or sub-Sellers shop at any time and they shall be provided all the necessary assistance and information to help
them perform their job.
9. OILS & LUBRICANTS:
The first filling of oils and lubricants, if any, required for every equipment shall be supplied inline with MR. The Seller shall
also recommend the quality and quantity of oils and lubricants required for one years continuous operation.
10. SPARE PARTS:
The Seller must furnish item-wised priced list of spare part(s) required for two years normal operation and maintenance
of the equipment.
The Seller shall provide the necessary cross - sectional drawings to identify the spare part(s) numbers and their location
as well as an interchangeability chart.
11. RESPECT FOR DELIVERY DATES:
Time of delivery mentioned in the Purchase Order shall be the essence of the agreement and no variation shall be
permitted except with prior authorization in writing from the Purchaser. Goods should be delivered securely packed and
in good order and condition at the place and within the time specified in the Purchase Order for their delivery. By the time
of delivery, is meant the date on the Bill of Lading/Airway Bill at FOB Port of Exit.
12. DELAYED DELIVERY:
The time and date of delivery of materials/ equipment as stipulated in the Purchase Order shall be deemed to be the
essence of the agreement. For any delay in delivery of equipment / materials or part thereof beyond the delivery date
stipulated, the Seller shall be liable to pay compensation as stipulated in the RFQ document.
Such compensation shall be paid by way of equivalent reduction in the Invoice value before presenting to Purchaser/
Bank for payment. This is without prejudice to Purchasers right of cancelling the purchase order wholly or in part for any
delay exceeding the period of maximum compensation and the Seller shall be liable to all consequences thereof. If the
delay in delivery is due to Force Majeure, the Purchaser shall be free to act in terms under Clause 13 of this text.
13. DELAYS DUE TO FORCE MAJEURE:

In the event of causes of Force Majeure occurring within the agreed delivery terms, the delivery dates can be extended
by the Purchaser on receipt of application from the Seller without imposition of penalty. Only those causes which depend
A133-02-GPC (Imp.)-R0
on natural calamities, wars and national strikes which have duration of more than seven consecutive calendar days and
Government Acts and other direct legislative enforcement are considered the causes of Force Majeure. The decision of
Purchaser shall be final and binding on Seller.
The Seller must advise the Purchaser by a registered letter duly certified by a local Chamber of Commerce or statutory
authorities, the beginning and the end of the delay immediately, but in no case later than within 10 days of the beginning
and end of each cause of Force Majeure condition as defined above.
The extension of time shall be the sole remedy of the Seller for any cause or event of delay and the Seller shall not be
entitled in addition to or in lieu of such extension to claim any damages or compensation for extended stay or otherwise
whether under the law governing contracts or quasi-contractor or any other relationship, and the Seller hereby waives
and disclaims any and all contrary rights.
14. REJECTION, REMOVAL OF REJECTED GOODS AND REPLACEMENT:
In case the testing and inspection at any stage by Inspectors reveal that the equipment, material and workmanship do
not comply with the specification and requirements, the Seller at his/its own expense and risk shall remove the same
within the time allowed by the Purchaser. The Purchaser shall be at liberty to dispose of such rejected goods in such a
manner as he may think appropriate, in the event the Seller fails to remove the rejected goods within the period as
aforesaid. All expenses incurred by the Purchaser for such disposal shall be to the account of the Seller. The freight
paid by the Purchaser, if any, on the inward journey of the rejected materials shall be reimbursed by the Seller .The
Seller will have to proceed with the replacement of that equipment or part of the equipment, if so required by the
Purchaser, without claiming any extra payment. The time taken for replacement in such event will not be added to the
contractual delivery period.
15. PRICE:
Unless otherwise agreed to in the terms of the Purchase Order, the price shall be Firm and not subject to escalation for
any reason whatsoever even though it might be necessary for the order execution to take longer than the delivery period
specified in the order.
16. TERMS OF PAYMENT:
Payment will be made by the Purchaser against an irrevocable Letter of Credit (L/C) against submission of despatch
documents (bill of lading or air way bill in case of air freight). L/C shall be opened through Government of Indias
Nationalised Bank and hence need not be confirmed. In case any bidder insists for confirmed L/C then the confirmation
charges shall be borne by the bidder. L/C shall be established within 45 days of receipt of acknowledgement of FOA/ PO
alongwith submission of required performance bank guarantee within 30 days of FOA/PO.
17. PART ORDER/REPEAT ORDER:
Seller hereby agrees to accept part order at Purchasers option without any limitation whatsoever and also accept repeat
order(s) during a period of 6 months from the date of original purchase order on same unit prices, terms and conditions.
18. RECOVERY OF SUMS DUE:
Whenever any claim against the Seller for payment of sum(s) of money arises out of or under the contract, the Purchaser
shall be entitled to recover such sum(s) from any sum(s) then due or which at any time thereafter may become due from
the Seller under this or any other contract with the Purchaser including right to encash the PBG. In the event of
encashment of PBG the Seller shall re-store the same to its original amount and should this sum is not sufficient to cover
the recoverable amount, the Seller shall pay to the Purchaser on demand the balance remaining due.
19. MODIFICATIONS:
The Purchaser shall have the right to make technical changes or modification in the technical document/specifications
comprised in the Purchase Order. The Seller shall comply with such a written request or make alternative suggestion.
Any such changes or modifications shall be at the cost, if any, of the Purchaser. As soon as possible after receipt of the
written request for changes, the Seller shall furnish in writing to the Purchaser, an estimate of cost for the changes and
modifications / effect on the FOB delivery date. On receipt of Purchasers written authorization, the Seller shall promptly
proceed with the changes/modifications.
20. CANCELLATION:
The Purchaser reserves the right to cancel the Purchase Order or any part thereof and shall be entitled to rescind the
contract wholly or in part in a written notice to the Seller if:
A133-02-GPC (Imp.)-R0
i) The Seller fails to comply with the terms of the Purchase Order
ii) The Seller fails to adhere to delivery schedule in progressing to manufacture or fails to deliver the goods on
time and/or replace the rejected goods promptly.
iii) The Seller becomes bankrupt or goes into liquidation.
iv) The Seller makes a general assignment for the benefit of creditors.
v) A receiver is appointed for any of the property owned by the Seller.
Upon receipt of the said cancellation notice, the Seller shall discontinue all work on the Purchase Order and matters
connected with it.
The Purchaser in that event will be entitled to procure the material in the open market and recover excess payment over
the Sellers agreed price, if any, from the Seller reserving to itself the right to forfeit the security deposit (including PBG),
if any.
21. PATENTS AND ROYALTIES:
On acceptance of the order, the Seller will be deemed to have entirely indemnified the Purchaser/Purchasers
representatives from any legal action or claims regarding compensation for breach of patent rights which the Seller
deems necessary to apply for manufacturing the ordered equipment and/or materials or which can in any way be
connected in the manufacture.
22. PERFORMANCE GUARANTEE:
The Seller shall guarantee that any and all materials used in execution of the Purchase Order shall be in strict
compliance with characteristics, requirements and specifications and that the same shall be free from any defects.
Checking of the Sellers drawings by the Purchaser/Purchasers representatives and their approval and permission to
ship or despatch the equipment and materials granted by Inspectors shall not relieve the Seller from any part of his/its
responsibilities of proper fulfilment of the requirements.
The Seller will guarantee that all materials and equipments shall be repaired or replaced as the case may be, at his own
expense, in case the same have been found to be defective in respect of material, workmanship or smooth and rated
operation within Guarantee Period as stipulated in the RFQ document.
The guarantee period for the part that may be altered, repaired or replaced shall be 18 months from the date on which
the same is put in service or period as specified above in case of critical items, whichever is later.
Acceptance by the Purchaser or its Inspectors of any equipment and materials or its replacement will not relieve the
Seller of its responsibility of supplying the equipment/materials strictly according to the specification and according to the
guarantees agreed by the Seller. The Seller shall furnish a Bank Guarantee alongwith the order acceptance for the
amount equivalent to 10% of the FOB value of equipment/ materials to support Sellers performance of his obligations
and discharge of liability under the contract, as per proforma hereunder. This Bank Guarantee shall remain in force for
the entire period covered by performance guarantee plus 3 months. It will be the responsibility of the Seller to keep the
Bank Guarantee fully subscribed. Any shortfall in the value of the Bank Guarantee as a result of encashment by the
Purchaser either in full or in part in terms of Sellers Performance shall be made good by the Seller within one week
thereof.
23. NON-WAIVER:
Failure of the Purchaser/Purchasers representatives to insist upon any of the terms or conditions incorporated in the
Purchase Order or failure or delay to exercise any rights or remedies herein or by law or failure to properly notify Seller in
the event of breach, or the acceptance of or payment of any goods hereunder or approval of design shall not release the
Seller and shall not be deemed a waiver of any right of the Purchaser / Purchasers representatives to insist upon the
strict performance thereof or any of his or their rights or remedies as to any such goods regardless of when goods are
shipped received or accepted nor shall any purported oral modification or revisions of the order by
Purchaser/Purchasers representative act as waiver of the terms hereof.
24. NON ASSIGNMENT:
The Seller without obtaining prior written consent of the Purchaser shall not assign the Purchase Order to any other
agency.
A133-02-GPC (Imp.)-R0
25. SELLERS DRAWINGS AND DATA REQUIREMENT:
The Seller shall submit drawing, data and documentation in accordance with but not limited to what is specified in the bid
document and/or in the Sellers drawings and data form attached to the Purchase Order. The types, quantities and time
limits of submitting these must be respected in its entirety failing which the Purchase Order shall not be deemed to have
been executed for all purposes including settlement of payment since the said submission is an integral part of Purchase
Order execution. All post order correspondence shall be addressed to Project Manager (Projects), Coker Block of Resid
Upgradation Project of CPCL , Engineers India Limited, 1 Bhikaiji Cama Place , R K Puram, New Delhi-110066, with a
copy to DGM (Inspection), Engineers India Ltd., 1,Bhikaiji Cama Place, New Delhi-110 066.
26. TECHNICAL INFORMATION:
Drawings, specifications and details shall be the property of the Purchaser and shall be returned by the Seller on
demand. The Seller shall not make use of drawings and specifications for any purpose at any time save and except for
the purpose of the Purchaser. The Seller shall not disclose the technical information furnished to or gained by the Seller
under or by virtue of or as a result of the implementation of the Purchase Order to any person, firm or body or Corporate
authority and shall make all endeavours to ensure that the technical information is kept CONFIDENTIAL. The technical
information imparted and supplied to the Seller by the Purchaser shall at all times remain the absolute property of the
Purchaser.
27. SERVICES OF SELLERS PERSONNEL:
Upon one month advance notice, the Seller shall depute the necessary personnel to India for supervision of erection and
start up of the equipment and train a few of the Purchasers personnel for the operation and maintenance of the
equipment, if required by the Purchaser. The terms and conditions for the services of the Sellers personnel shall be as
per Purchasers enquiry document / Purchase Order.
28. HEADINGS:
The headings of the conditions hereof shall not affect construction thereof.
29. ARBITRATION:
Any dispute or difference between the parties hereof arising out of any notified claim of the SELLER included in his final bill
and /or arising out of any amount claimed by the OWNER (whether or not the amount claimed by the OWNER or any part
thereof shall have been deducted from the Final bill of the supplier or any amount paid by the OWNER to the SELLER in
respect of the work) shall be referred to arbitration in accordance with the UNCITRAL Rules as adopted in India by the
Arbitration & Conciliation Act, 1996.
The venue of the arbitration shall be New Delhi, India.
Notwithstanding the existence of any dispute or arbitration in terms hereof or otherwise, the Seller shall continue and be
bound to continue and perform the works to completion in all respects according to the Contract (unless the Contract or
works be determined by the Owner or by the Seller under the provisions of the Contract), and the Seller shall remain liable
and bound in all respects under the Contract.
30. FOREIGN LIABILITY CLAUSE IN CONTRACTS:
It is expressly understood and agreed by and between Seller and Purchaser that they are entering into this agreement
solely on their own behalf and not on behalf of any other person or entity. In particular, it is expressly understood and
agreed that the Government of India is not a party to this agreement and has no liabilities, obligations or right hereunder.
It is expressly understood and agreed that the Purchaser is an independent legal entity with power and authority to enter
into contracts solely on its on behalf under the applicable laws of India and general principles of contracts law. The Seller
expressly agrees, acknowledges and understands that the Purchaser is not an agent, representative or delegate of the
Government of India. It is further understood and agreed that the Government of India is not and shall not be liable for
any acts, omission, and commissions, breaches or other wrongs arising out of the contract. Accordingly, Seller actions or
claims including cross claims, implored claims, or counter claims against the Government of India arising out of the
Contract and covenants not to sue the Government of India as to any manner, claim, and cause of action or thing
whatsoever arising out of or under this agreement.
31. JURISDICTION:
The Seller hereby agrees that the Court situated at New Delhi alone shall have the jurisdiction to hear and determine all
action and proceedings arising out of this contract.
A133-02-GPC (Imp.)-R0
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(PERFORMANCE)
(For Foreign Suppliers)
To
Engineers India Bhawan
R.K. Puram
New Delhi 110 066
Kind Att.: Head (-LSTK-Finance)

RFQ NO.: _______________________
OFFER NO. ______________________
ITEM : _________________________
SUPPLIERS NAME:________________
Dear Sirs,
In consideration of the Engineers India Limited, 1 Bhikaiji Cama Place, R.K. Puram, New Delhi-110066 (hereinafter called the
Purchaser which expression shall include its successors and assigns having awarded ________________________________
work to M/s (Name) _______________________________________ (Constitution) ___________________________ (Address)
_____________________________ (hereinafter referred to as the Supplier which expression shall wherever the subject or
context so permits include its successors and assigns) a supply contract in terms inter-alia, of the Purchasers Letter No.
______________________ dated __________ hereinafter referred to as the Contract and the general purchase conditions of
the purchaser and upon the condition of Suppliers furnishing security for the Performance of the Suppliers obligations and/or
discharge of the Suppliers liabilities under and/or in connection with the said supply contract for a sum of (Currency)
________________________ only amounting to 10% (ten percent) of the total contract value.
We _______________________________________ (name) a body / corporate registered/constituted under the laws of

___________________________ and having a Branch at ______________________ (hereinafter called the Bank which
expression shall include its successors and assigns) with the intent to bind the Bank and its successors and assigns, hereby
undertake to pay the Purchaser at __________________ (place) on first demand in writing without protest or demur or proof or
satisfaction or condition and without reference to supplier any and all amounts from time to time demanded by the Purchaser from
the Bank with reference to this Guarantee/Undertaking upto an aggregate limit of (Currency in figures) _____________ (Currency
in words________________________ only).
AND THE BANK DOTH HEREBY FURTHER AGREE AS FOLLOWS:-
1. This Guarantee/Undertaking shall be a continuing Guarantee/Undertaking and shall remain valid and irrevocable for all
claims of the Purchaser and liabilities of the Supplier arising upto and until ___________ plus claim period of 3 months.
2. This Guarantee/Undertaking shall be in addition to any other guarantee or security whatsoever that the Purchaser may
now or at any time have in relation to the Suppliers obligations liabilities under and/or in connection with the said supply
contract and the Purchaser shall have full authority to take recourse to or reinforce this security in preference to the other
security(ies) at its sole discretion, and no failure on the part of the Purchaser in enforcing or requiring enforcement of any
other security shall have the effect of releasing the Bank from its full liability hereunder.
3. The Purchaser shall be at liberty without reference to the Bank and without affecting the full liability of the Bank
hereunder to take an other security in respect of the Suppliers obligation and/or liabilities under or in connection with the
said supply contract and to vary the terms vis--vis the Supplier of the said supply contract or to grant time and/or
indulgence to the Supplier or to reduce or to increase or otherwise vary the prices of the total contract value or to release
or to forebear from enforcement of all or any of the obligations of the Supplier under the said supply contract and/or the
remedies of the Purchaser under any other Guarantee(s) or Security(ies) now or hereafter held by the Purchaser and no
such dealing(s), variation(s), reduction(s) or other indulgence(s) or arrangement(s) with the Supplier or release or
forbearance whatsoever shall have the effect of releasing the Bank from its full liability to the Purchaser hereunder or of
prejudicing rights of the Purchaser against the Bank.
4. This Guarantee/Undertaking shall not be determined or affected by the liquidation or winding up, dissolution, or change
of constitution or insolvency of the Supplier or any change in the legal constitution of the Bank or of the Purchaser.
5. Bank hereby waives all rights at any time inconsistent with the terms of this Guarantee/Undertaking and the obligations
of the Bank in terms hereof shall not be anywise affected or suspended by reasons of any dispute or disputes having
been raised by the Supplier (whether or not pending before any Arbitrator, Officer, Tribunal or Court) or any denial of
liability by the Supplier or any other order for Communication whatsoever by the Supplier stopping or preventing or
purporting to stop or prevent any payment by the Bank to the Purchaser in terms hereof.
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6. Notwithstanding anything contained herein:
(a) The Banks liability under this Guarantee/Undertaking shall not exceed (Currency in figures)
_________________ (Currency in words ______________________ only).
(b) This Guarantee/Undertaking shall remain in force upto _____________ (here put the entire period required for
the performance of the contract and the defect liability period plus 3 (three) months claim period and any
extensions thereof if any).
(c) The Bank shall be released and discharged from all liability under this Guarantee/Undertaking unless a written
claim or demand is issued to the Bank on or before _____________ plus 3 months period or the date of expiry
of any extension(s) thereof if this guarantee/undertaking has been extended.
7. The Bank doth hereby declares that Shri ______________________ (name & designation of the person authorized to
sign on behalf of the Bank) is authorized to sign this Guarantee/Undertaking on behalf of the Bank and to bind the Bank
thereby.
Yours faithfully,
(Signature)
NAME & DESIGNATION
NAME OF THE BANK
NOTE
2. The Performance Bank Guarantee shall be strictly as per above proforma and shall be through a scheduled bank
operating in India, including the Indian Branch of a Foreign Bank recognized as a scheduled Bank in India.
3. Bank Guarantee from Foreign Branch will be accepted only if same is counter signed by their Indian Branch or by any
scheduled Indian Bank.
4. The bank shall provide details viz. contact person, telephone number, fax number, e-mail address and address of the
Controlling/Regional Office of issuing bank for verification of authenticity of Bank Guarantee.
5. This Guarantee is required to be sent by Sellers Bankers directly to the Head (LSTK-Finance), Engineers India Limited,
rd
EI Bhawan, 3 Floor, 1, Bhikaiji Cama Place, New Delhi-110066.

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ADVANCE (FOREIGN)
To
New Delhi 110 066
Attn.: Head (LSTK-Finance)
RFQ. NO. :
OFFER NO. :
ITEM :
SUPPLIERS NAME :
Dear Sirs,
Engineers India Limited, 1, Bhikaiji Cama Place, New Delhi-110066 (hereinafter called the Purchaser which expression shall
include its successors and assigns) has awarded M/s ____________________________________ (hereinafter called The
Supplier which expression shall include its successors and assigns) the work of designing, manufacturing, fabricating and supply
of ______________________ in terms of a contract as constituted by Purchase Order No. ____________________ dated
_________________ issued by the Purchaser to the Supplier (hereinafter called The Contract which expression include all the
amendments and/or modifications of the Purchase Oder).
AND WHEREAS the Purchaser has agreed to advance the Supplier a sum of (Currency in Figures) _________________
(Currency in Words_________________________________________ only) hereinafter called The Advance as financial
assistance to the Supplier under the Contract on the condition, inter alia, that the advance shall be secured by a Bank Guarantee
as hereinafter appearing:
We ______________________________ Bank _____________________ a Bank incorporated/ constituted under the laws of

_____________________ and having it registered/principal office at _________________________________ (hereinafter called
The Bank which expression shall include our successors and assigns) in consideration of the aforesaid promises and at the
request of the Supplier DO HEREBY bind ourselves and our successors and assigns, and irrevocable undertake to pay the
Purchaser on first demand in writing without protest or demur or proof or condition and without reference to the Supplier any and
all amounts at any time and from time to time claimed by you, as due to you under or in respect of the said advance, and
demanded by you from us, with reference to this undertaking for an aggregate limit of (Currency in Figures) _____________
(Currency in Words __________________________only ).
AND, we, the Bank DO HEREBY further agree as follows:
(i) The Purchaser shall have the fullest liberty without reference to the Bank and without affecting in any way the liability of
the Bank under this Guarantee/Undertaking, at any time and/or from time to time to anywise vary the Contract and/or any
of terms and conditions thereof or of or relative to the advance and to extend time for the performance of the Contract
and/or repayment of the advance or to postpone for any time or from time to time the obligations of the Supplier and to
waive or postpone exercise of any of the rights available to the Purchaser against the Supplier or to forebear from
enforcing any of the terms or conditions of the Contract and/or the advance or any security(ies) available to the
Purchaser, AND the liability of the Bank shall remain in full force and effect notwithstanding any exercise by the
Purchaser of the liberty with reference to any or all the matters aforesaid or by reason of time being given to the Supplier
or any forbearance, waiver, act or omission on the part of the Purchaser or any indulgence by the Purchaser to the
Supplier or any other act, matter or thing whatsoever which under the law relating to sureties would have the effect of
releasing the Bank from its liability hereunder or any part thereof, AND the BANK DOTH HEREBY waive all rights at any
time inconsistent with the terms of this Guarantee/Undertaking.
(ii) It shall not be necessary for the Purchaser to proceed against the Supplier before proceeding against the Bank and this
guarantee/undertaking shall be enforceable against the Bank as principal debtor notwithstanding the existence of any
other security for any indebtedness of the Supplier to the Purchaser (including relative to the advance) and
notwithstanding that any such security shall at the time when claim is made against the Bank or proceedings taken
against the Bank be outstanding or unrealized.
(iii) As between the Bank and the Purchaser for the purpose of this guarantee/undertaking the amount claimed by the
Purchaser from the Bank with reference to this guarantee/ undertaking shall be final and binding upon the bank as to the
amount payable by the Bank to the Purchaser hereunder.
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(iv) The liability of the Bank to the Purchaser under this guarantee/undertaking shall remain in full force and effect
notwithstanding the existence of any difference or dispute between the Supplier and the Purchaser, the Supplier and the
Bank and/or the Bank and the Purchaser, or otherwise howsoever touching or affecting these presents or the liability of
the Supplier to the Purchaser, and notwithstanding the existence of any instructions or purported instructions of the
Supplier or any other person(s) to the Bank not to pay or for any cause withhold or defer payment to the Purchaser under
these presents with the intent that notwithstanding the existence of such difference, dispute or instruction, the Bank shall
be and remain liable to make payment to the Purchaser.
(v) This guarantee/undertaking shall not be affected by any change in the constitution of the Bank or that of the Supplier or
the Purchaser, or any irregularity in the exercise of borrowing powers by or on behalf of the Supplier.
(vi) This guarantee/undertaking shall be valid for all claims/demands made by the Purchaser to or upon us upto
____________________ provided always that if for any reasons, the Supplier is unable to complete supplies under the
Contract, the Bank shall at the request of the Purchaser and without recourse to the Supplier extend the validity of this
guarantee/undertaking for a further period of six months. For the purpose of this clause, the Purchasers statement that
the Supplier is unable to complete supplies under the contract shall be conclusive and final binding on us.
(vii) Notwithstanding anything contained herein:
(a) The Banks liability under this Guarantee/Undertaking shall not exceed (Currency in Figures)__________
(Currency in Words_______________________________ only).
(b) This Guarantee/Undertaking shall remain in force upto ______________ and any extension(s) thereof; and
(c) The Bank shall be released and discharged from all liability under this Guarantee/ Undertaking unless a written
claim or demand is issued to the Bank on or before ________ plus 3 months claim period, or the date of expiry
of any extension(s) thereof, if this guarantee/undertaking has been extended.
(viii) The Bank DOTH HEREBY declare that Mr. ______________ (name of the person signing on behalf of the Bank) who is
_____________ (his designation), is authorized to sign this guarantee/undertaking on behalf of the Bank and to bind the
Bank thereby.
Dated this ________________________ day of ______________
Yours faithfully,
For _____________________________________________
Signature ________________________________________
Name & Designation ________________________________
Name of the Branch ________________________________
NOTE
2. The Performance Bank Guarantee shall be strictly as per above proforma and shall be through a scheduled bank
operating in India, including the Indian Branch of a Foreign Bank recognized as a scheduled Bank in India.
3. BG from foreign branch will be accepted only if same is counter signed by their Indian Branch or by any scheduled Indian
Bank.
4. The bank shall provide details viz contact person, telephone number, fax number, e-mail address and address of the
Controlling/Regional Office of issuing bank for verification of authenticity of Bank Guarantee.
5. This Guarantee is required to be sent by Sellers Bankers directly to the Sr. Manager (F&A), Engineers India Limited, 1,
Bhikaiji Cama Place, New Delhi-110066.

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TERMS & CONDITIONS FOR INSTALLATION/SITE WORK
For
1.0 The Vender shall perform their jobs in eco-friendly manner and in consonance with the
objectives of CPCL Refinery environment management system.
2.0 Construction / erection work for several other project facilities at various locations within
refinery site will be progressing concurrently. It will be the responsibility of vendor to seek
approvals from the Purchaser for working within & outside the refinery limits and also of
taking all suitable safety measures as per regulations in force for the safety of existing-
refinery.
3.0 The material shall be collected by the vendor from Purchasers stores/Project Site/vendors
own stores (as the case may be) and transported to the erection site at Vendors cost and
risk.
4.0 All labour (both skilled and unskilled), tools, tackles and consumables, shall be arranged by
Vendor at his own cost.
5.0 Vendor shall arrange for the necessary transport, accommodation, medical, canteen and
other facilities for their employees/staff at their own cost and abide by all labour laws,
safety codes and statutory regulations and keep Owner/ Purchaser indemnified in respect
thereof.
6.0 Purchaser shall arrange the Marine cover Insurance and Erection. All Risk Cover Insurance
for the project for permanent incorporation of material and services. Vendor shall arrange
and pay for all other insurances as may be required under the law for their employees/
materials/subcontractor(s) and shall also cover against all risk for the materials issued by
Purchaser. Vendor shall be working at Owners site along with agencies that will be engaged
in the other activities. For this purpose the third party risk shall also be covered by Vendor.
7.0 The Vendor is responsible for keeping his work place neat and clean and shall always avoid
scattering of any materials around the work place. The Vendor shall clear the work site of all
debris, materials, tools, tackles etc. immediately upon completion of the job. Any temp.
line/cables etc. laid after due approval of Engineer in-charge of EIL at site for the purpose of
execution of a particular job shall be immediately removed to an agreed location and the
site cleared off all such materials.
8.0 The Vendor shall not throw out gaskets, used electrode pieces, hand gloves, cotton wastes,
gunny bags, polythene bags etc. into open channel, any drains or pipe line system. These
are to be collected together and deposited in bins/waste collectors earmarked for the
purpose of disposal after consultation with Engineer-in-Charge.
9.0 Construction power shall be arranged by the CONTRACTOR at his own cost. Contractor
should arrange adequate no. of DG Sets, suitable for usage at site.
10.0 Construction water shall be given free of cost at one point and all further distribution shall
be under the scope of the Contractor. Raw water for hydro test shall be provided free of cost
and all further distribution shall be under the scope of the Contractor. Demineralized Water,
if required for hydro testing, shall also be provided free of Cost. However, the Contractor
shall arrange for drinking water at his own cost.
11.0 EIL may permit the bidder, reasonably required land, free of any liability to establish a
temporary site office, fabrication yard and storage area at the job site, at the discretion of
Engineer-in-charge. EIL shall not permit any land at site to be used for residential purposes
nor shall otherwise provide or arrange any land for temporary accommodation of the
bidders personnel or labour.
The bidder shall at its own cost and initiative arrange land for residential accommodation
for its staff and workers and the price of services shall be deemed to include the same.
12.0 All Cranes, handling equipment etc, as required, shall be arranged by Vendor at his cost.
A133-Site Work Conditions-Rev 0 Aug13 Page 1 of 2

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13.0 As per the applicable Factory Act the Labour License, if required, shall be taken by Vendor
before starting the works.
14.0 All necessary compliances to various statutory requirements including Factories Act, Labour
Welfare legislations etc. shall be vendors responsibility.
15.0 The Contractor shall adhere to the Health, Safety and Environment (HSE) management
system as per EIL specification no. A133-00-6-82-0001 Rev. 0, CPCL Safety Regulation and OISD
Guidelines 192 and OISD Guidelines 207, enclosed.
16.0 It shall be vendors responsibility to comply with all rules and regulations in force at
construction site.
17.0 Surplus material, if any, after completion of site work, shall not be allowed to be taken out
of the refinery premises.
18.0 TAXES & DUTIES
18.1 Foreign vendors quoted prices shall be exclusive of Indian Income Tax/ withholding Tax and
Indian vendors quoted prices shall be inclusive of Indian Income Tax.
18.2 Quoted prices shall be Exclusive of Service Tax plus Ed.-cess on Service Tax, the same shall
be paid extra at actuals against submission of CENVATABLE Documents.
18.3 Necessary tax registration, if any, for site activity shall be done by vendor and cost shall be
included in the quoted price.
19.0 REQUIREMENT OF EMPLOYMENT VISA FOR FOREIGN NATIONALS
All foreign nationals coming to India for execution of Projects / Orders will have to apply for
Employment Visa only and that grant of Employment Visa would be subject to strict
adherence of following norms:
19.1 Employment Visa is granted only for the skilled and qualified professional or to a person who
is being engaged or appointed by a company, organization, Industry or undertaking etc. in
India on contract or employment basis at a senior level, skilled position such as technical
expert, senior executive or in managerial position etc.
19.2 Request for employment Visa for jobs for which large number of qualified Indian are
available, is not considered.
19.3 Under no circumstances an Employment Visa is granted for routine, ordinary secretarial /
clerical jobs.
Bidders are advised in their own interest to check latest Visa rules from Indian Embassy/
High Commission in their country in case foreign nationals are required to be deputed to
Indian during execution of the Order.
RFQ NO: VENDORS SIGNATURE & DATE

ITEM: NAME
OFFER NO: DESIGNATION
SEAL/ STAMP
A133-Site Work Conditions-Rev 0 Aug13 Page 2 of 2

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SPECIFICATION No.
SPECIFICATION FOR A133-00-6-82-0001 Rev. 0
HEALTH, SAFETY & ENVIRONMENT
MANAGEMENT AT DCU,CPCL Page 1 of 101
CHENNAI
SPECIFICATION FOR
(HSE) MANAGEMENT
AT DCU,CPCL ,CHENNAI
0 25.07.2013 ISSUED AS JOB SPECIFICATION SM DJ MD
Rev Date Purpose Prepared by Checked by Approved by
Format No. 8-00-0001-F1 Rev. 0

Copyright EIL All rights reserved
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SPECIFICATION No.
CHENNAI
TABLE OF CONTENTS
Section I Safety Management Program

0.0 Definitions
1.0 Purpose
2.0 Compliance
3.0 Objectives
4.0 Contractor Safety Policy and Assurance Plan
5.0 Site Safety Organisation
6.0 Roles and Responsibilities
7.0 Safety Meeting
8.0 Proactive Safety Monitoring
9.0 Site Safety Training and Competence of Employees
10.0 Safety Awareness and Promotional Activities
11.0 Documents and information to be submitted by Contractor
12.0 Incident Reporting
13.0 Site Emergency Response Action Plan
14.0 Site Access and Security Procedure
15.0 Permit to Work System
Section II - Occupational Health and Welfare Facilities

16.0 Welfare Facilities
17.0 Occupational Health Services
18.0 Sanitation and Hygiene Measures
Section III - Site Safety Program

19.0 Personal Protective Equipment (PPE)
20.0 Housekeeping
21.0 Safety Signs
22.0 Site Electricity
23.0 Form Work
24.0 Excavations
25.0 Hot Work
26.0 Fire Prevention and Control
27.0 Compressed Gases and Combustible Liquids
28.0 Working at height
29.0 Manual Handling
30.0 Sling and Lifting Gears (Rigging)
31.0 Lifting Appliances
32.0 Lifting Activities
33.0 Construction Vehicles
34.0 Construction Machineries
35.0 Noise

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SPECIFICATION No.
CHENNAI
TABLE OF CONTENTS
36.0 Confined Space

37.0 Radiography
38.0 Hand Tools
39.0 Demolitions
40.0 Temporary Structure/Fixtures
Section IV Liquidated Damages

Penalties for Violation/Non-Adherence of Safety Procedures and
41.0
Practices
42.0 Compensation in case of Accidents
Attachments
Attachment 1. Legal Obligations / Requirements for Construction
Attachment 2. Safety Assurance Plan
Attachment 3. Site Safety Organisation Chart
Attachment 4. Minutes of Meeting
Attachment 5. Field Safety Observation Report (SOR)
Attachment 6. SOR Summary Sheet
Attachment 7. Safe Plan of Action (SPA)
Attachment 8. General Inspection Report
Attachment 9. Routine Inspection Plan
Attachment 10. Safety Audit Checklist
Attachment 11. Safety Induction Checklist
Attachment 12. Tool Box Format
Attachment 13. Training Matrix
Attachment 14. Training Register
Attachment 15. Safety Update Board
Attachment 16. Weekly Safety Report
Attachment 17. Monthly Safety Report
Attachment 18. Incident and Investigation Report
Attachment 19. Incident Report Chain
Attachment 20. Contents of First-aid box
Attachment 21. IS Code for PPE
Attachment 22. PPE Issue Register
Attachment 23. PPE Stock Register
Attachment 24. DG Checklist
Attachment 25. Excavation Checklist
Attachment 26. Hot Work Activity Checklist
Attachment 27. Welding Set Checklist
Attachment 28. Gas Cutting Set Checklist
Attachment 29. Grinding Machine Checklist

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SPECIFICATION No.
CHENNAI
Attachments
Attachment 30. Fire Extinguisher Monthly Inspection
Attachment 31. Scaffolding Checklist
Attachment 32. Slings and Lifting Gear Register
Attachment 33. Wire Rope Sling Checklist
Attachment 34. Synthetic Web Sling Checklist
Attachment 35. Crane Register
Attachment 36. Mobile Crane Daily Inspection
Attachment 37. Monthly Mobile Crane Inspection
Attachment 38. Pre-Lift Checklist
Attachment 39. Construction Vehicle Checklist

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SPECIFICATION No.
CHENNAI
0.0 Definitions
Owner : Chennai Petroleum Corporation Limited, Manali Refinery, Chennai
Consultant : Jacobs Engineering India Private Limited
Contractor : Person, Firm or Corporation to whom the work will be awarded by the Owner.
LSTK Contractor: Engineers India Limited (EIL)
Shall : Mandatory requirement.
Should : Guideline that is strongly recommended.
May : Guideline that is to be considered.
Supervisor : Contractors engineer responsible for specific tasks.
1.0 Purpose
The field HSE specification set forth is the minimum requirements that shall be implemented
during the project execution. The contractors are required to implement these standards and any
additional requirements as per local laws and statutory requirements and best practices in industry
whichever are higher. Owner, consultant and EIL may issue further changing requirements from
time to time as the work progresses to fit changing site conditions, which will be binding on the
contractor.
The owner is fully committed for providing safe and healthy working conditions for all employees
working on the project and our goal is zero incidents in our operation. Safety is an overriding value
that the operation shall be conducted in such a manner that reasonably practicable measures are
taken to protect people not only in our employment but also others who may be affected by our
activities.
We believe that incidents are caused and eliminating the causes of incident can prevent them.
Safety is the responsibility of every employee but line management is ultimately responsible for the
implementation of safety requirements.
Everyone involved must be committed to achieving high standard of HSE Performance with proactive
approach at all levels in the organization with excellent teamwork.
All personnel should share a sense of empowerment on safety matters with an effective
communication system to facilitate the flow of safety information both up and down through the
organization
2.0 Compliances
All activities shall be in compliance with relevant local laws, statutory requirements, codes and
practices pertaining to health & safety of employees
2.1. Contractors or other third parties in the refinery shall abide by

Fire & Safety rules and regulations of the Refinery (Latest revision)
Security instruction issued by refinery management time to time
All requirements under the Factory Act 1948
The Contract Labour Act 1970
All requirements of Worker Compensation Act 1923 & ESIS Act including all amendments thereto.
Other statutory requirements shall also be applicable as mentioned.
Attachment 1: Legal Obligations / Requirements for Construction
2.2. The Contractors shall not employ minors (persons below the age of 18 years) in any part of the
refinery.
2.3. Contractor shall display notice at the conspicuous place showing the rates of wages of the workers,

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SPECIFICATION No.
CHENNAI
hours of work, wage periods, date of payment of wages, names and addresses of the Inspectors.
having jurisdiction and date of payment of unpaid wages, in English, Hindi and in the local language
understood by the majority of workers.
2.4. Contractors personnel shall abide by the applicable instructions as may be issued from time to time
to handle any emergency situations, such as explosion, fire, terrorist attacks, major accident, etc. In
the event of such emergencies, the Contractors personnel shall stop their work and proceed to a
safe designated place assembly point in the area of their work and inform the Engineer-in-Charge
immediately. If needed, they shall be safely evacuated.
2.5. Contractors vehicles, trucks, tractor, cranes and other portable equipments e.g. Air Compressor, DG
Set, Dewatering pumps etc. used inside Refinery premises (where Hydrocarbon is used as fuel) for
execution of the job must be mechanically sound and have an approved spark arrester and have
exhaust complying pollution norms. Idle running of those vehicles and equipments shall be avoided.
2.6. The Owner or the Engineer-in-charge or EIL may at any time require the Contractor to subject any
contract workman, to a medical examination, generally or in relation to specific jobs such as in
canteen, tank cleaning, work at height, etc.
2.7. Contractor shall not carry any work without having supervisor at site. If it is required to work
simultaneously in more than one location under the same contract, one supervisor must be put in
each of the locations. If a supervisor has to leave his site for any reason, he must stop his activities
for that period of time.
2.8. Female employee shall not be allowed to bring their child to workplace inside Refinery premises.
Contractor shall make suitable arrangement in case need, outside Refinery premises at his own cost.
2.9. The Contractor shall not be entitled to any extra or additional payment or other compensation for the
compliance with all applicable safety rules.
2.10. The requirement to comply with all applicable safety rules shall not entitle or justify the Contractor to
demand or claim any time or cost overrun.
2.11. The Contractor shall be solely responsible for any and all liability under the Workmens
Compensation Act, and other applicable laws with respect to all those engaged by the Contractor or
any sub-contractor.
2.12. In addition to this specification, contractor shall adhere to Health Safety Environment Procedure
(HSEP) of owner, consultant and EIL.
3.0 Objectives
3.1 General
The contractor shall practice safety leadership, demonstrate visible commitment to the project's
safety policy and strategic objectives, and provide resources to promote a culture that embraces and
accepts absolute safety behavior
Developing, signing, distributing, and emphasizing the safety policy at the outset of the project.
Leading and driving the project safety program in order to achieve a world class performance,
together with active participation at all levels with owner and consultant to ensure safe completion
of the project.
Implementing proactive monitoring system that provides feedback to ensure continuous
improvement in HSE performance.
Ensure compliance with all applicable laws, statutory requirements, codes of practices and
standards set forth.
In essence NO SAFETY NO WORK.

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3.2 Targets
The following Safety targets apply to the Project:
Injuries and Illness - Zero

Environmental Incidents - Zero
Property Damage - Zero
Vehicle Incidents - Zero
4.0 Contractors Safety Policy and Safety Assurance Plan

4.1 The contractor shall formulate a Safety & Health policy and shall be signed by authorised person.
The copy of the Safety & Health Policy shall be displayed at conspicuous places at work sites in
English, Hindi and a local language understood by the majority of construction workers.
4.2 The contractor shall submit copy of safety policy, HSE plan and safety assurance plan to
owner/consultant/ EIL in the standard form for implementation and monitoring of HSE requirements.
Attachment 2: Safety Assurance Plan

5.1 Contractor shall post a qualified and experienced Safety Manager and deploy Safety Engineers /
Officers, Supervisors and observers in every shift, to exclusively oversee and ensure compliance with
all applicable safety rules. Contractor shall notify the name of the safety manager, safety officer/
engineer and other safety personnel along with their bio-data to the owner /consultant and EIL for the
approval. Only on approval by the owner/consultant/ EIL, these personnel are authorised to work.
5.2 Qualifications of Safety Managers and Safety Engineer/officer shall not be less than as prescribed in
local regulations and the general requirements are described as under.
(a) A person shall not be eligible for appointment as Safety Officer unless he :
(i) Possesses a recognised degree in any branch of engineering or technology and has had practical
experience of working in factory in a supervisory capacity for a period of not less than 2 years; or a recognized
degree in physics or chemistry and has had practical experience of working in a factory in a supervisory
capacity for a period of not less than 5 years; or a recognised diploma in any branch of engineering or
technology and has had practical experience of working in a factory in a supervisory capacity for a period of
not less than 5 years.
(ii) Possesses a degree or diploma in industrial safety recognised by the State Government in addition to
possessing other qualification laid down in the said sub rule.
(iii) had adequate knowledge of the language spoken by majority of the workers in the region in which the
factory where he is to be appointed is situated.
(b) Notwithstanding the provision contained in clause (a), any person who:-
Possesses a recognised degree or diploma in engineering or technology and has had experience of not less
than 5 years in a department of the Central or Union Territory, State Government which deals with the
administration or the Factories Act! 1948; or
Possesses a recognised degree or diploma in engineering or technology and had experience of not less than
5 years, Full time, on training education consultancy, or research in the field of accident prevention in industry
or in any institution, shall also be eligible for appointment as a Safety Officer:

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5.3 Contractor shall submit site safety organization chart along with HSE plan.
Attachment 3: Site Safety Organisation Chart
5.4 Working hours per shift shall not exceed 12 hours per day.
5.5 Contractor shall appoint safety personnel as given below for every work shift:
Safety Observer : At all times minimum one observer for workers not exceeding 100 in numbers.
That means contractors are expected to deploy additional safety observers when
number of workers crosses beyond 100 and thereon.
Safety Supervisor: In addition to above, contractor shall depute one Safety Supervisor for every 250
workers.
Safety Engineer : In addition to above, one safety engineer/ officer for every 1000 workers.
Safety Manager : Minimum of one Safety Manager at all times required to be at site.
Requirement of Safety Personnel for every shift

No. of Workers
deployed Safety Engineer/
Safety Observer Safety Supervisor Safety Manager
Officer
1- 50
One
51-100
101-150 One
Two
151-200
201-250
Three
251-300 One
One
301-350
Four
351-400 Two
401-450
Five
451-500
Up to 1000 Ten Four
Up to 2000 Twenty Eight Two
5.6 In case any of the safety personnel leave the contractor the same shall be intimated to the owner/
Consultant/ EI L. The contractor shall recruit new personnel and fill up the vacancy.
6.0 Roles & Responsibilities

The contractor shall ensure that an employee of suitable seniority and authority with responsibility
for health and safety is always present on site during the course of the work, to supervise and
direct the work and to receive and implement instructions from the owner/ Consultant/ E IL s senior
representative.

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Contractor skilled workmen like riggers, scaffold erectors, welders, fitters, crane operators etc
should have sufficient past experience and skill on the relevant jobs. The electrician deployed
must have valid wireman License.
All supervisory staff and workmen shall be capable of following instructions and shall be made
aware of their responsibilities.
6.1 All Employees involved in project

Take reasonable care for the health and safety of him and other persons who may be affected by
his acts or omissions at work.
Co-operate with his management or others to enable compliance with statutory requirements.
Report to their immediate supervisor about hazardous situations and defects found in premises,
plant and equipment.
Avoid improvisation, which might entail risk.
Consider and suggest means of eliminating hazards.
Co-operate in maintaining a safe and healthy working environment.
Attend safety-training classes as and when organized.
Attend safety meetings if invited.
Participate in safety campaigns when organized.
Never intentionally or recklessly interfere with, or misuse, anything provided in the interests of
health, safety or welfare.
Draw to the attention of management /supervision improvements to health and safety which
appear to be necessary or advisable.
Immediately report any incident/ near misses to his/her supervisor.
Demonstrate leadership and commitment to HSE, setting a personal example at all times.
6.2 Contractors Construction Manager

He shall understand the owner/ Consultant/ EI Ls HSE requirements and the responsibility
allocated to each grade of supervision.
Understand and implement the contractual HSE requirements along with relevant Central / Local
legal and statutory regulations.
Assign clear responsibilities to achieve safety objectives and verify that sub-ordinates are
executing these responsibilities properly.
Ensure compliance of all the HSE policy and procedures.
Provide written method statements to establish safe work methods. (Explaining the sequence of
operations, provide outline potential hazards at each stage and identify safety measures to be
adopted).
Provide the resources necessary to maintain a safe and healthy work environment.
Locate storage areas, access and site office locations in line with owner/ Consultant/
EI L s requirements.
Ensure availability of all welfare, First -aid and sanitation facilities.
Enforce identified work permit procedures and requirements.
Check over work methods and precautions with supervision before work commences.
Shall lead the safety meetings and safety inspections/ audits and ensure safety deficiencies
identified are correct promptly.
Enhance safety awareness by promoting safety meetings, motivation programs, Trainings etc.
Ensure all incidents and near miss incidents are reported immediately and submit investigation
reports, participate in any other investigations as may require.
Set a personal example on site by adopting a safe working attitude.
6.3 Contractors Safety Personnel

He shall understand the owner/ Consultant/ E I Ls HSE requirements and advice management to
ensure
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Legal and contractual requirements affecting Health, Safety and Environmental issues.
Assist site management in identifying resources required to work safely.
Monitor the site activities to ensure only safe work methods are practiced at site, Health and
safety requirements are being observed, all welfare and first aid facilities are adequate and
properly maintained.
Inspect the work site and daily, report and correct unsafe conditions/ acts.
Ensure all persons have undergone safety induction training before engaging the on the job.
Check the provision and status of PPE requirements of the site.
Assist supervisor in preparing Safe Plan of Action (SPA).
Conducting investigation of all accidents and incidents at site, measures to prevent recurrence of
such incidents.
Facilitate, conduct and participate safety meetings, trainings, promotional activities at the site.
Initiate safety awareness and safety promotional activities
Review overall safety performance, record and analyse accident/ incidents and
Document and maintain all HSE statistics, reports and records.
Submit all documents related to HSE to owner, Consultant and E IL regularly.
6.4 Contractors Supervisory Personnel

Understand the owner/ Consultant/ EI L s HSE policy requirements and implement:
Organise work to the required safety standards to prevent injuries, damage to property and
environment.
Prepare and implement only safe and approved work methods, instruct and ensure compliance by
work force.
Enforce and comply with all work permit procedures.
Prior to assigning the days task inspect the work site, correct unsafe conditions if any and report
to site management to prevent recurrence.
Prepare Safe Plan of Action (SPA) and communicate the same to his workforce.
Communicate and ensure all identified hazards and preventive measures related to the task are
understood by the workforce.
Ensure all required safety resources are available and in good condition.
Inspect all scaffold, elevated platforms, fall and fire preventive/protective equipments involved in
the task,
Inspect all tools and equipments, safety guards, instruments are in good operating conditions.
Ensure required Personal Protective Equipments are available.
Plan and ensure a good housekeeping.
Monitor and control the task for unsafe acts and conditions.
Co ordinate task with other activities in the job site.
Ensure awareness of Emergency procedures, First aid, Fire fighting etc among the workforce.
Cooperate and implement instructions from Safety and Fire departments.
7.0 Safety Meetings

Effective communications raises safety awareness, and is vital to the successful implementation of
the Site Safety Plan. Objective of safety meeting is to improve the understanding of safety matters, to
obtain the support, co-operation and commitment of all interested parties.
7.1 Safety Kick-Off Meeting

On award of contract, a safety kick off meeting will be arranged and shall be attended by Contractor.
The agenda shall include
Type and nature of work.
Scope of work.
Contractor Safety Policy

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Contractors HSE plan.

Site Safety Organisation
Allowable working hours.
Legal requirements and documents to submit
Entry of Personnel and vehicle in to premises
Personnel Protective Equipment
Safety Management Programs
- Safety Induction
- Toolbox Talks
- Job Specific Training
- Safety Observation Report (SOR)
- Safe Plan of Action (SPA)
- Safety Inspections and Colour Coding Program
- Monthly Safety Audit
Reporting of incidents.
Permit System - administration and requirements.
Plant and equipment and test certificates
Safety Promotional Activities.
Interfaces with other contractors.
Any other specific anticipated hazards related to the work scope.
Emergency Response Action Plan
Welfare facilities for workers
Work Stoppages and Disciplinary Actions
7.2 Weekly Safety Meetings

Contractors Site Manager, Contractors Safety Managers/officers, Contractors Discipline Heads shall
attend weekly safety meeting with consultant / EILs site management team. At these meetings
previous week safety performance would be analyzed and the activities planned for the forthcoming
week would be reviewed.
Coordinator Consultants Safety manager
Contractors/ EIL RCM
Contractors/EIL Safety Manager
Contractors/ EIL discipline heads

Members Consultants RCM
Consultants Safety Representatives
Consultants discipline head
Owners representative
7.2.1 Weekly meeting in weekdays shall be predetermined with mutual agreement between contractor and
owner/consultant.
7.3 Monthly Safety Committee Meeting

7.3.1 In order to ensure better communication and coordination for realising safety targets, the project shall
establish an independent safety committee comprising of Owner Representative, Consultants
Construction Manager, Consultants Safety Manager, and Consultants Discipline Heads, Contractors
Site Manager, Contractors Safety Managers/officers, Contractors Discipline Heads and workers
representatives.

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Chairman Owners Representative

Secretary Owners Safety Manager
Consultants RCM
Members Contractor/EIL RCM
Contractor /EIL Safety Representatives
Contractors/EIL discipline head
Workers Representative
7.3.2 Site safety committee meeting shall be conducted at least once in a month. The agenda shall include
Review of previous minutes
Review of site safety performance
Monthly safety statistics
Contractors safety performance
Challenges ahead
SOR trend
Safety inspection & Audit reports
Issues by owner/ Consultant/ E IL
7.3.3 Contractor/EIL shall send circular to all safety committee members about the date and venue of
monthly safety committee meeting at least seven days prior to the day of meeting.
7.4 The Minutes of the meeting shall be prepared and sent to all members within 1 working day
preferably by mail/fax followed by hardcopy. Safety Committee meeting minutes shall also be
displayed in the notice board for wider publicity to all concerned.
Attachment 4: Minutes of Meeting
8.0 Pro-Active Safety Monitoring

Contractor shall implement proactive safety monitoring programs that provides feedback to ensure
continuous improvement in safety performance and compliances.
8.1 Safety Observation Report (SOR)

8.11 The SOR is used as a tool for supervisors to record good safety practices unsafe acts/conditions and
the steps taken (immediately and as follow-up) to correct the unsafe practices and recommendation
to prevent its recurrence.
8.12 It is everyones responsibility to take immediate corrective action if any unsafe act/ conditions are
observed.
8.13 Contractors job supervisor is responsible to close-out the SOR by taking corrective action during
follow-up action.
8.14 SOR shall be submitted to consultant and it shall be summarized periodically for effective tracking, to
analyse the trend and identify frequently occurring unsafe act/ conditions for improved safety
implementation.
Attachment 5: Safety Observation Report (SOR)
Attachment 6: Safety Observation Report Summary Sheet

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8.2 Method Statement

Contractors shall submit method statements for each work to owner/ Consultant/ E IL at least
seven days prior to the commencement of the work. The method statement shall detail:
The job to be undertaken
The steps of activities required completing the job.
The individual trades/disciplines involved in the activity.
Plant, equipment, tools to be used in the activity.
Any hazardous substances/chemicals to be used along with their MSDS.
A detailed description of how the work will be done including control measures and procedures to
complete each activity and the overall job safely.
Compliance with the procedure on the work method statement and relevancy to current operations
shall be monitored on a daily basis and also shall be discussed on safety meetings.
8.3 Safe Plan of Action (SPA)
8.31 The SPA is the primary tool used at site to identify and plan to mitigate safety hazards. This form
shall be completed by the contractors supervisor along with crew before starting a new activity and
kept at the work place for ready reference.
8.32 The SPA has sections for the employees to:

State the task to be performed
Location of the task to be performed
Safety hazards anticipated
Steps to be taken to prevent the risks identified
Equipment, tools, or materials needed for protection against the hazard and to perform the work
safely.
Authorisation by reviewing and approving personnel
The name(s) of the Supervisor(s) for each activity.
The name of the person in overall charge of the job.
Duration of the job.
8.33 It is the responsibility of the supervisor to ensure that all resources (equipment, tools, materials etc)
identified through SPA are implemented and all the steps identified to prevent the hazards are
implemented while executing the job.
8.34 It is the responsibility of the job supervisor to communicate the SPA to all workmen involved in that
specific task
8.35 A copy of SPA shall be displayed proximity to the actual works location in Hindi /vernacular language
& English.
Attachment 7: Safe Plan of Action (SPA)
8.4 Safety Inspections

The purpose of safety inspection is to identify any variation in construction activities and operations,
machineries, plant and equipments for ensuring an activity whether it is executed in accordance to a
general set of safety rules.
All equipments, machineries, tools, slings, lifting gears, lifting appliances involved in site shall be
inspected periodically.
Monthly colour coding program shall be implemented by the contractor and after the periodical
inspection, stickers for the corresponding month shall be pasted. Documents related to the inspection
shall be maintained and submitted to owner/ Consultant/ EI L regularly.

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Month Colour code

January & July Yellow
February & August Orange
March & September Pink
April & October Green
May & November Red
June & December Blue
8.41 General Inspection (Safety Walk Around)

General inspections shall be performed at predetermined intervals and the inspection shall involve
contractors RCM and contractors safety manager, owner/ Consultant/ E I Ls representatives.
Attachment 8: General Inspection Format
8.42 Routine Inspections

Routine inspections referred to the inspection of work site, equipment, temporary structures, work
activities etc.
Job specific inspections are performed on activities without a predetermined date. Competent
supervisors usually perform inspections for ensuring an activity whether it is executed in accordance
to a general set of rules.
Contractor shall inspect all equipments, tools etc initially before putting those into the service.
Contractor shall formulate the required checklist for all activities and equipments. As a minimum,
contractor shall conduct inspection as per the attachment.
Attachment 9: Routine Inspection Plan
8.5 Safety Audit

Safety audits are mandatory. The purpose of safety audit is to monitor and assess the effectiveness
of the site safety plan at workplace. It helps to develop the safety procedures further if the existing
procedures are found un-satisfactory. It assesses potential risk, liabilities and the degree of
compliance of construction safety plan and its supplementary procedures and programs against
applicable and current safety legislation regulations and requirements of the owner/ Consultant/ EI L.
Contractors construction manager holds the ultimate responsibility in ensuring implementation of

safety audit program during the construction work.
8.5.1 Monthly Safety Audit

Monthly Safety Audit shall be performed once in a month with prior notice. It shall be organised by
consultants safety manager with representatives from owner and contractor with a pre-determined
format.
These audits will play a vital role in assessing the Contractors Safety performance rating.
Based on the audit team observation, the evaluator shall allot the score based on the compliance
observed of the requirement and summarise the overall scoring of the audit.
The audit findings along with the recommended corrective actions with target date shall be circulated
to the respective contractors. The contractor should complete the recommended corrective actions
and submit the corrective action report.
The date for the audit shall be agreed by the owner/ Consultant/ E I L and

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contractor.
Attachment 10: Safety Audit Checklist

Contractor must ensure that his employees are adequately trained and experienced to carry out
their work safely. Training should continue throughout the project and should include regular
toolbox discussions.
Contractor must also ensure that specific hazards likely to be experienced on the site are notified
to their workforce together with any precautions to be taken and local rules to be observed.
Where particularly severe or unusual hazards arise, consultant reserves the right at no additional
cost to request contractors employees to attend safety training and instruction sessions, whether
carried out on site or externally.
Contractor shall provide a dedicated training room for conducting training for their workers.
9.1 Initial site orientation / safety induction and ID cards

9.11 All personnel working on the site shall be required to attend a safety induction briefing before
commencing work. Safety induction shall cover all topics included in the attached checklist.
Attachment 11: Safety Induction
9.12 The contractor shall conduct a site visit for his new employees in groups of less than 25 to familiarize
the new employees with essential services, their work place, and general site layout.
9.13 It is the responsibility of the contractor to familiarize all new personnel to the project on the actual
location of assembly points, fire alarm points, first-aid center, welfare facilities and other important
locations.
9.14 Contractors are responsible for arranging site safety induction for their workmen and they shall
inform consultants safety representative at least one day in advance.
9.15 Induction card duly stamped as Safety Inducted and the date of induction by contractor shall be
issued after the completion of Induction.
9.2 Toolbox Talks

Contractor shall conduct job specific and weekly tool box talks to encourage two way
communications with the employees.
Contractor shall maintain records of Toolbox Talks and shall be submitted to Consultant on regular
basis.
Attachment 12: Tool Box Talk
9.21 Job specific tool box talk

Contractors task supervisor shall conduct job specific toolbox talks (SPA) for all workers before
commencement of their job.
Topics shall include hazards and safety precautions as identified in the SPA.
9.22 Weekly tool box talk

Contractors safety manager shall conduct weekly tool box talk preferably on Monday at the start of
the shift.
Duration of talk shall not be less than 15 minutes.
Topics may be the current site safety issues that shall be agreed between the contractor,
owner/ Consultant/ EI L
9.3 Training from Owner

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Contractors and their supervisory staff shall undergo a one-day training programme annually from
owner on Safe Working Practices in the Refinery Premises so as to familiarize themselves with the
safety rules, regulations and practices. Contractor shall be in possession of valid safety training
badge while working in the Refinery premises.
The Contractors shall ensure that their supervisors must undergo Fire & Safety Training &
subsequent Test at Fire Station before starting the job. All contractors must disclose to CLM Cell the
name of supervisors and arrange safety training at Refinery Fire Station, before obtaining a gate
pass. CISF will issue the gate pass meant for supervisor, only after getting the confirmation from Fire
& Safety. It is the duty of supervisor to train his work force in Fire & Safety on regular basis. The
violation of this will be viewed seriously.
9.4 Site safety training

Contractor is responsible for site safety awareness training for all personnel working in his areas.
Training includes
Personal Protective Equipment Scaffold

Housekeeping Fall prevention and protection
Work permit Hot work
First-aid Heavy lifting and Rigging

H2S Fire prevention and protection
Mock drill including fire rescue, evacuation etc Electrical Safety

Excavation Hand and power tools
Manual handling Confined Space Entry

Driving Safety Pre-commissioning Safety
Working at Height Lock-out and Tag-out
Completion of specific hazard training is mandatory before working on such tasks. A list of all trained
persons shall be maintained at site.
The contractor shall prepare the training calendar for safety activities and submit to owner/
Consultant/ EI L on monthly basis.
Attachment 13: Safety Training Matrix
Contractor shall maintain records of training register and copy shall be submitted to owner/
Consultant/ EI L after completion of training program
Attachment 14: Training Register
9.5 Safety Hand Book

The contractor shall ensure that the workmen working with him comply with safety rules mentioned in
the Safety booklet for Contractor and their employee. Booklet can be had free of cost from owners
Fire & Safety Dept.

In order to develop safety consciousness and awareness amongst the employees, the contractor site
management shall organize suitable Safety campaigns, Safety competitions and Safety rewards.
10.1 Safety Posters

The contractor shall take every effort to communicate the safety measures through displaying

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posters, banners and sign boards around the work site.

Posters should be in Hindi, English and other suitable language deemed appropriate.
Posters should be replaced at least once in a month to maintain its effectiveness.
10.2 Safety Update Board

Contractor shall display safety statistics board at conspicuous locations such as site, contractor site
office; workers rest shed etc and shall be updated on regular basis.
Attachment 15: Safety Update Board
10.3 Safety Notice Board

Contractor shall provide a dedicated notice board for display of safety alerts, safety shares or any
other safety related notices for awareness among work force.
10.4 Safety Campaigns

Contractor may organize monthly/weekly safety campaigns by on different safety themes to maintain
the focus on the hazards involved in the activities.
10.5 Safety Competitions

Contractors may plan for various safety competitions to motivate employees to take active part in
safety program.
10.6 Awards and Recognitions

Construction site safety awards programs may be instituted with focus on remarkable achievements
and contributions towards safety.
Contractor shall formulate safety reward program for individuals safety performance excellence as
Supervisor of the Month
Worker of the Month
10.7 Important days to observe

Contractor should observe the following important days related to Health, Safety and Environment by
displaying banners, badges, distributing pamphlets, competitions etc
4th March - National Safety Day
14th April - Fire Safety Day
5th June - World Environment Day
9th July - Occupational Health day
11.0 Documents and Information to be submitted by Contractor

11.1 Apart from safety policy, safety plan, safety organisation chart, safety assurance plan contractor shall
also submit the documents as required.
11.2 Contractor shall submit Man Power Report on daily basis at least by 10.00 am every day.
11.3 Contractor shall submit Weekly Safety Report every Monday as per the approved format. The data
shall be from Monday to Sunday.
11.4 Contractor shall submit the listed supporting documents along with the weekly safety report.
Safety Induction
Tool box Talks
Safety Observation Report (SOR)
Safety Observation Summary Sheet
Safety inspection reports
Safety Audit Report (if any)
Safe Plan of Action (SPA) of each activity.
Method statements

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Safety training and mock drill records

Incident and Investigation Report (if any)
Attachment 16: Weekly Safety Report
11.5 Contractor shall submit Monthly Safety Report as per the approved format
Attachment 17: Monthly Safety Report
Test Certificates for lifting tools and tackles, lifting gear, lifting equipment and appliances.
Test certificates of air receivers.
Information relating to hazardous materials used and their MSDS.
Employers liability insurance certificate.
Copies of all Statutory Registers maintained by the contractor when asked for.
11.6 Display of Safety Instructions

The Contractor shall display a Safety Policy at a prominent place at his site office and each work
spot.
At all work sites, contractor has to display a board containing following information:-
Name of the Contractor;
Name of the work; Work Order No.;
Job site warning instruction;
Emergency Telephone Number;
Do's and don'ts on safety and security;
Working under the Department;
OWNER site in-charge name;
Permit No. & Validity period.

12.1 Any incident at site how slight they are or which entails a person reporting to hospital or leaving site
for treatment shall be verbally reported immediately to owner/ Consultant/ EI Ls representative. This
will enable the owner/ Consultant/ EI L to reach to the scene of incident / dangerous occurrences to
monitor/assist any rescue work and/or start conducting the investigation process so that the
evidences are not lost.
12.2 The return date of injured workmen back to the work shall be reported to owner/ Consultant/ EI L
promptly.
12.3 Written reports of all incidents and dangerous occurrences shall be submitted within 6 hours as per
format attached
Attachment 18: Incident and Investigation Report
12.4 Contractor shall ensure that any incident that occurs is fully investigated to find root cause and
preventive measures are adopted to prevent its reoccurrence. owner/ Consultant/ EI L shall have a
right to conduct independent inquiry of the incident.
12.5 Near misses and minor incidents should also be investigated by the Contractor as soon as possible
as they are signals that there are inadequacies in the safety management system.
12.6 Incident reporting chain and emergency contact numbers shall be displayed at conspicuous locations
at site and contractor offices.
Attachment 19: Incident Reporting Chain and Emergency Contact Numbers
13.1 A detailed site emergency procedure shall be worked out and communicated to all employees at site.

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Necessary arrangements shall be made to deal with such emergency situations. An emergency
response team will be formed to tackle such situations.
13.2 The contractor shall ensure that an Emergency Response Plan is prepared to deal with emergencies
such as
Fire and explosion
Collapse of lifting appliances and transport equipment
Collapse of building, sheds or structure etc.
Gas leakage or spillage of dangerous goods or chemicals
Excavation collapse
Fall of person from height
13.3 The following shall be considered to establish emergency procedures.

Make a list of available emergency services and confirm their communication channels.
Set up emergency response teams.
Ensure that supervisors clearly understand their responsibility and role in the site emergency
procedures.
Designate first aid and provide medical supplies and other material and equipment that may be
required for emergency use.
Determine emergency evacuation routes for work areas and construction site.
Make sure that all personnel clearly understand emergency warning siren signals or other warning
signals used by owner.
Designate a supervisor to conduct a head count and give instructions to evacuees as necessary.
Post-emergency information for each work area on the site.
13.4 Contractor shall conduct an onsite emergency mock drill once in every month for all his workers.
13.5 Bombs, Unattended Baggages/Objects

The following actions shall be taken by the contractor and his employees/workmen about Bombs,
Unattended baggage / Objects lying in secluded places in the Plant.
On noticing any bomb/ unattended baggage or object lying in the plant area, they should
immediately inform the CISF control room on Telephone No.3685 & 3660 and OWNER Fire
Control Room No. 3630 & 3663.
They should not touch the object or try to open the baggage or fiddle with the wires or battery if
found attached to the object.
They should move away to a safety distance of approximate 300 m. without creating any panic.
In case of unattended baggage, they should help CISF personnel in identifying the claimant.
They should not move to the area unless clearance is given by security personnel.
Dos & Donts in case of Bomb/Unattended baggage lying secluded places in the Plant.
Sl. Sl.
Dos Donts
No. No.
1. On noticing any bomb or unattended 1. Do not touch the bomb / unattended
baggage, in form CISF Control Room baggage.
by quickest possible means or on 2. Do not lift any attended baggage
Intercom Telephone No. 3685 / 3660
and OWNER Fire Control Room on 3. Do not go very close to the object
101 / 3630 / 3663.
2. Move away from the bomb/unattended 4. Do not create panic.
baggage.
3. Help security personnel in identifying 5. Do not fiddle with wires or battery if
unattended baggage. found attached with any object.

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4. Help ladies and injured person during 6. Do not open any unattended
evacuation process from the affected baggage.
area.
5. Move back to your place of work after 7. Do not try to defuse any bomb or
clearance has been given by CISF. explosive material
14.0 Site Access and Security Procedures

14.1 Site Entry Permit Personnel and Machinery
Refinery is an operational area, therefore, contractor and his employee shall observe all fire &
safety regulations of the refinery and shall so organise his work as not to interfere with the running
of the Refinery in any manner whatsoever. The contractor shall ensure that their staff/workmen
carry with them valid passes/work permits etc for proper identification inside the battery area.
Contractor shall arrange to apply for and secure valid gate passes for the entry and exit of his
men, materials and equipment, including those of the sub-contractors, from the concerned
authorities of the Owner.
The contractor shall ensure that their workmen/ supervisors shall not move to other places other
than their work premises without proper permission / authorisation.
The contractor shall ensure verification of antecedents of the labourers/ supervisors from Polices/
other officials before they are engaged by him. No person having adverse antecedent shall be
employed by the contractor. The contractor shall be held responsible for all the acts carried out by
his workmen.
Access to the site must be at all times via recognized roadways and footpaths. Personnel must
not access to construction areas through unauthorized areas. Anyone found disregarding this rule
would be subject to disciplinary action.
Contractor shall prepare and display the workers and vehicle site movement chart. The same
shall be communicated to all workmen in the site.
Persons without proper PPE shall be restricted at gate by security personnel. Entry to the site will
be permitted with PPE only.
Contractor must obtain this permit prior to the start up of the job, column, vessels, tanks or any
enclosed area where the chemicals or hazardous materials is either used or stored into it. It is the
contractors duty to see that daily, the above permits are obtained from the area-in-charge till the
completion of the job. All points stipulated in the permit must be strictly complied with.
14.2 Gate Pass/ ID Card

The Contractor shall make his own arrangements of Gate Pass with photo for his employees as
prescribed and instructed by the Security dept. i.e. CISF, and Contract Labour Management Cell
(CLM) at his own cost, each gate pass has to be endorsed by the Security Officer of the Refinery
before the pass be used by any employee. In case of termination of the service of any of his
employee during the contractual period, the contractor shall have to surrender the Gate Pass
issued to the employees to the Security Dept. At the end of the project all the gate passes
endorsed by the Security Dept. for use of the contractors employees shall have to be returned.
Gate pass shall be issued only after completing the site orientation / induction and local
statutory regulation formalities.
Separate entry passes shall be issued for visitors. Visitor passes will be valid only for a day
(Normal working hours) and at entry gate visitor shall undergo site safety instructions to be
followed during the visit and shall be provided with required PPE.
14.4 Working in Night

Contractor shall arrange necessary arrangement for working at night. The authorisation for
working at night shall be obtained from owner/ Consultant/ E IL.
Responsible person shall be assigned as in-charge and it shall be informed to owner/ Consultant/
EI L.
Contractor shall arrange Necessary lighting, emergency vehicle and emergency DG.

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14.5 Prohibited Items and Activities

Gambling, fooling on the work, horseplay, mock fighting or fighting is strictly forbidden in the
Refinery premises Project area.
Fooling on the job, mock fighting or fighting within the Refinery premises will not be tolerated.
Gambling within the Refinery premises is strictly forbidden.
Entering the Refinery premises while in possession of weapons such as knives & gun etc. is
prohibited.
Contractor personnel shall not pick up quarrel or get into arguments with Refinery personnel or
act in any misunderstanding, such problems should be referred to appropriate Refinery personnel.
Working under influence of alcohol/ narcotics and entering Refinery premises while in the
influence of alcohol/ narcotics is strictly forbidden. The contractor should ensure compliance of
above by him and all his workmen.
Contractors are prohibited from using Cellular phones within the Refinery premises, except to the
extent permitted by the Owner by special or general order / instruction.
Carrying Match Boxes / Lighters and No Smoking

Carrying / Striking of matches, lighters inside the Owners premises or smoking within the refinery,
tank farm or dyke limits are strictly prohibited. Owners regulatory officials shall be entitled to
forthwith remove, using force if necessary, anyone violating the No Smoking and other fire safety
rules.
Any contractors employee who is found smoking or in the possession of matchbox or lighter or
any other means of ignition in a prohibited area will be turned out from the premises of the
Refinery. Suitable action as decided by the Management will also be taken against the
contractor/contractors employees.
Unsafe Practices: Any unsafe practices or disregard of normal safe working practices by contractor
personnel when pointed out by company personnel shall be immediately corrected.
14.6 Disciplinary Actions

Contractor shall implement a disciplinary action policy whereby contractor and sub-contractors
employees, found violating safety rules.

15.1 A permit to work system is a safety strategy designed to protect personnel and plant and which
consists of an organized and predefined safety procedure. It forms a clear record of all foreseeable
hazards, which have been considered in advance of the construction operations.
15.2 The contractor shall not commence the job without the valid permit for the area and for the job.
Clearance shall be obtained from the area-in-charge and shift engineer
15.3 The following is the list of some of the activities, which would require permit, and list may change
depending upon work situation.
Working at Height
Excavations
Lifting Operations
Hot Work
Electrical Works (Isolation & Energisation)
Confined Spaces
Radiography
High Pressure test
Commissioning of equipment
15.4 Before starting any work, contractor shall apply at least one day ahead for fire & safety permit for
excavation, electrical, gas welding and cutting work to Engineer-in-Charge of work/ works who in turn
will arrange for such permits. The contractor shall take all the precautions given in the permit before

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starting of the work to the full satisfaction of the Engineer-in-Charge of the sections. On account of
operational problem it is possible that the clearance and permit may get delayed for which the
contractor shall not ask for the idle charges. Fire equipment such as fire extinguishers, fire hoses,
control type nozzles, personal protective equipment, Blow man air apparatus etc required for safety
precautions are to be arranged by contractor himself. However in case of emergency on
authorization from Engineer-in-Charge those items will be issued from the Refinerys Fire Station on
chargeable basis and shall be returned after completion of the work / works in working conditions, to
the full satisfaction of the Fire & Safety Officer. In case of any damage to the fire & safety equipments
issued or used by the contractor, the contractor shall bear the cost of such damage in full and the
same will be recovered from his bills.
15.5 Safety measures stipulated in the respective Work Permits shall be strictly complied at all times when
within the premises of the Owner.
15.6 Owner/EIL reserves the right to cancel a work permit without assigning reasons. When called
upon to stop the work by the Engineer-in-charge/EIL, the Contractor shall immediately cease to
continue the work. Before re-commencement, fresh work permit must be obtained.
15.7 The Engineer-in-Charge/EIL reserves the right to terminate the contract and forfeit any or all
amounts due to him in case he finds that the precautions written on the permit are not strictly
adhered to by the Contractor.
15.8 Permit to work shall be valid for a shift (8 Hours) only. However, Engineer may extend the permit to a
maximum of another 4 hours if necessary.
15.9 A copy Permit to Work shall be displayed, during its validity, in a conspicuous location in close
proximity to the actual works location to which it applies.
15.10 Hot work Permit

The entire job is to be carried out within the running unit of Refinery. The Contractor shall take all
necessary safety precautions and obtain required certificates/ fire permits / safety/ work permits etc.
from the competent authority before carrying out any hot works during the execution of the entire
works covered by this tender.
A hot work permit issued by the concerned department or area-in-charge must cover any work
carried out within Refinery. In addition a clearance must be obtained from the concerned
departments officer or supervisor prior to commencement of any job. A hot permit is required for:
Any work involving open flames, spark such as welding, gas cutting, soldering, grinding, concrete
breaking, use of hurricane lamps and internal combustion driving vehicles / Radiography / Crane
lifting / Vessel entry.
Sand blasting, Trucks, Jeeps, Cranes, Lifts, Cars or any kind of vehicle driven by an internal
combustion engine or by batteries
Use of gasoline, diesel or electrical power engines or tools.
Entry of vehicles inside battery limits of process area within tank dykes and adjacent to pump
houses and loading gantries etc.
While carrying out the hot job, the contractor and his workmen must ensure the following safety
measures and job should be carried with
Valid hot job permit,
Availability of tested and proper fire extinguisher at the work places
Provision of running fire water hose at work place.

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The owner may provide certain facilities. However the contractors shall provide drinking water,
required number of toilet for male and female, washing facilities and rest shelters in suitable locations
as per statutory regulations.
16.1 Drinking water

16.11 The contractor shall make in every worksite, effective arrangements to provide sufficient supply of
wholesome drinking water. Quality of the drinking water shall conform to the requirements of national
standards on Public Health.
16.12 While locating these drinking water facilities due care shall be taken so that these are easily
accessible within a distance of 200m from the place of work for all workers at all location of work
sites.
16.13 All such points shall be legible marked Drinking Water in a language understood by a majority of the
workmen employed and shall be situated within six meters of any washing places, urinals or latrines.
16.2 Latrine and urinals

16.21 The contractor shall provide sufficient latrine seat and urinal facility in the worksite.
16.22 When women are employed, separate latrine and urinals accommodation shall be provided.
16.23 Notice shall be displayed outside each block of latrines or urinals a containing therein "For Men
Only" or "For Women Only", where both male and female workers are employed, written in the
language understood by the majority of such workers.
16.3 Canteen
16.31 In every workplace wherein not less than 250 workers are ordinarily employed the contractor shall
provide an adequate canteen.
16.32 The charges for food stuff shall be based on no profit no loss basis. The price list of all items shall
be conspicuously displayed in such canteen.
16.33 Building of the canteen shall be situated at the distance not less than fifteen point two meters from
any latrine or urinal or any source of dust, smoke or obnoxious fumes.
16.34 Waste water from canteen shall be carried away in suitable covered drains and shall not be allowed
to accumulate in the surroundings of canteen

The owner at project site may provide a first-aid center for the treatment of minor injuries and illness.
However all major injuries and illness cases shall be referred to the Hospitals and contractor shall
make his own arrangement for such treatment as required.
The contractor shall provide sufficient number of stretchers and shall be readily available in an
emergency.
The contractor shall maintain injury record. A separate first-aid register shall be maintained and it
shall be submitted to owner/ Consultant/ EI L on regular basis.
17.1 First Aid Box

The contractor shall provide sufficient number of First-aid box for providing First-aid to the injured
workers. Every First-aid box is distinctly marked First-aid and is equipped with the articles specified
in Attachment

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Attachment 20: Contents of First-Aid box
17.2 Hospital Tie-up and Emergency vehicle

17.2.1Contractors shall require to tie-up with the hospitals located in the neighbourhood for attending
medical emergencies.
17.2.2Emergency vehicle shall be kept on standby duty during all working hours for the purpose.
17.2.3The emergency vehicle shall not be used for any other purposes other than its indent purpose.

18.1 Prevention of mosquito breeding
Empty cans, oil drums, packing and other receptacles, which may retain water shall be deposited
at a central collection point and shall be removed from the site regularly.
Still waters shall be treated at least once every week with oil in order to prevent mosquito
breeding.
Drainages shall be cleaned regularly.
The contractor at periodic interval shall arrange to prevent mosquito breeding by fumigation /
spraying of insecticides.
18.2 Prevention of snake bite

Contractor shall remove weeds from site regularly to keep away the snakes.

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19.1 The contractor shall provide all required PPE to his employees & workers, which are duly inspected
and approved by the owner/ Consultant/ EI L. NO PPE ZONE would be identified separately.
All PPE provided by the contractor shall confirm to Bureau of Indian Standards (BIS).
Attachment 21: Bureau of Indian Standards for PPE
Copy of Manufacturers test certificates of PPE used shall be submitted to owner/ Consultant/ EI L.
19.2 The contractor shall:

Maintain records of issue and replacement of PPE.
Maintain 10% PPE stock of total requirement available at their store and stock record.
Issue PPE to worker free of cost.
Maintain all personal protective equipment in good working condition.
Periodically check and replace all defective / broken personal protective equipment.
Contractor shall submit PPE issue register and PPE stock record to owner/ Consultant/ EI L on
regular intervals.
Attachment 22: PPE Issue Register
Attachment 23: PPE Stock Register
19.3 As a minimum, every worker shall wear safety shoes, safety helmet and safety goggles at project
site.
Depending upon the job requirement other PPE shall used.
Head Protection Safety Helmet
Foot Protection - steel toe cap shoes, steel toe cap gumboot
Eye Protection - Goggles, Helmet mounted face shield
Hand Protection - Gloves
Respiratory Protection - Nose mask, Self Contained Breathing Apparatus
Hearing Protection - Ear plugs, Ear muffs
Personal Fall Protection - Full body harness with double lanyard, Rope-grab fall arrester, etc
Body Protection - Full body apron
19.3.1Head Protection
Safety helmet shall be worn by all persons at all times on project site. It shall consist of
suspension cradle and chin strap.
All persons on the project site shall wear chin strap at all time.
Logo of corresponding main contractor shall be affixed on the safety helmet.
Damaged helmet shall not be used and should be discarded from the site immediately.
19.3.2Foot Protection
All personnel shall wear suitable safety footwear with steel toe cap at all times while on the project
site.
19.3.3Eye/Face Protection
Contractor shall provide suitable eye/face protectors where there is a potential of injury to the
eyes and face from dust, flying particles, molten metal, chemicals, fumes or vapors, light radiation

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or combination of these.
Operation Hazards Eye Protectors
General site use Dust, flying particles Safety goggles (Plain)

Sparks, harmful rays,
Welding goggles (Black Shade) -
Gas Cutting molten metal, flying
eyecup type
particles.
Sparks, intense rays, molten
Electric (Arc) welding Welders hood mounted on helmet
metal
Grinding Flying particles Face shield mounted on helmet
Chipping goggles (Plain) eyecup
Chipping Flying particles
type
Chemical resistant goggles and face
Chemical handling Splash, acid burns, fumes
shield.
Contractor shall inspect the goggles used by workmen and shall replace the defective goggles
immediately.
Eye protection for Helpers exposed to light radiation from welding, gas cutting activity shall be
provided with black shaded welding goggles.
19.3.4Hand Protection
Contractor shall choose and use suitable gloves for the task.
Protection Level
Hand protector Sharp Activity
Heat Chemical Electricity
objects
Cotton dot type Inspection work, Climbing
Medium Poor Poor Poor
glove Ladders.
Leather & cloth
Good Medium Poor Poor Scaffolding
type glove
Leather riggers Hot work, Rigging, Manual
Good Good Poor Poor
Gloves Handling.
Rubber moulded For use with Chemicals &
Poor Medium Good Good
gloves Acids
Rubber Gloves Poor Poor Poor Good Electrical works
In addition to above, gloves shall be used by personnel involved in works with possibility of the
risk from abrasion, cutting, tearing, chemical, or other burn, infection.
19.3.5Respiratory Protection
19.3.5.1 Respiratory protective equipment to be used in confined space and activity involving any
chemicals shall be as advised by owners Engineer-in-Charge / Fire & Safety Dept.
19.3.5.2 Supplied Air Respirators and Self Contained Breathing Apparatus (SCBA) used for working in
hazardous atmosphere shall be advised by owners Engineer-in-Charge / Fire & Safety
Department. The same shall confirm to BIS and shall be approved by owner/ Consultant/ E IL.
19.3.5.3 Contractor shall organise practical demonstration training on the methodology to use SCBA or
Supplied Air Respirators in consultation with owner/ Consultant/ E IL.
19.3.5.4 Air Purifying Respirators

Contractor shall use appropriate particulate filter respirators like dust mask depending upon the
fineness of particulates to filter.
Personnel involved in housekeeping, handling cement, insulation material etc shall use suitable

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dust mask.
Contractor shall use chemical cartridge respirators while performing outdoor spray painting.
19.3.6Hearing Protection
Hearing protection shall be worn by personnel involved in works in areas of high noise levels, or
when working with equipment that generate high noise levels.
Hearing protection can be of an external cup-type protector normally ear muff which fits over
the outside of the ear, or plug-type, usually disposable type ear plugs made of compressible
foam, which fits inside the ear.
Disposable ear plugs shall be of one time use and shall be disposed properly.
19.3.7Personal Fall Protection

Full body safety harness shall be required when working two meters or above. It shall be fitted
with double lanyard and the maximum length of the lanyard shall be not greater than 1.8 m.
The lanyard shall be fitted with shock absorber and anchoring hook shall be of scaffold type snap
hook.
Full body safety harness fitted with shock absorber shall be used while working 3 m or above.
19.3.8Body Protection
Full body apron suitable for the task such as hot work, chemical handling shall be used.
Contractor personnel shall not wear loose clothing while working around moving or rotating
equipment.
20.0 Housekeeping
20.1 Contractor shall maintain very high standard of housekeeping at all times.
Keep the site neat and tidy. Keep adequate number of skips / waste bins.
Keep the access clear of all obstructions.
Remove the nails or bend them down from the wooden scrap and remove them from job site.
Store the material in an orderly manner.
20.2 The contractor shall on daily basis keep the premises and surrounding area free from accumulation
of waste materials or rubbish caused by activities.
20.3 At the completion of days work contractor shall remove these materials to avoid Slip/ Trip hazards
and provide safe areas for movement of all workers and supervisors.
20.4 Empty gas cylinders shall be removed from the site and shall send back to the contractors store.
22.5 Contractor should establish regular maintenance program of sweeping and hosing to minimise
accumulation of dirt and dust in such areas.
20.6 If the Contractor does not clear the area after the completion of work, the same shall be got done by
owner /EIL and recoveries shall be made from the bills of the Contractor at double the rate at which
the owner /EIL has got it done.
20.7 On completion of the job the contractor shall remove all his construction material, tools etc. and
remove all temporary constructions and leave the job site thoroughly cleaned up and ready for use. A
job will not be considered completed until all surplus material, scrape and debris / rubbish are
removed from the job site.
20.8 When required contractors should suspend other operations and do housekeeping.
20.9 Waste Disposal

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Waste generated at site shall be segregated at source and disposed off in accordance with
environmental control regulations and municipality rules. Consultant shall be informed of procedure
followed by the contractor before disposal.
20.9.1Scrap yard shall be identified and waste shall be disposed temporarily at designated scarp yard.
Scrap yard shall be barricaded and shall be clearly marked as Scrap Yard in English and other local
languages.
22.9.2All receptacles shall be constructed of metal or other suitable types of containers of non-flammable
materials. Cardboard, wooden boxes or crates and similar types of containers shall not be used for
the collection of combustible waste.
22.9.3Skips containing combustible waste should be strategically placed to ensure fire does not spread in
the case of combustion within a skip.
22.9.4Contractor shall maintain routine housekeeping inspection record and shall be submitted to
owner/consultant/ EIL.
21.0 Safety Signs

Contractor shall post safety signs which give a general safety message in workplaces to draw
attention rapidly to the objects and situation affecting health and safety.
21.1 Colours of safety signs, dimension and layout shall confirm to IS 9457:2005
Red : Prohibition signs
Yellow : Warning signs
Green : Mandatory action signs
Blue : Safe condition signs
21.2 Bands
The band colour for indicating hazard location shall be the combination of Yellow and Black.
The band colour for indicating prohibition shall be the combination of Red and White.
The band colour for indicating mandatory action shall be the combination of Blue and White.
The band colour for indicating safe condition shall be the combination of Green and White.
21.3 Tags
Contractor shall implement tag system for scaffold, LOTO and unsafe equipment.

22.1 Competency
The contractor shall appoint a competent person on site who will be responsible for the control of
all electrical systems.
All maintenance and repairs of electrical system shall carried-out qualified and authorised
electricians only.
22.2 Power Supply

If the owners supply electricity, it will be provided at one point, which would be determined by the
owner. The supply would be of 230V, 50Hz, and single phase or of 415/ 433V, 50Hz, three phase.
Power distribution beyond this point shall be through armoured cable only. No deviation on this
would be permitted. The provision of all connections and equipment required beyond this point shall
be responsibility of the contractor.
If the electricity supply is in contractor scope, the contractor shall assess required electrical loads and
shall install required capacity diesel generators for power supply.

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The contractor shall submit electrical Single Line Diagram (SLD), schematic diagram and the details
of the equipment for all temporary electrical installation to the owner/consultant/ EIL.
22.3 Diesel Generator (DG)

The contractor shall install only acoustic DG. It shall confirm to national standards.
The DG shall be placed on firm base and shall be protected from water logging.
The noise level from DG shall not exceed 85dbA.
The DG shall be barricaded to restrict any unauthorised entry.
The body of the DG and main electrical panel shall be properly grounded.
DGs Exhaust shall be fitted with spark arrestor.
Barrel shall be kept on spill tray while transferring diesel to DG. Any diesel spillage around DG
shall be cleaned immediately.
Diesel barrels irrespective of empty or full shall not be stored near DG.
Adequate fire extinguishers and sand buckets shall be provided.
Rubber mat shall be provided for main electrical panel.
22.3.1Contractor shall display the following details near the DG.

Name with photograph and contact number of authorised person to operate the DG
Single Line Diagram (SLD)
Safety signs
Cardio Pulmonary Resuscitation (CRP) and electric shock first-aid treatment chart.
Location of nearest first-aid box availability.
List of emergency services contact numbers.
22.3.2Contractor shall inspect DG periodically and the record shall be submitted to owner/consultant/ EIL.
Attachment 24: Diesel Generator checklist
22.4 Distribution System

Contractor shall ensure that all distribution board (DB) used in the site shall be of IP type which
specification confirms to national standards.
The contractor shall provide sufficient ELCB (maintain sensitivity 30 mA) / RCCB for all the
equipments (including Portable equipments), electrical switchboards, distribution panels etc. to
prevent electrical shocks to the workers
Earth Leakage Circuit Breaker (ELCB) should be provided on all distribution boards and main
switchboards. Single switch multiple socket system would not be permitted.
Rating of fuses and circuit breakers used for the protection of circuits should be coordinate with
equipment power ratings. Use of makeshift wires or conductors as fuse wire is strictly prohibited.
Protection against lightning shall be ensured to all equipment kept in open at sites.
22.5 Cables
Periodic check shall be carried out for defective cables, cracked or perished insulation, loose
joints in conduits, damaged fuse boxes and switchboards, loose pins, faulty sockets and defective
earth wire.
Kinking, twisting, binding or crushing of cables shall be avoided all the time. No electrical
equipments shall be left open or unsecured at the end of the days work.
All power distribution cables should be taken overhead with sufficient headroom.
Cabling passing under the walk way and across way for transport and mobile equipment shall be
laid in ducts at a minimum depth of 0.6 meters.
All switch boards, extension boards, etc. should be protected from rain and water. No water
logging should be allowed around switchboards.
22.6 Plugs, Sockets and Couplers

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The contractor shall ensure plugs; sockets and couplers used shall be splash proof type. The
minimum degree of Ingress Protection should be of IP44 in accordance with national standards.
Plugs and fittings used shall be of the weatherproof type and they should be colour coded in
accordance with the internationally recognised standards
110 volts: Yellow.

240 volts: Blue.
415 volts: Red.
No loose connections or tapped joints shall be allowed any where in the work site, office area, stores
and other areas. Proper cable connectors as per national standards shall only be used to connect
cables
Plugs shall be used to connect with sockets. Inserting the leads into the sockets shall be strictly
prohibited.
22.7 Lighting
The contractor shall provide sufficient lighting at site, of the right type and at the right place.
A far as possible contractor shall provide flood lighting to cover maximum work area.
The access and storage yard shall be well illuminated.
Luminaries should be robust and water proof especially at the point of the cable entry.
Hand held lamps used shall be of 115V and suitably guarded to protect from any mechanical
damage.
Light fitting for hazardous environment shall be of flame proof type which specifications shall
confirm to national standards.
Contractor shall use only 24V lamp in to confined space It shall be guarded and of flame proof
type.
22.8 Power Tools

Power tools include grinder, Drilling machine, Jack Hammer and Concrete breaker etc
The contractor shall ensure all portable power tools do not exceed 125 volts rating and free from
defects and properly grounded.
Rotating tools shall be switched off and held until rotation has completely stopped.
Tools must be disconnected before changing bits, blades, cutters or wheels.
Electrical power hand tools shall be of double insulated type.
All tools shall be used with extension cords which are as short as possible.
Drilling of large holes shall be done stage by stage by using small bore drills and gradually
increasing the drill bit size.
Contractors shall provide suitable storage with suitable racks and bins for storing tools and
equipment.
The contractors qualified electrician shall inspect and tag electrical power hand tools regularly.
The tag shall display name, signature of the individual inspecting the tool, date of inspection.
The contractor shall keep, on site, a register of all electrical power hand tools in use giving all
relevant details about the tool and its inspection.
No electrical powered hand tool shall be used other than it is tagged with a current
INSPECTION tag.
All electrical leads must be connected to the power source through standard industrial
waterproofed plugs and sockets, which shall be in good condition.
While working at higher elevation, adequate precaution to be taken to ensure that they do not fall
down.
22.9 Lock-Out and Tag-Out (LOTO)

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Contractor shall form a LOTO procedure and shall be implemented during any maintenance,
repair, pre-commissioning and commissioning activities.
The equipment shall be isolated from energy sources before carrying any maintenance work.
LOTO register shall be maintained and shall be controlled by a designated person.
Contractor shall be responsible for arranging locks for locking the feeders or panel boards.
All locks shall be neatly labelled for easy identification and the keys of the locks shall be
maintained by the designated person.
22.10 Earthing
Contractor shall ensure all earthing shall confirm to IS 3043:1987
Body of electrically operated tools, equipments, distribution board, electrical panel etc shall be
grounded properly.
Earth pit shall be clearly marked and earth resistance shall be measured on monthly basis and
register shall be maintained by contractor.
23.0 Form Work

Contractor shall ensure no workers shall be allowed to work above vertically protruded reinforcing
steel unless it has been bent over or capped.
Reinforcing steel for wall, pier, column and similar vertical form work structures shall be guyed
and supported to prevent collapse and to guard against possible wind pressure.
Pump concrete or similar system using discharge pipe shall be provided with pipe supports.
Compressed air hose in discharge pipe systems shall be provided with positive fail-safe joint
connectors to prevent separation of section when pressurised.
Banks man shall be deployed for backing the transit mixer and wheel stopper shall be paced.
Form work an shoring shall be designed, erected, supported, braced and maintained so that it will
safety support all vertical and lateral loads that may be imposed during concrete pouring.
No persons shall be allowed closed to the shoring during pour operation.
Scaffolds used for supporting Form Work should be constructed on a firm ground with a base
plate. The staging should as per IS 3696. Staging should be inspected frequently even after
completion of concrete work, or after completion of intended use.
24.0 Excavations
24.1 The contractor shall obtain work permit from owner/consultant/ EIL before starting excavation
24.2 Contractor shall prepare a method statement by considering the following factors
Nature & type of the soil
Weather and moisture conditions
Underground utilities
Methodology adopted to avoid cave-in
Depth and width of excavation
Duration of the excavation job
Proximity of other structures, services
Dewatering systems
24.3 Contractor shall stabilise the sides of an excavation by designing the shoring, if the depth is 4 metre
or more and which shall be approved by owner/consultant/ EIL.
24.4 All excavations and trenches depth of 0.60 m or more shall be hard barricaded.
The hard barricade shall be made of steel pipes of minimum 40 NB.
The hard barricade shall have hand rail at 1100mm and mid rail at 550 mm and the spacing
between two vertical members should not be more than 1000 mm.
The hard barricade shall withstand a lateral load of 100 kg.
The hard barricade shall be provided at least 1.0 meter away from the edge of the excavation.

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24.5 Excavations and trenches depth less than 600 mm shall be cordoned off and suitable sign boards
warning tapes posted.
24.6 Access shall be provided by mean of portable ladder or ramp if the depth is more than 1.5m.
24.7 Portable ladders shall be provided at intervals of not more than 15 m, depending on the number of
workmen present.
24.8 All excavated materials shall be deposited minimum 1.5 m away from the edge of the excavation.
24.9 Excavating equipments and vehicle shall be operated 2.0 m away from excavated area.
Attachment 25: Excavation Checklist
25.0 Hot Work

Any work involving open flame/ spark shall be considered as hot work.
All hot work involved equipments and fitting shall confirm to relevant IS Standards and the
manufacturers test certificate shall be submitted to owner/consultant/ EIL.
Contractor shall obtain hot work permit from owner/ consultant prior to the commencement of the
job.
Fire watcher shall be engaged for each hot work activity and shall be competent in using fire
extinguishers
Work area beneath or adjacent to hot works shall be made free from combustible materials, and
cordoned-off to prevent personnel being injured by welding spatters.
Barriers or screens shall be erected whenever necessary to protect the workmen working near by.
Suitable safety signs & notices shall be displayed near the hot work area.
Contractor shall use non asbestos fire blankets to avoid falling of spatters. Manufacturers test
certificate shall be submitted to owner/consultant/ EIL.
Fire extinguisher shall always be carried with each welding set, preferably a dry chemical powder
type.
After hot work, contractor shall ensure a good housekeeping by sweeping the work area, stacking
the materials, winding the cables/ hoses and placing the equipments properly.
Appropriate PPE mentioned in clause 19.0 shall be used depending up on the hot work activity.
Attachment 26: Hot Work Activity Checklist
25.1 Welding Activity
25.1.1As far as possible D.C. Generator / Rectifiers should be used in preference to A.C. Transformer sets.
25.1.2The contractor shall get welding transformer certified by the owner/consultant/ EIL Electrical Engineer
before start of work and shall obtain a certificate valid for a period of three months renewable after
every three months.
25.1.3A copy of the certificate shall be displayed on respective welding sets.
25.1.4The contractor shall ensure

The welding transformer is kept away from any wet area and shall be located close to work site.
The body of the welding transformer shall be properly earthed.
The length of supply cable to welding transformer shall not exceed 5 m.
The size of the cable used shall be proportional to the voltage supply.
Damaged supply and lead cables are not used.
Lugs shall be used for connecting the lead and return cables with welding transformer.
The welding transformer shall have separate on/ off switch.
The electrode holder handle shall be of non metallic body.

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Grounding from welding return connection shall be done only on work piece. Return connection
shall not be grounded with scaffold member, pipe racks or pipes containing flammable liquid or
gases.
Used electrode shall be collected and shall be disposed properly.
25.1.5Periodic Inspection shall be carried on the welding transformer and the record shall be submitted to
owner/consultant/ EIL
Attachment 27: Welding Set Checklist
25.2 Gas Cutting Activity

The contractor shall ensure that
All gas cutting set shall be inspected prior to entry into the site
All gas cutting sets shall be kept at upright position and fastened in the trolley.
Cylinder valve key shall be made available all the time along with the cylinder when on use.
Domestic type LPG (14KG) shall not be used at the site.
Hose clamp shall be used to connect hoses firmly in both sides of cylinders and torch.
Approved type Non-return valve shall be fixed at torch end and Flashback arrester shall be fixed
at cylinder end.
All gas cylinders shall be fixed with pressure regulator and double head dial gauges.
Hoses used shall be free from any damage. Soap solution test shall be carried-out on the entire
length of hoses to check any leak.
Hoses quality shall confirm BIS. Also Red hose shall be for fuel gas and blue hose for oxygen.
Cutting torch nozzles shall be cleaned before commencing the job to avoid any backfire.
Cutting torch showing any physical damage shall be immediately replaced.
The torch shall be ignited by friction lighter. Igniting by match-box and welding arc is strictly
prohibited.
Gas cylinders shall not be placed beneath the hot work area.
Material Safety Data Sheet (MSDS) of gas cylinders shall be displayed at store yard.
Empty/ full cylinders shall be handled by the means of trolley.
Valve protection cap shall be fitted on the cylinder while shifting and storing.
When handling oxygen cylinders, ensure hands, clothes, gloves are free from oil, dirt, grit and
grease. Under no circumstances oil shall be allowed to contaminate a cylinder containing oxygen.
Periodic Inspection shall be carried on the gas cutting set and the record shall be submitted to
Attachment 28: Gas Cutting Set Checklist
25.3 Grinding/ Cutting Activity

Grinding/ cutting activity shall be always carried out by trained and experienced person.
Only reinforced resin-bonded or resin-bonded abrasive wheels must be used in portable grinding
machines.
Grinding wheels should be stored in dry place and shall avoid direct contact of heat. Wet or
soaked grinding wheels shall not be used.
Wheels shall not be used at any time beyond their expiry date.
The RPM of grinding/ cutting wheel should be equal or greater than the machine spindle RPM.
Grinding Wheels should be segregated size wise to avoid wrong selection of the wheel. Grinding
wheel fitted shall be of suitable size for the grinding machine.
Power supply cable used shall be of rated current carrying capacity with plug-top and shall be free
from damages.
Supply shall be routed through ELCB.
Machine selected shall be of non-metallic body. Body earthing shall be ensured the in case of
metallic body.
All grinding machine shall be fitted with Dead-Man switch and this shall not be bypassed any time.

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All grinding/ cutting machines shall be guarded.

Check shall be done for any abnormal sound and/or vibration.
Grinding wheel without manufacturers specification showing size, speed and expiry date shall not
in used.
Portable grinding machine shall not be used as bench grinder. Small work piece shall be fixed on
bench vice.
Proper spanner shall be used for fixing grinding wheel with the machine.
Machine shall be put OFF from the main switch when not in use.
Grinding activity shall not be carried out in confined space without a valid work permit.
Periodic Inspection shall be carried on the grinding/cutting machine and the record shall be
submitted to owner/consultant/ EIL.
Attachment 29: Grinding Machine Checklist

26.1 The contractor shall take every precaution and use all reasonable means to prevent an outbreak of
fire and shall tender immediate assistance in case of fire. Any outbreak of fire in or near the
workplace shall immediately be reported to the owner/consultant/ EIL.
26.2 The contractors shall provide adequate number of well-maintained fire extinguishers at each work
area.
26.3 Extinguishers should be sited in such a way that it is not necessary to travel more than 15 meters
from the site of the fire to reach the extinguishers. The location of fire extinguishers shall be clearly
marked by sign boards.
26.4 Contractor shall provide fire extinguishers as per IS 2190:1992
Type of occupancy Recommended scale of equipment to be installed

One 4.5 kg capacity carbon dioxide extinguisher for every 100
Office, Computer installations, 2
m of floor area or part thereof with minimum of
record rooms,
two extinguishers so located as to be available within 10 m
2
radius.
5 kg capacity dry powder extinguisher for every 600 m area
Workshops, painting shops,
with minimum of four extinguishers per compartment.
generator rooms
Extinguishers should be available within 15 m radius.
Flammable liquid stores, 2
5 kg capacity dry powder extinguisher for every 600 m area
storage in drums and cans in
open, paints and varnishes
godown.
One 10 kg dry powder extinguisher or 6.8 kg carbon dioxide
2
extinguisher for 100 m of floor area or part thereof,
Storage area of LPG and other
with minimum of one extinguishers of the same type for
industrial gases.
every compartment; extinguisher should be available within a
radius of
15 m.
26.5 The contractor shall ensure that workmen are trained in the use of fire extinguishers, understands the
basics of fire fighting and train the workmen to become familiar with such Fire Fighting Procedures
26.6 Fire drills should be held at regular intervals to ensure personnel are familiar with the location, of
Assembly Point and response expected of them in case of emergency.
26.7 Smoking on site is strictly prohibited. No Smoking signboards shall be displayed at prominent
location including stores/ storage places.
26.8 Care of flammable materials, oily rags, waste etc. shall not be left lying around or allowed to
accumulate. Covered metal skips should be used for disposal of flammable waste.

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26.9 If hot work operations are to be carried out, non-flammable screens and blankets shall be used to
confine sparks hot metal or slag. A fire extinguisher should also be readily available.
26.10 Chemicals and other such goods should be stored in stable racks properly labelled. Mutually
reactive chemicals should be kept away from each other. Storage place should have proper
ventilation.
26.11 Fire extinguishers shall be Periodically Inspected and the record shall be submitted to
Attachment 30 Fire Extinguisher Checklist

27.1 Compressed Gases
Contractor shall ensure that
Handling and Storage of gas cylinder shall comply Gas cylinder rules 2003.
Oxygen cylinders and fuel gas cylinders shall be stored separately, at least 6.6 meters apart or
separated by a fire proof, 1.6 meters high partition.
Flammable substances shall not be stored within 15 m of cylinder storage areas.
Valve protection caps over the cylinder shall be provided in storage yard as well as while not in
use.
All compressed gas cylinders shall be used, stored and transported in an upright position.
Compressed gas storage facilities shall be positioned at a sufficient distance from work area,
offices and roads in such a manner as not to cause a hazard to employees, facilities and/or other
contractors.
Cylinders should be stored in suitably designed racks, which must have chains so that any
number of cylinders can be securely and safely stored.
Signs indicating the contents with separate storage for full or empty shall be displayed.
Warning signs must be posted - DANGER - HIGHLY FLAMMABLE - NO SMOKING and NO
NAKED FLAME.
Fire extinguisher shall be provided within accessible distance and adequate quantity and shall
confirm IS 2190:1992.
Oxygen cylinder shall be separated from other combustible gas, oil or grease.
27.2 Combustible Liquids

The handling and storage of combustible liquids shall comply The Petroleum Act, 1934 and
Rules 1976
Flammable and combustible liquids must be stored in a metal storage cabinet with a prominent
sign boards FLAMMABLE - NO SMOKING and NO NAKED FLAME.
The area should be well ventilated and free from flammable material
28.0 Work at Height

Work involving above 1.8m from ground level that include all work activities where there is a need
to control the risk of falling which is able to cause personal injury.
It includes working on scaffolds, access and egress through ladder and working near unprotected
excavation.
The contractor shall ensure that work at height is carried out only when the weather conditions do
not endanger the safety of persons involved in the work.
Life line shall be installed and full body safety harness with double lanyard of 1.8m with shock
absorber and scaffold type snap hook shall be used to ensure 100% protection.
Fall protection devices shall be secured to an anchorage point or a structural member which can
support a minimum dead weight 2450kg.
Ladders shall be only used as access for ascending and descending. Using scaffold member as
access is strictly prohibited.

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No loose materials shall be kept on working platform and shall be kept on baskets.
Safety net shall be used for all height works, where ever feasible.
28.1 Scaffolds
Scaffolding shall be properly designed and erected, with its intended use, where additional,
anticipated loads are to be applied; the structure shall be redesigned and modified accordingly. All
scaffolding material shall be as per relevant IS specification.
Light Duty Scaffold

Distribution load on platform is 0.75 KN/sq.m. (Maximum bay length 2.7 m)
Medium duty scaffold
Heavy duty scaffold
Bamboo and wooden scaffolding is prohibited. Only steel pipe scaffold shall be permitted.
Return cable of welding machine shall not be connected with scaffolds member.
Scaffold shall be inspected every week or after any adverse weather condition like rain, cyclone
etc.
Scaffold inspection record shall be submitted to owner/consultant/ EIL immediately after inspection.
28.1.1Scaffold Erection
Scaffold shall be erected by competent scaffold erectors under the supervision of competent
supervisor.
Scaffold shall be erected with a factor of safety not less than 4.
Survey for all underground utility systems such pipe line shall be identified and possible worst
scenario shall be assessed before erecting the scaffold.
Scaffold should be vertical and plumb.
The footing shall be placed on levelled and firm ground capable of carrying indented load without
settling or displacement.
Base plate shall be provided at a size of 150 mm X 150mm and thickness of not less than 6mm.
Uses of concrete blocks, barrels, boxes, loose bricks as supports are strictly prohibited.
The height of the scaffold shall not be more than four times of its minimum base dimension unless
guy ropes, ties or braces are used.
Scaffold having more than 10 m height shall be secured with fixed structure for stability at every 8
m.
Vertical member shall be connected with horizontal members using right angle type clamp.
Only bracing may be connected with vertical member using swivel clamp.
Landing platform shall be provided at every 9m. Platform shall not be extended beyond 150 mm
from the end.
Platform shall be made of minimum 2 gratings (at least 46 cm) and fastened properly
Hand rail shall be provided at a height of 1100mm, mid rail at 600mm and toe board width shall be
150mm.
Scaffold shall be braced at all four sides.
Access shall be provided by means of portable ladder and it is the duty of supervisor to provide
safe access. It shall be immediately installed after the completion of second level horizontal or 6
m.
Ladders shall be extended at least 3 rungs from platform.
Full body harness with double lanyards fitted with shock absorbers with scaffold type snap hooks
shall be worn by scaffold erectors.
The completed scaffolding shall be inspected and certified by scaffolding supervisor and engineer
using scaffold.
After completion of scaffold inspection if safe, green tag shall be displayed near the access
ladder. If scaffold found unsafe, red tag shall be displayed near access ladder.

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Attachment 31: Scaffolding Checklist
28.1.2Scaffold Dismantling
Scaffold shall be dismantled by scaffolders under the supervision of competent supervisor.
Area shall be cordoned-off before commencement of scaffold dismantling.
Warning/ notice board shall be displayed as Scaffold Dismantling under progress Shall be
displayed in Hindi, English or vernacular languages.
Dismantling shall be from top to bottom plan wise.
Bracing shall be removed first and then all horizontal members in one plane.
After reaching to second last horizontal plane, first bracing of 3 m from ground level plane shall be
installed. Then the horizontal members from second level shall be removed.
Loose members shall be segregated and shall be collected in boxes and shall be lowered
properly.
Loose scaffold member shall be lowered down by rope and not by using men chain or throwing.
While dismantling or erecting scaffold spanner shall be used with proper string in hand to avoid
any fall.
28.1.3Mobile Scaffolds
Mobile scaffold shall be used on a level and smooth surface only.
The minimum base dimensions for mobile scaffolds used internally and externally shall be 3.5 and
3.0 times respectively.
If the tower is exposed to movement or exposed to more than light winds, physical ties shall be
used.
Mobile tower scaffolds shall have wheels fitted at base with a locking device.
Mobile scaffold shall not be moved by carrying any workmen or loose materials.
28.1.4Ladders and Staircases

Ladders shall be of good construction, sound material and made as per standard specifications.
Wooden ladders shall not be permitted at site.
Portable single ladder length shall not exceed 9m.
The space between two rungs shall not be more than 300mm.
The width between side rails in portable ladder shall not be less than 0.45m.
Ladder shall use only after inspection and approval from owner/consultant/ EIL.
Ladders shall be checked for defects such as worn and missing rungs, loose tie rods, and split or
frayed feet. Defective ladder shall be removed from service immediately.
Ladder shall be installed on level surface and shall be tied properly at the top.
Solid footing shall be provided if the ladders are placed on loose soil.
0
Ladder shall be placed at angle of 75 .
Ladder shall be extended at least 1m from the landing platform.
Three point contacts shall be made while ascending and descending the ladder.
No load shall be carried while ascending and descending the ladder. Load shall be pulled or
lowered by ropes by means of pulley.
Ladders are a means of access, and they should not be used as working platforms.
Ladders shall not be placed in front of the door or in the path of moving object unless it guarded.
While ascending and descending should be facing towards the ladder
Portable ladder used shall be of anti slip base.

The contractor shall ensure that no worker lifts by hand or carries overhead or over his back or
shoulders any material, article, tool or appliances exceeding in weight as said below.
Adult man : 55 Kg
Adult woman : 30 Kg
Capability of worker for manual material handling should be considered in before assigning the task.

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Contractor shall train the workmen on safe lifting posture.

Whenever load-handling operations are essential, consideration should be given to the use of
mechanical handling, like use of lifting appliances or fork lifts. The contractors should consider the
use of such mechanical aids at the planning stage of their activities.
30.0 Slings and Lifting Gears (Rigging)

30.1 General
Slings include wire rope slings, synthetic web slings, chain slings and metal mesh sling. Lifting gears
include block, hook and shackles.
The contractor shall offer his slings and lifting gears for inspection and approval of
owner/consultant/ EIL before putting it in to the job.
Contractor shall submit manufacturers test certificate and test certificates from Govt. approved
certifying authorities for all of his lifting gear and slings.
Lifting gear in use shall be thoroughly examined once at least in every twelve months by a competent
person.
The Safe Working Load (SWL) and manufacturers serial numbers shall be clearly marked on the
slings and the lifting gears, either by tagging, stamping, engraving or embossing. These markings on
lifting gears and slings shall be inspected and a register shall be maintained.
If SWL and manufacturers serial numbers is not clearly marked, those slings and lifting gears shall
be prohibited to use.
Attachment 32: Slings and Lifting Gear Register
30.2 Wire Rope Sling

Contractor shall use wire rope sling made with suitable thimble to eye splices and loops of ropes for
the attachment of hooks, rings and other such parts.
Contractor shall not use homemade (hand spliced) wire rope slings made of at site.
Wire rope slings made of wire rope clips (bull dog clips) shall not be used at site.
All wire ropes shall be properly handled and stored to avoid any damage.
Contractor shall discard all damaged sling if there are
Ten random broken wire ropes in one lay
Four broken wires in one strand of a rope lay.
Severe localised abrasion or scraping
Kinking, crushing, bird-caging or other damage causing distortion.
Deformed or excessively worn
Severe corrosion and evidence of heat damage.
Attachment 33: Monthly Wire Rope Inspection Checklist
30.3 Chain Sling

SWL of all attached fittings (hooks, rings, shackles, etc) to chain slings shall be equal to the SWL of
chain sling.
Using of onsite welding repaired chain slings is strictly prohibited and shall be discarded immediately.
Chain slings of bent links, cracked welds and excessive wear shall be discarded immediately from
site.
30.4 Synthetic Webbing Slings

Synthetic webbing slings are manufactured from woven manmade fibre. These slings shall not be
subjected to point loading, sharp edged objects and non vertical lifting.

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Attachment 33: Monthly Web Sling Inspection Checklist
30.5 Hooks
Hooks shall be fitted with safety latch on hook opening so that slings cannot be displaced.
Loads shall be applied only in the part designed to take them, Point load shall be avoided as point
load results in overstressing the hook causing it to break.
0
The hook shall be removed from the service if there is a visible crack and if it is twisted 10 out of
place.
30.6 Shackles
Contractor shall use the correct pin for each shackle. Rebar, mild steel bolts are not acceptable
replacement for shackle pin.
30.7 Spreader Beam

SWL and serial number of all spreader beams shall be clearly marked. Test certificates from Govt.
approved certifying authorities shall be submitted to owner/consultant/ EIL.
Register of spreader beam shall be maintained by contractor and same shall be submitted to

31.1 General
Lifting appliances means mobile cranes, derricks, tower cranes, overhead cranes, chain pulley
blocks, forklift, strand jacks, hydraulic jacks etc.
All lifting appliances including all parts and gears thereof, whether fixed or movable shall be
thoroughly tested and examined by a competent person at least once in a year or after it has
undergone any alterations or repairs liable to affect its strength or stability. Within the validity, if the
lifting appliances are shifted to a new site, re-examination by the same competent person for
ensuring its safety shall also be done.
Contractor shall maintain list of lifting appliances, lifting appliances maintenance register and shall be
submitted to owner/consultant/ EIL on regular basis.
The contractor shall not employ any person to drive or operate lifting appliances unless he is above
twenty-one years of age and possesses a valid heavy transport vehicle driving licence as per Motor
Vehicle Act and Rules.
The operator shall possess the knowledge of the inherent risks involved in the operation of lifting
appliances.
The operator shall be is medically examined and the report shall be submitted to owner/consultant/
EIL.
The laminated photocopies of test certificates issued by competent person, the operators photo,
manufacturers load chart shall be displayed in the operator cabin.
Safe Working Load (SWL) shall be clearly displayed on lifting appliances.
Lifting appliances shall be periodically inspected and reports shall be submitted to owner/consultant/
EIL.
Attachment 35: Crane Register
31.2 Hydraulic Mobile Crane

All alarms and signals like safe load indicators (SLI), boom angle indicators, boom extension
indicators, over lift boom alarm, swing alarm, hydraulic safety valves, mechanical radius

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indicators, etc. shall be periodically examined and maintained always in working condition.
Boom shall be free from bents, cracks, rust, flaking or cracked paint, bulges, greases etc.
Hydraulic pipes any fittings shall be free from any leak.
The operator cabin shall have wind shield, wipers etc. The wind shield shall be clean ad free from
cracks.
Fire extinguisher shall be provided at operator cabin.
Attachment 36: Daily Crane Inspection by Operator
Attachment 37: Monthly Crane Inspection
31.3 Chain Pulley Blocks

The contractor shall ensure the strength of the structure to withstand the load before hanging
chain pulley block.
Chain pulley block shall have safety latch.
Loads in excess of SWL shall not be lifted or lowered.
The hand and load chains shall hand freely without any twist or knots.
Chain pulley blocks are designed for lifting the loads vertically and shall not be used to pull the
loads horizontally.
31.4 Tower Cranes

The instructions of the manufacturer of a tower crane and standard safe practices regarding such
crane are followed while operating or using such crane.
No person other than the operator trained and capable to work at heights are employed to operate
tower cranes
The ground on which a tower crane stands has adequate bearing capacity;
Bases for tower cranes and trucks for rail-mounted tower cranes are firm and levelled and such
cranes are erected at a reasonably safe distance from excavations and are operated within
gradient limits as specified by the manufacturer of such cranes;
Tower cranes are sited where there is a clear space available for erection, operation and
dismantling.
Tower cranes are sited in such a way that the loads on such cranes are not handled over any
occupied premises, public thoroughfares, railways or near power cables, other than construction
works for which such cranes are used;
Where two or more tower cranes are sited and operated, every care is taken to ensure positive
and proper communication between operators of tower cranes to avoid any dangerous
occurrences.
32.0 Lifting Activity

32.1 Lifting of Material
Contractor shall designate a rigging co-ordinator who shall have adequate knowledge, skill,
experience, qualification and training who shall successfully demonstrate to solve problems related to
safe crane operation. This rigging co-ordinator shall prepare a rigging plan, supervise and control all
lifting activities.
Contractor shall submit a detailed method statement/ rigging plan for critical and heavy lift by
considering following
Rigging sketch
Details of the crane
Rated capacity of crane
List of rigging hardware
Rated capacity of rigging components
Weight of the rigging gear
Weight of the load
Total weight of the lift (Weight of the rigging gear + Weight of the load)
Dimension of the load
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Crane Radius
Boom Length
Safe working limits of the crane as per load chart
Ground and site condition
Placement of crane
Swing radius
Sling angles
Hand signal and necessary communication to be used.
Contractor shall submit all manufactures operator manual, third party test certificate to
Before beginning any crane operation the supervisor and operator shall complete the pre-lifting
checklist. The same shall be submitted to owner/consultant/ EIL.
Attachment 38: Per-Lift Checklist
The outrigger of the crane shall be fully extended prior to the lift and shall be padded on firm base.
The operator shall have valid operator license.
Lifting activity shall not be carried out when wind velocities is 25km/hr or greater or during other
adverse condition.
Sufficient clearance shall be maintained while working near over head power lines
Up to 250,000 volts at least six meter clearance shall be maintained.
Above 250,000 volts at least 7.5 meter clearance shall be maintained.
Contractor shall deploy only the riggers having sufficient knowledge, experience and skill.
A trial lift shall be carried out, raising the load a short distance above its pick-up point, to check the
stability of the crane, and the efficiency of the brakes.
Tagline shall be used to control the load swing.
Crane boom swing radius shall be barricaded and safety sign boards shall be displayed.
Signal man shall be provided with retro-reflective jacket and he is the only authorised person to give
signal to the operator.
No person shall move beneath the load and travel on the load.
32.2 Lifting of Personnel

Contractor shall avoid lifting of personnel by crane. The preference shall be scaffold. If the nature
of job demands, then such lift shall be authorized by owner.
The suspended personnel basket shall be limited to a capacity of six persons.
Suspended personnel basket and attaching device shall be designed with factor of safety greater
than five.
Suspended personnel basket shall have name plate specifying the weight of the empty basket,
maximum number of allowed persons and rated capacity of personnel basket.
Personnel lifting basket shall be tested by third party competent person and the test certificate
shall be submitted to owner/consultant/ EIL.
Personnel lifting basket shall have hand rail at 1100mm, mid rail at 550mm and toe guard width
shall be of 150mm.
A trail lift without personnel shall be carried with maximum anticipated load. The taril lift shall be
from ground level to the location to which the basket to be lifted.
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adverse condition.
Suitable anchor points shall be provided in the basket and personnel being lifted shall anchor their
full body safety harness to the anchor points.
The crane operator shall not leave the cabin after personnel are lifted. In case of emergency, all
personnel shall be lowered to ground and leave the cabin.
33.0 Construction Vehicle

33.1 Dumpers, trailers, trucks, excavators, transit mixers, road rollers, tractors piling rigs, cranes, tipper,
lorry loaders, skip wagons, crawler tractors, scrapers, graders, tankers etc are considered as
construction vehicles.
33.2 The contractors shall provide a list of vehicles needed to be used at site and formulate a procedure
relating to construction vehicle inspection, operation and maintenance. It must be consistent with the
manufacturer's recommendations and consultants requirements.
Contractor's construction vehicles are to be periodically inspected and maintained according to pre-
determined schedule. Records of all inspection and maintenance shall be maintained and submitted
to owner/consultant/ EIL on regular basis.
Vehicle maintenance or repairing work shall not be carried out inside the construction site.
33.3 Operators entering site shall be instructed to follow the safe system of work adopted on site. These
shall be preferably, written instructions showing the relevant site rules, the site layout, delivery areas,
speed limits, etc.
33.4 All vehicle operators shall undergo medical fitness test, audiometric test and vision check test. The
medical certificates of those operators shall be submitted to owner/consultant/ EIL.
33.5 Vehicle operator shall possess valid driving license.
33.6 All construction vehicles shall have

RC and Pollution under Control (PUC) certificate
Exhaust shall be fitted with flame arrestor.
Horn, mirrors, head and tail lights, indicators, reflectors etc.
Parking brake and brake light
First Aid kit
Fire extinguishers
All Vehicles shall be fitted with audible reverse alarms and maintained in good working condition.
Reversing shall be done only when there is adequate rear view visibility and under the directions of a
banksman.
All vehicles shall be equipped with wind shields and wipers. Cracked or broken wind shields shall be
replaced.
33.7 At start of each shift operator shall check oil, fuel, water and hydraulic levels, that all gauges are
working and the vehicle is functioning smoothly.
33.8 The maximum speed limit on the construction site is 20-km/ hr. The maximum speed limit in work
areas is 15-km/ hr.
Personnel must not be transported while standing on the bed of trucks or trailers or on material
handling / earth mounting equipment or they shall not be allowed to sit on doors.
Material extending from vehicle bed shall be indicated with red flag.
The latch on the dumper skips shall be in working order and release mechanism shall function
smoothly.
The operators shall turn-off the engine and remove the ignition key before leaving the vehicle.
Before moving the vehicle operator shall walk around it to see the area is clear. No one shall be
allowed to sit or lie around or beneath the vehicle.

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Wheel stopper shall be provided to while parked at slopes, place near any excavations etc.
33.9 Parking and Vehicle movement in Refinery Premises

Vehicles shall be parked only in designated areas. No vehicle shall be parked opposite fire
hydrants or at the intersection of roads or within 10 meters of any road corner or in front of the
Fire Station.
Vehicle shall not be parked, in any manner that will block emergency services, bends, building
exits and walkways etc.
No vehicles should enter into any operating area without valid fire permit followed by a safety
clearance from the area-in-charge (this includes process areas, tank farms and loading racks).
The contractors shall prominently display the name of their company on all the vehicles including
tractor trolleys, trucks, open jeeps, cranes which are allowed by the owner to enter inside the
Refinery for carrying out the job. The display board shall be put on front and rear side of each of
the vehicle.
Photocopy of the vehicle gate pass along with the drivers photo shall be pasted on the
windscreen for display. Driver shall keep valid driving license along with him
Attachment 39: Construction Vehicle
34.0 Construction Machinery

The contractor shall ensure at the construction site all motors, cogwheels, chains and friction
gearing, flywheels, shafting, dangerous and moving parts of machinery are guarded. The guard of
dangerous part of machinery is not removed while such machinery is in motion or in use.
34.1 Air receivers / compressors
Contractor shall ensure that air receivers/ compressors shall be
In good condition and properly maintained.
Individually identified and marked with their safe working pressure.
Be accompanied by a valid test certificate.
Fitted with a properly set pressure relief valve.
Examined and the pressure relief valve tested by an independent examiner at yearly intervals.
A register containing relevant details about the air receivers, compressors shall be maintained at
site such as identification numbers, dates of inspections, pressure ratings etc.
All compressed air fittings shall be wired and/or restrained to prevent them from whipping should
the coupling separate.
Only hose clamps designed for compressed air service shall be used. Worm drive (jubilee) clips
are not acceptable.
35.0 Noise
Noise must be kept to a minimum at all times and must not exceed acceptable and/or any work
activity which is likely to expose any employee on site to a noise level of 85 db(A) or above,
assessments should be carried out. In such circumstances, the contractor must keep stocks of
ear defenders or other suitable hearing protection and issue to the workmen who are exposed to
the higher levels of noise.
The Contractor shall ensure that noise generated from all powered mechanical equipment shall
be effectively reduced using the most modern techniques available including but not limited to
silencers and mufflers.
The Contractor shall construct acoustic screens or enclosures around any parts of the works from
which excessive noise may be generated.
Grinders, Cutters, Jack Hammer (pneumatic drills), Engine driven plant and the like, all give off
levels of noise that is harmful.
Earplugs and earmuffs are the commonest form of hearing protection to be used.

Page 144 of 674
SPECIFICATION No.
CHENNAI
36.0 Confined Space

36.1 General
A confined space is large enough and so configured that an employee can bodily enter and perform
assigned work, has limited or restricted means for entry or exit and is not designed for continuous
employee occupancy.
A person passes through an opening into a confined space and is considered to have occurred as
soon as any part of the entrant's body breaks the plane of an opening into the space is confined
space entry.
The danger may be as a direct result of a process being undertaken by persons in confined space
and the activities such as spray painting, use of cleaning fluids (solvents), hot work, abrasive
blasting, arc air gouging were considered as dangerous activities.
The hazards involved are asphyxiation, fire and explosion, oxygen enrichment or deficiency, dust and
fumes, electrocution, heat exhaustion.
36.2 Preparation
Contractor shall prepare method statement and submit to owner/consultant/ EIL for review at least
seven days prior to the commencement of the activity. Method statement for work in confined space
shall address the following as minimum.
Work scope and methodology
Nominated supervisors for obtaining permit to work and overall controller of the work activity.
Nominated stand by persons
Tools and equipments to be used
Explosion proof fittings
Flame proof lighting arrangement including emergency lighting
Ventilation arrangement
Access
Fire safety and fire extinguisher requirements
First-aid facilities
Rescue procedure and availability of equipment/ resource for rescue
36.3 Authorization
Nominated supervisor is a competent construction engineer who has adequate knowledge, skill,
experience and familiarity about working in confined space.
Contractors nominated supervisor shall ensure that workmen and other supervisors employed for
work in confined space are trained and competent in performing such task before signing the work
permit.
All entry into confined spaces shall be controlled by means of a permit to work and this shall be
obtained from owner/consultant/ EIL.
No new activity shall be introduced in to a confined space without permission and signed approval of
permit to work from owner/consultant/ EIL.
36.4 Access
Clear and safe access shall be maintained continuously while workers are in confined space.
Ladder shall be of suitable size and length.
Adequate lighting shall be provided at all access and egress points.
36.5 Communication
Effective communication shall be maintained between personnel in confined space and outside by
combination of visual/ voice or portable radio.
36.6 Ventilation
Contractor shall check the oxygen level and confined space entry shall only be permitted if level of
oxygen by volume is in between 19.5 percent to 23.5 percent.
The oxygen level shall be surveyed at regular interval while any task is performed in confined space.
The oxygen level survey details shall be maintained in log register.
Page 145 of 674
SPECIFICATION No.
CHENNAI
Exhaust fan or other mechanical means shall be used to bring Lower Explosive Limit (LEL) 0% or
toxic gas below Threshold Limit Value (TLV). Also Self Contained Breathing Apparatus (SCBA) shall
be used if necessary.
Whenever spray painting is carried out in confined space, forced ventilation shall be provided to
avoid any accumulation of flammable vapours.
36.7 Electrical Safety

Electrical hand tools to be used in confined space shall be inspected for good working condition, free
from defects, double insulated cables, connections through ELCB and valid test and inspection
stickers.
Contractor shall use only 24V lamp. Lamp shall be suitably guarded
All electrical fittings shall be of Flame proof and confirm to national standards
36.8 Fire Safety

All combustible materials shall be removed wherever possible before performing any hot work.
Fire protection equipments such as fire extinguishers or fire hoses shall be kept at the work area.
A fire watcher shall be deputed whenever hot work is carried out in confined space.
Compressed gas cylinders shall not be taken into confined space under any circumstance.
Gas cutting torch/ electric arc welding torch shall be removed from confined space during any
interval/break and as soon as the job is completed.
36.9 Emergency Rescue

Stand by person shall be deployed at the entrance of confined space to assist in rescue if any.
Stand by person shall be trained in rescue and his duties include evacuation of all entrants in
confined space. Also communicate for any emergency services and assist in rescue.
Stand by person shall be familiar with all possible hazards in confined space and remain outside
confined space entry until relived by another stand by person.
Rescue equipments such as full body safety harness, tripod, lifelines, Self Contained Breathing
Apparatus (SCBA), stretchers, Man basket, crane shall be kept readily available.
37.0 Radiography
Radiography camera must be operated only by licensed radiographers certified by BARC under
the direct supervision of site-in-charge.
Contractor shall submit list of competent persons involved in radiography at least seven days prior
to the commencement of the job.
Contractor shall submit a list of authorised person involved in radiography associated works such
as isolation of sources, radiation survey meter surveyor, area cordon-off crew.
Field radiography shall be carried out during night time where there is no occupancy around.
All radioactive sources must be clearly identified with its strength of the source, activity at different
levels. A warning label should be displayed indicating Danger Radioactive Material.
The area shall be cordoned-off whenever radiography is carried out and the distance to be
cordoned-off is determined by the type and strength of radiation source to be used, the type of
exposure given, nature of occupancy and the total exposure time per week.
The radiation levels along the cordon should be monitored by suitable and calibrated radiation
survey meter to confirm the cordon-off distance is adequate.
Everyone involved in field radiography activity shall wear personnel monitoring badges.
Radiation warning symbols shall be conspicuously posted along the cordon in English, Hindi and
vernacular languages. It shall be readable from a distance of 7 m under normal illumination.
All safeguards should be implemented to ensure that workmen are not crossing the barricades.
The boundary of cordon on all sides shall be adequately illuminated throughout the duration of
radiography.
Red warning lights must be posted at night along boundary of cordon and especially at the point
of entry.
38.0 Hand tools

Contractor shall ensure that all hand tools used shall be of correct type, size and weight for the job.
Page 146 of 674
SPECIFICATION No.
CHENNAI
Hand tools used for electrical operations shall be properly insulated and shall be non-conductive
type.
Screwdrivers used shall correct size of tip to fit the slot of the screw.
Screw drivers shall not be carried in pockets of clothing.
Hammers handles shall be made of smooth timber. Hammer head should be secured to wooden
handles with proper wedges.
Chisels edges shall be kept sharp all the time. The original shape and angle shall be maintained.
The chisel should be handled by tongs. Holding chisel by hand while chipping shall be avoided.
Shovel blade shall not be allowed to become blunt, turned, split or jagged.
Only spanners and adjustable wrenches shall be used. Improvised extension of spanners may
cause shearing of bolt and slip of tool.
The ordinary wrenches shall not struck by hammer.
Pipe wrenches should be large enough for the job. It should not be struck with hammer nor, shall
be used as hammer.
Pliers used for electrical works shall be fitted with insulated handle.
The hacksaw blade to cut shall be set in hacksaw frame. The teeth shall point forward direction
and sufficient tension should be applied to ensure the blade is maintained rigid.
39.0 Demolition
Prior to the commencement of any demolition work and also during the process of demolition
contractor shall follow the following additional precautionary steps shall be observed.
All roads and open areas adjacent to the particular site shall either be closed or suitably
controlled.
All underground / overground power / telephone cables or water / sewerage lines in the vicinity of
the particular site shall be either suitably diverted or made non-functional for the duration of the
demolition activity.
All practical steps shall be taken to prevent danger to persons employed from risk of fire or
explosion or flooding. No floor, roof or other part of the building shall be overloaded with debris or
materials as to render it unsafe.

Before erecting temporary shelters like sheds anywhere within the Refinery premises, written
permission of the Engineer-in-charge be obtained.
Temporary fixtures like sheds, tents, etc. shall be erected in conforming with normal safety
standards. Thatched roof to such fixtures will not be permitted.
Temporary piping, hose connections and electrical wiring must be laid in such manner that they
do not cause tripping or hitting hazard
Temporary sheds can be constructed only for the storing of the material / site office. It should not
be used for any other purpose.
However, for all jobs having value more than Rs. One crore, no temporary sheds shall be allowed
for office / stores of the contractor and instead the contractor shall arrange for portal cabin for site
office / stores.
Following information shall be clearly written on the shed:- Name of the contractor; Work Order
No.; Working under the Department; Name of the Engineer-in-charge; Permit No. & it's validity
period.
The shed shall be made of safe construction material and good aesthetic view. The shed shall be
made strictly at the authorised location and size.
All windows shall be either of wire mesh or glass.
Company has the right to open or break the door at any time to inspect the shed.
After completion of the job shed must be demolished within 10 days and area must be cleaned.
All precautions should be taken to ensure that any temporary electrics wiring used within the
Refinery will not cause sparks or shock

Page 147 of 674
SPECIFICATION No.
CHENNAI
41.0 Penalties for Violation/Non-Adherence of Safety Procedures and Practices

41.1 The contractor has to follow all Safety, Health and Environment rules & regulations of the Refinery. In
case of non-compliance of any of these rules and regulations by contractor or his employees, the
contractor shall be held responsible. If any violation or non-fulfilment of these Safety, Health and
Environment rules and regulation is observed by Refinery authorities during checking at any time, a
penalty of Rs. 5000.00 (Rs. Five Thousand Only) shall be imposed on the contractor for each
occasion of non-compliance to these rules and regulations by him or his employees. The decision of
Refinery authorities shall be final and binding on to the contractor in this regard. The amount of
penalties so imposed shall be recovered from the next R.A. Bill of the work or any other dues payable
to the contractor by Refinery
Event Penalty
Absence of Resident / safety Engineer of Contractor in

Rs 1000 per meeting
EIL/OWNERs safety meeting
Failure to have regular site safety Inspection (by contractors
Rs 1000 / week
themselves) every week
Failure to conduct Health / Safety / Environment (HSE)
meetings by Contractor at site (in-house) and maintain Rs 1000/month
records
Failure to submit HSE reports/check Lists, etc., by 5th of Rs 1000 /month and Rs 100 / day
every month to EIL/OWNER for further delay
Working without clearance Rs 5000/occasion
Hot work without proper Clearance / permit Rs 10000 / occasion
For not providing shoring / strutting / proper slope and not
keeping the excavated earth at least 1.5M away from the Rs 5000 / occasion
excavated area
41.2 In case the violation / non-compliance of above Safety, Health & Environment rules results in results
in any Physical Injury or Fatal Accident, an additional penalty as given below shall also be imposed
on to the Contractor:
41.3 For any reportable physical injury as per Indian Factories Act - 1948: Additional penalty of 0.5 % of
the contract value subject to a maximum of Rs.2,00,000 (Rs. Two Lakhs Only) per injury in addition
to the penalty of Rs.5000 as per 41.2 above
41.4 For Fatal accident: Additional penalty of 1 % of the contract value subject to a maximum of
Rs.10,00,000 (Rs. Ten Lakhs Only) per fatality in addition to the penalty of Rs.5000 as per 41.2
above.

In case of any accidents/injury of a contractor's workmen, the contractor shall pay a suitable
compensation (subjected to the minimum compensation as mentioned below) to the affected person /
his family members in the presence of Engineer-in-charge and in consultation with Chief Medical
Officer of the Refinery. The said compensation shall depend on the seriousness of injury, etc, and
shall be in addition to the hospitalization / treatment charges and Group Insurance Amount payable
to the effected person. The following are the minimum compensation shall be paid to the affected
person / his family as stated above:

Page 148 of 674
SPECIFICATION No.
CHENNAI
42.1 In case of fatal accidents: Rs.1.0 lacs (Rs. One Lakhs) within 5 days of accident.
42.2 In case of loss of both the limbs (hand / legs/eyes/ ears) : Rs.50,000/- (Rs. Fifty Thousand ) within 1
week.
42.3 In case of loss of one limb (hand / legs/eyes/ ears) : Rs.25,000/- (Rs. Twenty Five Thousand ) within
1 week.
42.4 In case of any injury not specified above, Rs.1000/- (Rs. One Thousand) to Rs.5000/- (Rs. Five
Thousand) as directed by Engineer-in-charge within 1 week.

Page 149 of 674
SPECIFICATION No.
CHENNAI

Page 150 of 674
SPECIFICATION No.
CHENNAI
LEGAL OBLIGATIONS / REQUIREMENTS FOR CONSTRUCTION
Factories Act, 1948,

Minimum Wages Act, 1948 and Rules 1950
Employees Provident Fund & Miscellaneous Provisions Act, 1952.
Contract Labour Act, 1970 and Rules 1971
Weekly Holidays Act, 1942.
Fatal Incidents Act, 1855.
Personal Injuries (Compensation Insurance) Act, 1963.
Workman Compensation Act, 1923 along with allied Rules
The Public Liability Insurance Act 1991 and Rules 1991
Child Labour (Prohibitions & Regulations) Act, 1986 and Rules 1950
Indian Electricity Act 2003 and Rules 1956
Motor Vehicles Act as amended in 1994 and The Central Motor Vehicles Rules, 1989.
The Petroleum Act, 1934 and Rules 1976
Gas Cylinder Rules, 2003
Environment Protection Act, 1986 and Rules 1986
Air (Prevention and control of Pollution) Act, 1981
Water (Prevention and Control of Pollution) Act, 1974
The Noise Pollution (Regulation & Control) Rules, 2000
Manufacture, Storage & Import of Hazardous Chemicals Rules, 1989
The Hazardous Waste (Management & Handling) Rules, 1989
Hazardous Waste Management Rules 1989 (as amended in 1999)
Building and other Construction Workers Act, 1996.

Page 151 of 674
SPECIFICATION No.
HEALTH, SAFETY & ENVIRONMENT MANAGEMENT AT Page 51 of 101
DCU,CPCL CHENNAI
HSE ASSURANCE PLAN
SR ACTIVITY FREQUENCY EXTENT OF CHECKING REMARKS
NO OPERATING CHECKING SUB CONTRACTOR LSTK CONSULTANT

/OWNER
Area Engr Safety Supervisor Safety Officer CONTRACTO
R
1. HSE Policy Communicate to all Once in the Review Contractor to submit.

working at Project site. beginning. implementation
As applicable system
2. Safety committee Through meetings at To be formed consisting Owner, Consultant, Contractor / Sub Contractor and Representatives of workers.
predefined interval.
3. Training (Induction and For everyone As per Training Requirement in HSE Manual Entry passes to be issued only
Periodic) after induction
4. Reporting
4.1 Safety Statistics Monthly Monthly NA NA Monthly Monthly
4.2 Weekly First Aid and Weekly Weekly W Weekly Once a Week R
Illness Reports
4.3 Labour Report with Work Daily Daily Daily Daily Daily R Summary at the end of
hours month
4.4 Incident Reports As applicable As NA W W R

applicable
4.5 Investigation Reports As applicable As NA W W R

applicable

Page 152 of 674
SPECIFICATION No.
DCU,CPCL CHENNAI
HSE ASSURANCE PLAN


/OWNER
Area Engr Safety Safety Officer CONTRACTOR
Supervisor
5. Statutory requirements Regular Once in 3 NA NA Monthly R Once in Quarter

(Registration, Records of months
Payment, Licenses)
6. Facilities
i. First Aid Regular R NA W R R Once in a Month
ii. Emergency care services Advance R NA Daily Periodic S Once in a Month

(Doctor, Ambulance) arrangement.
iii. Medical examination (Pre & Regular Periodic N.A. N.A. Periodic S Once in a Month
Periodic)
iv. Temporary accommodation In the beginning R N.A. R R R R
v. Drinking Water tank Filling everyday, Through R N.A. R S R

cleaning once a Records
week
vi. Urinals & Latrines Daily sweeping R N.A. R R R R If applicable

arrangement.

Page 153 of 674
SPECIFICATION No.
DCU,CPCL CHENNAI
HSE ASSURANCE PLAN


/OWNER
Area Engr Safety Safety Officer CONTRACTOR
Supervisor
vii. Septic tank/disposal system In the beginning S N.A. W R R R If applicable
viii. Mosquito control Once a week, Through records N.A W R R R If applicable

disinfecting
arrangement
ix. Crches for Children below Required if 50 or R N.A Daily Monthly R R

6 yrs. more females
employed at site
x. Canteen Required if more R N.A. Daily Monthly R R If applicable

than 250 workers
are employed.
xi. Waste disposal Daily R N.A. Daily monthly R R
7. Fire fighting system S Once in a month N.A. W R R R
8. Traffic rules Daily Daily N.A. W R R R
9. Use of PPE Daily Daily By all, regular basis.

Page 154 of 674
SPECIFICATION No.
DCU,CPCL CHENNAI
HSE ASSURANCE PLAN

NO
OPERATING CHECKING SUB CONTRACTOR LSTK CONSULTANT
CONTRACTOR /OWNER
Area Engr Safety Safety Officer
Supervisor
10. Work permit system S W W R R As applicable
11. Safety publicity Continuous Periodic N.A. N.A. W R
12. Excavation S NB W W R R S
13. Cutouts/openings S NB W W R R S
14. Barricading S Daily W W R R
15. Scaffolds S Regularly W W W R
16. Ladders S Regularly R R R R
17. Welding/cutting M/C S Once in 3 W W W R S
months
18. Elect. Hand tools & S Once in 3 W W R R
Distribution Boards month
19. Mechanical Equipment S Once in 6 W W Rw R S
months
20. LOAD TESTS FOR Heavy lifts W N.A. Rw Rw S Formal procedure
required for heavy lifts
Legends: W Witness
Rw Review of Sub-Contractors document
R Random verification
S Surveillance
NA Not applicable

Page 155 of 674
SPECIFICATION No.
DCU,CPCL CHENNAI
Site Safety Organisation Chart

Owner
Owners/PMCs Project Owner/PMCsSafety Representative
/PMC Representative
EIL
Resident Construction Manager
Safety officer

Contractor
Safety Manager
Safety Engineer
Safety Supervisor Safety Supervisor Safety Supervisor
Safety Observer Safety Observer Safety Observer Safety Observer Safety Observer

Page 156 of 674
SPECIFICATION No.
DCU,CPCL CHENNAI
Client: Weekly Safety Meeting

Safety Committee
Project:
Meeting
Project Number Meeting Number:
Confirmation of Meeting Telephone Talk

Date Held : Location :
Date Issued : Recorded by:
Issued By : Distribution:
Subject:
Participants:
Client Consultant Contractor/
EIL
Agreed date
Sl. Target
Remarks in Previous Action by
No Date
meeting

Page 157 of 674
SPECIFICATION No.
DCU,CPCL CHENNAI

Page 158 of 674 Copyright EIL All rights reserved
SPECIFICATION No.
A133-00-6-82-0001 Rev. 0
SPECIFICATION FOR
HEALTH, SAFETY & ENVIRONMENT MANAGEMENT AT DCU,CPCL CHENNAI Page 58 of 101
SAFETY OBSERVATION REPORT (SOR) SUMMARY SHEET
Project Contractor Date From: To:
P - Positive; AR - At Risk: UA - Unsafe Act; UC - Unsafe Condition; LB - Lack of Belief; LT - Lack of Training; LI - Lack of Interest; LR - Lack of Resource; C - Closed; O-Open
SOR
Direct
Observation Indirect Cause SOR SOR Status Closed
Date Time Observer Location Description Cause Corrective Action
category on
P AR UA UC LB LT LI LR C O
Contractors RCM Name Contractors Safety Manager Name

Signature Signature
Date Date
1.7.7.1

Page 159 of 674
SPECIFICATION No.
A133-00-6-82-0001 Rev. 0
SPECIFICATION FOR
Safe Plan of Action
Contractor Date: From: To: Doc no:

Activity/ Task Work area/ location Rev 0
Job description:
PPE Required
Full body double lanyard Hand gloves
Helmet Safety shoes/ Gumboot Safety goggles
safety harness
Nose mask Ear plug Hard hat with welding Shield Grinding visors/ face shield Others
Safety Devices
Caution tape/ Barricading Sign/Display boards Fluorescent jackets Lifeline/Fall Arrestor Safety net
pipes
Flash back Arrestor Fire extinguisher Fire blanket Warning lights
Others
Steps of Activity/Task Hazard/Reaction to Change Safe Plan Resources
Description Performer (Team members) Approved by Reviewed by

Name
Signature
Company
Date
The signature of the supervisor confirms the completion of the hazard assessment and Safe Plan of Action by the crew.
Supervisors Signature: Date

Instructions: 1. Write name of job or task in space provided. 2. Conduct walk-through survey of work area. 3. Write the steps of the task in a safe sequence. 4. List all possible hazards involved in each step and
reaction to change. 5. In the Safe Plan column, state actions that will be taken to prevent the hazards or injury from reaction to change. 6. In Resources column, list equipment, tools, etc. needed to do the job. 8. Ask
each team member, who helped develop and will use this SPA, to sign in spaces provided. 9. Review the SPA at the end of the task for improvements.
Work shall stop when conditions change, the job changes, or a deficiency in the plan is discovered, and the current SPA will be modified or a new SPA created.

Page 160 of 674
SPECIFICATION No.
DCU,CPCL CHENNAI
General Inspection Report (Safety Walk Around)

Project Contractor
Location Date Time
Name of team members involved in inspection

Sl.No Observation Hazard Identified Corrective Action Remarks
Signature of team members
Contractor shall complete the corrective action and submit the compliance report to EIL/ owner/consultant

Page 161 of 674
SPECIFICATION No.
A133-00-6-82-0001 Rev. 0
SPECIFICATION FOR
Attachment 9

Page 162 of 674
SPECIFICATION No.
A133-00-6-82-0001 Rev. 0
SPECIFICATION FOR
Attachment 9

Page 163 of 674
SPECIFICATION No.
A133-00-6-82-0001 Rev. 0
SPECIFICATION FOR
Monthly Safety Audit Checklist

Page 1 of 6
Project Date Location
Contractor Audit No. Audit Team members:
Sl. Possible Obtained

Description Observation
No Points Score
A Training 20
1 Induction training given to all new joining workers 5
2 Toolbox talks conducted frequently 5
3 Fire drill & site specific training conducted frequently 5
4 Records maintained for all training given at site? 5
B Personal Protective Equipment 25
5 PPE issue and inspection register maintained? 5
6 Compliance of safety shoes, safety goggles and helmets 5
7 Full body safety harness (lanyard length - 1.8 m) anchored 5
8 Welding shield & grinding visor mounted helmet used 5
9 Other necessary PPEs 5
C House Keeping 35
10 Clear walkways are maintained without any obstructions? 5
11 All materials are stacked properly? 5
12 Waste materials/ scraps dumped properly at identified areas? 5
13 Electrical cables are properly routed to prevent trip hazards or 5
damages due to vehicle movement
14 Nails or other sharp objects being removed or bent? 5
16 Scrap yard identified at site and waste disposed from site 5
regularly

Page 164 of 674
SPECIFICATION No.
A133-00-6-82-0001 Rev. 0
SPECIFICATION FOR
Page 2 of 6


No Score Score
D Work at height 20
17 Edge protection & floor opening protection provided? 5
18 Fully planked working platform with handrails, mid rails & toe- 5
guards with secured access ladder extending 1 m from
19 Fall
the arrestors, lifelines & safety nets in use wherever 5
necessary?
20 Ensuring everyone anchoring the safety harness when 5
exposed to a fall of 2m and above
E Scaffolds & ladders 40
21 Scaffold designed & erected by trained personnel 5
22 Scaffolding checklist prepared and displayed? Scaffold 5

tags displayed?
23 Scaffold erected on a level surface with base plate / sole plate? 5
23 Appropriate scaffold materials are used & installed 5

properly with necessary supports and back ties wherever
Staging for shuttering is designed for loads like worker movement,
necessary.
25 5
impact loads and other incidental loads during various construction
26 Dismantling of scaffolds done under proper supervision? 5
Are all materials properly lowered?
27 Ladders in use are without defects? Positioned in a safe angle 5
and secured properly?
28 Mobile scaffolds are used with proper lock system 5
and appropriate access to the working platform?
F Excavation 20
29 Sloping/ benching or shoring maintained 5
30 Adequate barricading provided for the pit/trench 5
31 Access ladder in place where work is carried out 5
32 Excavated earth removed or deposited 1.5 m away 5

Page 165 of 674
SPECIFICATION No.
A133-00-6-82-0001 Rev. 0
SPECIFICATION FOR
Page 3 of 6

No Score Score
G Electrical 50
33 Electrical Inspection register maintained? 5

34 All power tools are inspected and tagged? 5
35 Does cabling provide sufficient headroom? 5
36 Electrical connections are free of insulation damages, 5
joints and provided with plug tops
36 All electrical connections are taken through ELCB (30 mA) 5
37 Proper earthing for main panel & body earhting for DBs? 5
38 All DBs are provided with a rain protection canopy? 5
39 Adequate safety provisions at panel room? 5
40 Is there enough number of first-aiders having knowledge of 5
CPR for electrocution?
41 DG inspected and maintained 5
H Vehicle movement 30
42 All vehicles installed with reverse horns 5
43 Authorised driver/ operator with a valid driving license 5
is engaged?
44 Vehicle operators given adequate training on speed limit, 5
overloading & site rules
45 Spark arrestors available? 5
46 Banksman available for controlling the vehicle movement? 5
47 Maintenance record and inspection record maintained 5

Page 166 of 674
SPECIFICATION No.
A133-00-6-82-0001 Rev. 0
SPECIFICATION FOR
Page 4 of 6


No Score Score
I Welding, gas cutting and grinding 50
48 Adequate PPEs are provided and used? 5
49 Earth connectors are securely connected to the job and not to 5
the adjoining structure or scaffold?
Welding cable used is maintained in good condition without any cut or
50 open/ tapped joints? Gas cutting hose is without any crack/ damage?
5
51 Flash Back Arrestors installed in the cutting set (both at 5

cylinder end and torch end)
52 Cylinder storage area clearly identified for fuel gas 5
and oxygen? Not exposed to sunlight kept in upright position
53 Cylinder keys are always available on acetylene cylinders? 5
Double pressure gauges are in working condition?
54 Grinding machine are with proper guards? 5
55 Grinding wheel used of proper RPM rating as marked on the 5
grinding machine?
56 Grinding wheel is without any crack or deformation 5
on circumference?
57 Adequate precaution taken to prevent the hazards from 5
hot spatters and sparks
J Rigging 30
58 Inspection and test certificate records maintained for all lifting 5
tools and tackles, hydras and cranes?
59 SWL & date of testing are visibly marked/ painted on all lifting 5
tools/ tackles and equipments?
60 Crane operators are trained, qualified, and have valid license. 5
61 All rigging tools and lifting equipment are in good 5

condition, properly inspected and have current certification.
62 Tag lines are used appropriately. 5
63 Cranes are set up properly including extended outrigger pads. 5

Page 167 of 674
SPECIFICATION No.
A133-00-6-82-0001 Rev. 0
SPECIFICATION FOR
Page 5 of 6


No Score Score
11 Other 55
64 SPAs are prepared and displayed at site? 5
65 Emergency response plan established at site and 5
communicated to all. Assembly point identified?
66 Adequate First aid facilities maintained. First Aid 5
register maintained at site?
Confined space works are carried out with a valid authorized permit
67 and is the permit displayed? All requirements specified in the 5
permit are fulfilled before confined space entry?
68 Fire Extinguishers in place for all hot works 5
Are illumination levels at workplace and passage ways
69 adequate? Sufficient lighting arrangements are made for night 5
works?
70 Sign boards and caution boards are kept wherever necessary? 5
71 All rotary parts of machinery are properly guarded? 5
73 Restrooms are made & well maintained. Designated place for 5
drinking water & clearly labeled
74 Participation of execution engineers in implementation of safety 5
program
75 Safety awareness and promotional activity 5
Safety Performance Rating Indicator (Score %) Contractor's Safety Performance

GOOD 90 100 % No of points attended
SATISFACTORY 76 89 % Possible Score
UNACCEPTABLE < 75 % Scores Obtained
Score %

Page 168 of 674
SPECIFICATION No.
A133-00-6-82-0001 Rev. 0
SPECIFICATION FOR
Page 6 of 6
Sl. Responsible Completion

Observation Corrective Action Target date
No Person date
Contractors RCM Endorsement

Date
Note: Contractor shall complete the corrective action and submit the sheet to EIL/Consultant/Owner.

Page 169 of 674
SPECIFICATION No.
HEALTH, SAFETY & ENVIRONMENT MANAGEMENT Page 69 of 101
AT DCU,CPCL CHENNAI
Safety Induction Induction Number

Project Name Project Number
Contractor Date of Induction
Inductee Name Designation
Age Blood Group Experience in Role:
1.0 Introduction about site
2.0 Safety Policy of Owner, Consultant & Contractor
3.0 Alcohol policy, Drugs, No smoking
4.0 Gate pass procedure
5.0 First aid facilities
6.0 Emergency procedure
8.0 Welfare facilities
9.0 Personal Hygiene
10.0 Good housekeeping
11.0 Fire preventions and protections
14.0 Working at height (Ladders, Scaffolding, Safety harness)
15.0 Fall prevention and protection (Open edges, floor cut outs)
16.0 Safe use of hand and power tools
17.0 Material handling
18.0 Electrical safety
19.0 Gas cutting, welding and Gas Cylinders
20.0 Traffic rules
21.0 Movement on site

Your
22.0HealthPermit
- should the Company and your work colleagues know about your health? Are you
to work
taking specially prescribed medication? Are you epileptic or diabetic, or do you have a heart problem/
23.0
disease? IfDont
we allput yourself
know and help
- we can otherif at
yourisk. If youill,
become have any
if we doubts
don't ask
know, your
any supervisor
help forlate.
may be too help.
...................................................................
24.0 of Inductor
Name Return home safety Name of Inductee

Signature Signature/ Thumb Impression
25.0 Any other topic
Date Emergency Contact Number

Page 170 of 674
SPECIFICATION No.
A133-00-6-82-0001 Rev. 0
SPECIFICATION FOR
Safety Induction Attendance Register (Required only for two or more attendees)
Date of Induction: Total Number of Attendees: Induction Number:
Emergency Signature/
Gate Pass Blood Experience
Sl.No Full Name Designation Age Contractor Permanent Address Contact Thumb
Number Group in Role
Number impression

Page 171 of 674
SPECIFICATION No.
AT DCU,CPCL CHENNAI

Page 172 of 674
SPECIFICATION No.
AT DCU,CPCL CHENNAI

Page 173 of 674
SPECIFICATION No.
HEALTH, SAFETY & ENVIRONMENT Page 73 of 101
MANAGEMENT AT DCU,CPCL CHENNAI
Safety Training Matrix

Project Number Project Name
Contractor Training Matrix for the Month of
Supervisor
Electrician
Strength
Bar binder
Operators
Carpenter
Unskilled
Planned
operator
Scaffold
operato
Grinder
Vehicle
Painter
erector
Sl.No Training Topic
Welder
worker
Rigger
Mason
mover
Crane
Earth
Date
Fitter
r
1. Safety Induction
2. Personal Protective Equipment
3. Housekeeping
4. Work permit
5. First-aid
6. H2S
7. Mock drill
8. Excavation
9. Manual handling
10. Driving Safety
11. Working at Height
12. Scaffold
13. Hot work
14. Heavy lifting and Rigging
15. Fire prevention and protection
16. Electrical Safety
17. Hand and power tools
18. Confined Space Entry
19. Pre-commissioning Safety
20. Lock-out and Tag-out
Contractors Endorsement Date

Page 174 of 674
SPECIFICATION No.
HEALTH, SAFETY &
ENVIRONMENT MANAGEMENT Page 74 of 101
AT DCU,CPCL CHENNAI
Attendance Register for Safety Training

Project Project No
Contractor Topic
Date Location
Time Conducted by
Signature/ Thumb
Sl.No Name Designation Organisation
Impression
1
10
11
12
13
14
15
16
17
Facultys Signature
Date
1.

Page 175 of 674
SPECIFICATION No.
A133-00-6-82-0001 Rev. 0
SPECIFICATION FOR

Page 176 of 674
SPECIFICATION No.
Weekly Safety Report
Project Name Name of the Contractor

Project Started on Report Number
Report for the period From to
Descriptio For the Week Cumulative
n
Work Hours
Average Strength (Staff + Workmen)
Total Recordable Incident Rate (TRIR)
Performance Indicators
Injuries & Illness
Fatal
Recordable
Incidents
Medical Aid
Days away from work
Restricted Workday case
First-aid case
Near miss
Property Damage
Environmental Damage
Motor Vehicle Incident
Brief description of the incident during the week (if any):
Safety Metrics
Safety Induction
Tool Box Talks
Safety Training
Positive SOR
Other SOR
Safety Inspection
Safety Audit
Safe Plan of Action (SPA)
Safety Meeting
Contractors RCM endorsement Contractors Safety Manager Endorsement

Date of Submission
Remarks: Contractor shall submit supporting documents along with weekly safety report.

Page 177 of 674
SPECIFICATION No.
MONTHLY HEALTH, SAFETY & ENVIRONMENT (HSE) REPORT
Actual work start Date: Project: For the Month of

Name of the Contractor Name of Work Report No
Job No : Status as on
Contractor in consultation with EIL shall generate the reports through web based package (www.eil.co.in/conthse)
UPTO THIS
ITEM CUMULATIVE
PREVIOUS MONTH
1) Average number of Staff & Workmen MONTH
2) Man-hours worked
(average daily headcount, not man days)
3) Number of Induction programmes conducted
4) Number of HSE meetings organized at site
5) Number of HSE awareness programmes conducted at site
6) Number of Tool Box Talks conducted
7) Number of Lost Time Accidents (LTA) Fatal
Other LTA
8) Number of Loss Time Injuries (LTI) Fatalities
Other LTI
9) Number of Non-Loss Time Accidents
10) Number of First Aid Cases
11) Number of Near Miss Incidents
12) No. of unsafe acts/ practices detected
13) No. of disciplinary actions taken against staff/ workmen
14) Man-days lost due to accidents
15) LTA Free man-hours i.e. LTA free man-hours counted from the Last
LTA (enter date: .)
16) Frequency Rate (No. of LTA per 2 lacs man-hours worked)
17) Severity Rate (No. of man days lost per 2 lacs man-hours worked)
18) Loss Time Injury Frequency (No. of LTI per 2 lacs man-hours
worked)
19) No. of activities for which Job Safety Analysis (JSA) completed
20) No. of incentives/ awards given
21) No. of occasions on which penalty imposed by EIL/ Owner
22) No. of Audits conducted
23) No. of pending NCs in above Audits
24) Compensation cases raised with Insurance
25) Compensation cases resolved and paid to workmen
26) Whether workmen compensation policy taken Yes No
27) Whether workmen compensation policy is valid Yes No
28) Whether workmen registered under ESI Act, as applicable Yes No
Remarks, if any
Date: Prepared by Safety Officer Approved by Site Head / Resident Construction Manager
(Signature and Name) (Signature and Name)
To : - OWNER & RCM EIL (2 copies)
Page 178 of 674

SPECIFICATION No.

Page 179 of 674
SPECIFICATION No.

Page 180 of 674
SPECIFICATION No.

Page 181 of 674
SPECIFICATION No.
Incident Reporting Chain and Emergency Contact Numbers
Project: Contractor:
Incident (First Witness)
Immediate Supervisor
Contractors RCM Emergency Services

(Name and Contact Number to be updated) (First-aid centre, Fire Services)
Consultants RCM
(Name and Contact Number to be updated)
Head Office Client

Emergency Contact Numbers

Services Name Contact Number Remarks
Medical Centre (To be updated) (To be updated)
Ambulance (To be updated) (To be updated)
Hospital (To be updated) (To be updated) Tie-up Nearest
hospitals
Fire Station (To be updated) (To be updated)
Project Security (To be updated) (To be updated)
Police Station (To be updated) (To be updated)
Consultants Safety Department (To be updated) (To be updated)
Contractors RCM (To be updated) (To be updated)
Contractors Safety Manager (To be updated) (To be updated)
Contractors First-aid centre (To be updated) (To be updated)
Consultant RCM (To be updated) (To be updated)
Client (To be updated) (To be updated)
Note:
First witness shall attend the injured person.
Supervisor shall inform emergency services and also the contractors RCM.
All incidents and near miss incidents shall be reported immediately.
Detail report shall be submitted within 24 hours irrespective of Sundays and holidays if any.

Page 182 of 674
SPECIFICATION No.
CONTENTS OF A FIRST-AID
BOX
A sufficient number of eye wash bottles filled with distilled water or suitable liquid clearly indicated
by a distinctive sign which shall be visible at all times.
4 per cent xylocaine eye drops, and boric acid eye drops and soda by carbonate eye drops.
Twenty-four small sterilised dressings.
Twelve medium size sterilised dressings.
Twelve large size sterilised dressing.
Twelve large size sterilised burn dressings.
Twelve (fifteen cm) packets of sterilised cotton wool.
(Two hundred ml) bottle of certimide solution (1 per cent) or suitable antiseptic solution.
One (two hundred ml) bottle of mercurochrome (2 per cent) solution in water.
One (one hundred twenty ml) bottle of salvolatile having the doses and mode of administration
indicated on the label.
One pair of scissors.
One roll of adhesive plaster (six cm X one metre).
Two rolls of adhesive plaster (two cms X one metre).
Twelve pieces of sterilised eye pads in separate sealed packets.
A bottle containing hundred tablets (each of three hundred twenty-five mg) of aspirin or any
other analgesic.
Twelve roller bandages ten cms wide.
Twelve roller bandages five cms wide.
One tourniquet.
A supply of suitable splints.
Three packets of safety pins.
Kidney tray.
A snake bite lancet.
One (thirty ml) bottle containing potassium permanganate crystals.
One copy of first-aid leaflet issued by the Directorate General.
Six triangular bandages.
Two pairs of suitable, sterilised, latex hand gloves.

Page 183 of 674
SPECIFICATION No.
Bureau of Indian Standards for PPE
IS : 1179 - 1967 Equipment for eye and face protection during welding.
IS : 1989 -1986 (Part - I & III) Leather safety boots and shoes.
IS : 2925 -1984 Industrial Safety Helmets.
IS : 3521 - 1983 Industrial Safety belts and harness.
IS : 3778 -1975 Rubber knee boots.
IS : 4770 -1968 Rubber gloves for electrical purposes.
IS : 5424 - 1969 Rubber mats for electrical purposes.
IS : 5557 -1969 Industrial and Safety rubber knee boots.
IS : 5983 -1978 Eye protectors.
Code of practice for selections, care and repair of Safety

IS : 6519 -1971
footwear.
IS : 6994 -1973 (Part - I) Industrial Safety Gloves.
Guide for selection of industrial safety equipment for

IS : 8519 - 1977
body protection.
Guide for selection of industrial safety equipment for eye,
IS : 8520 - 1977
face and ear protection.
Code of practice for maintenance and care of industrial
IS : 8990 - 1978
safety clothing.
IS : 9167 - 1979 Eye protectors.
Recommendations for the selection, use and

IS : 9623 - 1980
maintenance of respiratory protective devices.
IS : 10667 - 1983
protection of fool and leg.
IS : 11226 -1985 Leather Safety footwear having direct moulding sole.

Page 184 of 674
SPECIFICATION No.
HEALTH, SAFETY & ENVIRONMENT MANAGEMENT AT DCU,CPCL Page 84 of 101
CHENNAI
Project: Contractor
Personal Protective Equipment Issue Register
Personal Protective Equipment Signature/

Date of ID Card Inducted
Sl.No Name Discipline Safety Safety Safety Safety Hand Other Thumb Remarks
Issue No on
Helmet Goggles Shoe Harness Gloves PPE Impression

Page 185 of 674
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Personal Protective Equipment & Safety Equipments Stock Register
Date as on: Contractor:

PPE Quantity
Available in Unit Remarks
Items Procured Issued
Stock
Safety Shoes
Size 6 Pair
Size 7 Pair
Size 8 Pair
Size 9 Pair
Size 10 Pair
Gum Boot Pair
Safety Helmet No
Safety Goggles No
Hand Gloves Pair
Ear Muff No
Ear Plug No
Nose Mask No
Full Body Harness No
Fall Arrestor System No
Life Line No
Welders Hood No
Grinder Visor No
Fire Blanket No
Fire Extinguisher No
Caution Tapes Meter
Name of Stores In-charge Name of Safety Manager

Signature Signature
Date Date

Page 186 of 674
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Diesel Generator Set Checklist
Project Contractor
Inspection Date : Inspected By:
Location: DG ID:
DG Rating Output Current
Sl.No Particulars Observations Remarks
1 Whether DG is acoustic type

Does proper access exists for DG &
2
Unauthorized entry restricted
3 Whether body & Neutral is earthed
Condition of control panel
Are the doors lockable?
4 Is the termination of I/C cable done properly
with proper size of lugs?
Are the I/C & O/G terminals fixed and tighten
properly
5 Whether voltmeters, Ammeter are working
6 Whether DG panel has MCCB with proper rating
7 Whether Single Line Diagram displayed
8 Is their any spillage around DG
9 Whether fire extinguishers are provided
CRP chart & Danger sign board displayed in
10
English and local languages
Information such as authorized operator details,
11
nearest first aid kit availability displayed
12 Sound level is within limit
Is the spark arrestor in good condition and fixed
13
properly?
Is the emergency stop push button function
14
properly
15 Current months color coded stickers fixed
Name of Electrical Engineer

Signature
Date

Page 187 of 674
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Excavation Checklist
Project Contractor
Description of work: Dimension of the pit/ trench:
Sl. Day Mon Tue Wed Thu Fri Sat Sun
ITEMS
No Date
A) Before excavation
1 Excavation permit no -
Underground/ overhead facilities present are:
2
3 Underground cable detection done?
Has the exact location of excavation been
4
marked?
Has the operator possess a valid operating
5
license?
6 Whether SPA Prepared and displayed on site
The area to be excavated and hazards are clearly
7
communicated to the operator & the helper?
B) After excavation
Has adequate sloping maintained to prevent soil
8
collapse?
9 Any adjoining structure nearby?
10 Shoring / Sloping required?
Has the excavated pit hard barricaded (if
11
depth>0.6m), else soft barricaded?
12 Warning signs displayed?
Excavated earth stored 1m away from edge of
13
barrication?
14 Vehicle movement restricted?
Access/ egress ladder placed every 15m interval,
15
based on no of workmen?
16 Dewatering required?
Walkovers/ passageway provided at necessary
17
places?
18 Sufficient illumination inside the pit at all times?
Signature
Remarks: ( 3) good / YES, ( X ) Poor / NO. If No, Please indicate in the comments column.
Date: Comments

Page 188 of 674
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Hot Work Activity Checklist

Project Contractor
Description of work: Hot work permit no:

ITEMS
No Date
The work area has been barricaded and warning
1
signs displayed?
The work area has been made free from
2
combustible/flammable materials?
The sparks / radiation from the hot work have
3
been adequately contained?
Flammable wastes are disposed in a covered
4
container?
Are adequate number of well-maintained fire
extinguishers and fire blankets, provided at each
5
work area and all workers /supervisors in the work
area are aware of its location?
Fire extinguishers regularly inspected and kept at
6
designated places with clear access?
Are fire hydrant system, fire hose and foam
7
system in ready during critical works?
The contractor has been briefed on all the
8
necessary safety requirements?
Appropriate PPE/ protective clothing has been
9
provided for the job?
10 Tools and machineries to be used are inspected?
11 Fire watcher deployed?
Any hazardous work carried out nearby
12
simultaneously?
13 Gas Monitoring required? Yes (Y) No (N)
Are chances of flammable vapour cloud formation
14 at nearby area or likely to occur during the course
of work? eg: Spray painting?
All workers are trained in the use of fire
15 extinguishers, fire fighting procedure and
emergency response?
16 Whether SPA Prepared and Displayed on site?
17 Any other Fire prevention required?
Signature
Note: Fire Watcher to standby 15 mins after work completed
Date: Comments

Page 189 of 674
SPECIFICATION No.
AT DCU,CPCL CHENNAI
ARC WELDING MACHINE CHECKLIST

Project Contractor:
Site supervisor: Welding m/c ID
Date: Location
No Items Observation Remarks
A WELDING SETS
1 Connections are proper and effectively insulated.
2 ON / OFF switch in good working condition?
3 Voltmeter/ Ammeter connected & working properly?

4 Regulator working properly
5 Welding machine completely covered and no loose

connections?
6 Good earthing and grounding.(Double earthing)
7 Wheels freely rotating?

Compatible Fire extinguisher available for the welding set
8
B CABLE AND JOINTS
1 Supply cable's length exceeding 5m?
2 Connection taken through ELCBs?

Welding cables of proper rating and in proper
3
condition without any damages?
4 Connecting lugs tightened properly?
5 Well insulated and no exposed parts?
6 Size of cable used are proportional to voltage supply

Return earth cable of sufficient length? Are electrical
7
conductors prohibited from being used to complete
8 Any overloading, whereby cables become hot?
9 Any contact with oil / sharp edges or water?
Are cables properly placed to prevent tripping
10
hazards?
C ELECTRODE HOLDERS
Electrode holders used are in good working
1
condition?
2 Properly insulated and no exposed metal parts?
Holders are kept dried and properly hung up after use?
3
4 Not in contact with metal parts.

5 Electrodes are detached after welding.
Name of Electrical Manager Name of Safety Manager
Signature Signature
Format No.Page 190 of 674 Rev. 0

8-00-0001-F1
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Gas Cutting Set Checklist

Project Contractor:
Site supervisor: Gas cutting set ID
Date: Location

A GAS CYCLINDERS
Cylinders used are in upright and secured position,
1
tied with chain and used in a trolley?
Cylinders protected from direct fire, sparks or
2
excessive heat?
3 Double pressure gauges in working condition?
Cylinder valves, regulators, hoses are free from
4
oil/grease?
Any leakage observed after doing Soap solution/
5
leakage test?
Cylinders are kept away from live electric cables or
6
ground wires.
Empty and full cylinders are properly separated and
7
marked?
Oxygen and fuel cylinders kept separately in a
8
designated storage shed?
B REGULATORS / HOSES / TORCHES
Regulators and torches are in sound working
1
condition?
2
leakage test?
Hoses are free of any tape or wrapping materials
3
used for plugging leaks?
4 Proper connections are used for fastening?
5 All gas hoses are secured with clips at both ends?
6 Are regulators, hoses & fittings free from oil &

grease?
7 Any kinked or tangled hoses?
8 Hoses protected from being run-over?
Are approved flash back arrestors installed at both
9
cylinder and torch ends?
C OTHERS
1 Cylinder keys readily available on cylinder?
2 Proper lighter is used to light the torch?
3 Fire extinguisher & fire blanket readily available?
Name of Safety Manager

Signature
Format No.Page 191 of 674 Rev. 0

8-00-0001-F1
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Grinding Machine Checklist

Project Contractor:
Site supervisor: Machine ID
Date: Location

A GRINDING MACHINE
1 Any physical damages to the machine?
2 RPM punched/ marked?
3 Guard in place?
4 Double insulated body?
5 Proper size spanner/ key in place?
6 Electrical connection done properly?

7 Is Dead man provided with machine and in working
condition?
8 Handles tightly placed?
B GRINDING WHEEL
1 Appropriate selection of abrasive wheel?
2 Within expiry date?
3 RPM, size and type of the wheel marked?

4 Any cracks/ damps observed in the wheel?
5 Properly stored after use?
Grinding and cutting wheel stored & used
6
accordingly?
C CABLES & CONNECTIONS
1 Cable in proper condition without any damages?
2 Cable with plug tops?
3 Connection used through ELCBS?
Cables routed properly without obstructing the
4
passage ways?
Signature

Page 192 of 674
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Fire Extinguisher Monthly Inspection
Project
Contractor:
Inspected by:
Visual Inspection
Sl.NO Date Identification No. Result Location Date of Refill Date of Expiry
OK NOT OK
Checklist for Inspection

Located in its designated place
No obstruction to access or visibility
Operating instructions on the extinguisher label legible and facing outward
Seals and tamper indicators not broken or missing
Determine fullness by weighing
Examine for obvious physical damage, corrosion, leakage or clogged nozzle
Pressure gauge reading or indicator in the operative range or position.
Comments/Remarks
Name of the Inspector

Signature
Date

Page 193 of 674
SPECIFICATION No.
AT DCU,CPCL CHENNAI

Page 194 of 674
SPECIFICATION No.
CHENNAI
Slings and Lifting Gear Register

Project Contractor
Inspected by: Date: Signature:
Manufacturers Date into service Remarks

Sl.No Type of Sling Type of Gear SWL Diameter Length
Serial Number

Page 195 of 674
SPECIFICATION No.
CHENNAI
Monthly Wire Rope Inspection Report

Project Contractor Inspection for the Month
Inspected by: Date: Signature: Colour Code for Month:
Excess Wear Kinking , Bird-
Diameter 4 Broken 10 random broken
Sl. Manufacturers Location Thimble of 1/3 caging,
SWL Length Wires in 1 wire ropes in one Remarks
No Serial Number of Sling available diameter in Serious
Size Rope Lay lay
outside wires Corrosion

Page 196 of 674
SPECIFICATION No.
CHENNAI
Monthly Synthetic Web Sling Periodic Inspection Report

Worn or Slings
Sl. Manufacturers Location Chemical Tears, Snags, Slings Properly
SWL Length Broken Properly Remarks
No Serial Number of Sling Burns Holes or Cuts Stored
Stitches Tagged

Page 197 of 674
SPECIFICATION No.
CHENNAI
Crane Register
Project Contractor
Third Party
Capacity Certificate Date into service Remarks
Sl.No Crane Type Manufacturer Model Year Current Owner
Rating (SWL) Reference
Number
Name of Contractors P& M Manager Name of Contractors Safety Manager

Signature Signature
Date Date

Page 198 of 674
SPECIFICATION No.
CHENNAI

Page 199 of 674
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Mobile Crane Inspection
Date Time
Contractor Make
Owner Operator
Load Rating Registration No
Sl.No Description Observation Hazards Identified Remedial Measure

Condition of wire rope
1
(Visual Inspection)
2 Safety latch
3 Tyres Condition
4 Reverse horn
5 Limit Switch
Operator
6 License
Competency Certificate
7 Certificate from third party

8 Hook Condition
9 SWL Marked
10 Load Chart Displayed
11 Any oil leakage
12 Wind Screen
13 Out Riggers
Name of Contractors P&M Manager Name of Contractors Safety Manager
Signature Signature
Date Date
1.7.7.1

Page 200 of 674
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Pre-Lift Checklist
Project: Date:
Contractor
Lift Description:
Yes No
1. Crane Operator minimum qualification requirements?
2. Lift calculations and rigging plan completed?
3. Are all required approvals/permits signed?
4. Crane inspections up to date (Monthly/Daily)?
5. Weather conditions and wind speed acceptable?
6. Has the stability of the ground been assured?
7. Matting and/or outrigger pads inspected and approved?
8. Electrical equipment and power lines at required distance?
9. Rigging inspected for defects?
10. Connecting/disconnecting means have been developed?
11. Have the safety precautions been reviewed?
12. The total lifted weight is below 95% of crane capacity capacity?
13. Signal person(s) assigned?
14. Safe Plan of Action (SPA) Completed?
15. Pre-Lift Meeting/SPA talk held?
16. Hoist area & load path cleared of non-essential personnel?
17. Crane set up per the lift plan (radius, configuration, etc)?
18. Rigging equipment and tag line(s) installed per plan?

19. Emergency/Contingency plan in place for power failure, plant upset,
power line contact, lifting over operating equipment, etc.
Name of rigging coordinator:
Signature: Date:

Page 201 of 674
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Checklist for Construction Vehicles

Date of Inspection Inspected by
Registration No. Make
Driver Name License type
License No License valid up to
PUC Certificate No and Valid up to RC No and Valid up to
3. Sl.No Description Observation Remarks
1. Operator with valid driving permit

Banks man/Helper available to guide the
2
vehicle in construction area
2 Condition of headlights
Condition of indicators
a) Front indicators
3
b) Rear indicators
c) Side indicators
4 Condition of back lights
5 Condition of side lights
7 wipers in good working condition
8 Condition of side mirrors
9 Reverse horn
11 Are all breaking arrangements satisfactory?
12 Condition of tyres
15 Anchoring points &anchoring accessories
16 Spark arrestor fitted
17 Any fuel leakage
18 Wedges availability as wheel stoppers
19 Fire extinguisher availability
Whether parking brake and brake light in
20
working condition
Name of Contractors RCM Name of Contractors Safety Manager

Signature Signature
Date Date
Page
Format No. 202 of 674
8-00-0001-F1 Rev. 0
SAFETY PRACTICES DURING CONSTRUCTION
OISD-GDN-192
Oil Industry Safety Directorate

Government of India
Ministry of Petroleum and Natural Gas
OISD-192
Page 203 of 674

CONTENTS
SECTION Page No.
1.0 Introduction 1
2.0 Scope 1
3.0 Definitions 1
4.0 General Duties 2
4.1 General Duties Of Execution Agencies 2
4.2 General Duties Of Owners 3
5.0 Safety Practices At Work Places 3
5.1 General Provisions 3
5.2 Means Of Access And Egress 4
5.3 Housekeeping 4
5.4 Precautions Against The Fall Of Materials And Persons, 4
And Collapse Of Structures
5.5 Prevention Of Unauthorised Entry 4
5.6 Fire Prevention And Fire Fighting 4
5.7 Lighting 5
5.8 Plant, Machinery, Equipment and Hand Tools 5
6.0 Construction Activities 6
6.1 Excavation 6
6.2 Scaffolding, Platforms & Ladders 8
6.3 Structural Work, Laying Of Reinforcement & Concreting 10
6.4 Road Work 13
6.5 Cutting/Welding 13
6.6 Working In Confined Spaces 14
6.7 Proof/Pressure Testing 15
6.8 Working At Heights 16
6.9 Handling And Lifting Equipment 17
6.10 Vehicle Movement 21
6.11 Electrical 22
6.12 Offshore 24
6.13 Demolition 27
6.14 Radiography 28
6.15 Sand/Shot Blasting / Spray Painting 28
6.16 Work above Water 29
7.0 Additional Safety Precaution for Units with Hydrocarbons 29
8.0 First Aid 30
9.0 Documentation 31
10.0 Safety Awareness & Training 31
11.0 References 32
Annexure I 33
OISD-192
Page 204 of 674

SAFETY PRACTICES DURING CONSTRUCTION
replace or supersede the prevailing statutory

1.0 INTRODUCTION requirements, which shall also be followed
as applicable. For Personal Protective
Safety in Construction Management Equipment, OISD-STD-155 (Part I&II) shall
deserves utmost attention especially in the be referred to. The scope of this document
hydrocarbon industry, such as Exploration, does not include the design aspects and
Refineries, Pipelines and Marketing quality checks during construction.
installations, Gas Processing units etc.
Construction is widely recognised as one of 3.0 DEFINITIONS
the accident prone activities. Most of the
accidents are caused by inadequate Definitions of various terminology are given
planning, failure during the construction below:
process and/or because of design
deficiencies. Besides property loss, Adequate, appropriate or suitable are
accidents also result in injuries and fatalities used to describe qualitatively or
to the personnel; same needs to be quantitatively the means or method
prevented. used to protect the worker.
The reasons for accidents during Brace: A structural member that holds
construction activities are related to unique one point in a fixed position with respect
nature of the industry, human behaviour, to another point; bracing is a system of
difficult work-site conditions, extended odd structural members designed to prevent
duty hours, lack of training & awareness and distortion of a structure.
inadequate safety management. Unsafe
working methods, equipment failure and By hand: The work is done without the
improper housekeeping also tend to help of a mechanised tool.
increase the accident rate in construction.
Ensuring good quality of materials, Competent Authority: A stautory agency
equipment and competent supervision along having the power to issue regulations,
with compliance of standard engineering orders or other instructions having the
practices shall go a long way to in built force of law.
safety into the system.
Competent person: A person
The objective of this standard is to provide possessing adequate qualifications,
practical guidance on technical and educa- such as suitable training and sufficient
tional framework for safety and health in knowledge, experience and skill for the
construction with a view to: safe performance of the specific work.
(a) prevent accidents and harmful The competent authorities may define
appropriate criteria for the designation
effects on the health of workers
of such persons and may determine the
arising from employment in
construction; duties to be assigned to them.
(b) ensure appropriate safety during
implementation of construction;
Execution agency:
(c) provide safety practice guidelines Any physical or legal person, having
for appropriate measures of contractual obligation with the owner,
planning, control and enforcement. and who employs one or more workers
on a construction site
2.0 SCOPE
Owner:
This document specifies broad guidelines on
safe practices to be adhered to during Any physical or legal person for whom
construction activities in oil industry. construction job is carried out.
However, before commencing any job, It shall also include owner's designated
specific hazards and its effects should be representative/consultant/nominee/agent
assessed and necessary , authorised from time to time to act for
corrective/preventive actions should be and on its behalf, for supervising/
taken by all concerned. The document is
intended only to supplement and not to
OISD-192
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coordinating the activities of the construction work so that, there is
execution agency. no risk of accident or injury to health
of workers. In particular,
Hazard: Danger or potential danger. construction work should be
planned, prepared and undertaken
Guard-rail: An adequately secured rail so that:
erected along an exposed edge to
prevent persons from falling. (a) dangers, liable to arise at the
workplace, are prevented;
Hoist: A machine, which lifts materials (b) excessively or unnecessarily
or persons by means of a platform, strenuous work positions and
which runs on guides. movements are avoided;
(c) organisation of work takes into
Lifting gear: Any gear or tackle by account the safety and health of
means of which a load can be attached workers;
to a lifting appliance but which does not (d) materials and products used are
form an integral part of the appliance or suitable from a safety and health
load. point of view;
(e) working methods are adopted to
Lifting appliance: Any stationary or safeguard workers against the
mobile appliance used for raising or harmful effects of chemical,
lowering persons or loads. physical and biological agents.
Means of access or egress:

iii) establish committees with repre-
sentatives of workers and
Passageways, corridors, stairs, plat-
management or make other
forms, ladders and any other means for
arrangement for the participation of
entering or leaving the workplace or for
workers in ensuring safe working
escaping in case of danger.
conditions.
Scaffold: Any fixed, suspended or iv) arrange for periodic safety inspec-
mobile temporary structure supporting tions by competent persons of all
workers and material or to gain access buildings, plant, equipment, tools,
to any such structure and which is not a machinery, workplaces and review
lifting appliance as defined above. of systems of work, regulations,
standards or codes of practice. The
Toe-board: A barrier placed along the competent person should examine
edge of a scaffold platform, runway, and ascertain the safety of
etc., and secured there to guard against construction machinery and
the slipping of persons or the falling of equipment.
material.
v) provide such supervision to ensure
Worker: Any person engaged in that workers perform their work with
construction activity. due regard to safety and health of
theirs as well as that of others.
Workplace: All places where workers vi) Employ only those workers who are
need to be or to go by reason of their qualified, trained and suited by their
work. age, physique, state of health and
4.0 GENERAL DUTIES skill.
4.1 GENERAL DUTIES OF vii) satisfy themselves that all workers

EXECUTION AGENCIES are informed and instructed in the
hazards connected with their work
4.1.1 Execution agency should: and environment and trained in the
precautions necessary to avoid
i) provide means and organisation to accidents and injury to health.
comply with the safety and health viii) Ensure that buildings, plant,
measures required at the workplace. equipment, tools, machinery or
ii) provide and maintain workplaces, workplaces in which a dangerous
plant, equipment, tools and defect has been found should not be
machinery and organise used until the defect has been
rectified.
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ix) Organise for and remain always substances, running machines or
prepared to take immediate steps to vehicles and heavy equipment etc.
stop the operation and evacuate
xvii) Obtain the necessary
workers as appropriate, where there
clearance/permits as required and
is an imminent danger to the safety
specified by owner
of workers.
x) establish a checking system by xviii) As per the Govt. circular as
which it can be ascertained that all amended from time to time all
the members of a shift, including contractors who employ more than
operators of mobile equipment, have 50 workers or where the contract
returned to the camp or base at the value exceeds Rs. 50 crores, the
close of work on dispersed sites and following facilities are to be provided
where small groups of workers by contractor at site :
operate in isolation. Arrangement for drinking water
xi) provide appropriate first aid, training Toilet facilities
and welfare facilities to workers as
per various statutes like the A creche where 10 or more women
Factories Act, 1948 etc. and, workers are having children below
whenever collective measures are the age of 6 years
not feasible or are insufficient, Transport arrangement for attending
provide and maintain personal to emergencies
protective equipment and clothing in
line with the requirement as per xix) should deploy a safety officer at site
OISD-STD-155 (Vol. I& II) on 4.2 GENERAL DUTIES OF OWNERS
Personnel Protective Equipment.
They should also provide access to 4.2.1 Owners should:
workers to occupational health
services. i) co-ordinate or nominate a
competent person to co-ordinate all
xii) Educate workers about their right activities relating to safety and
and the duty at any workplace to health on their construction projects;
participate in ensuring safe working ii) inform all contractors on the project
conditions to the extent of their of special risks to health and safety;
control over the equipment and iii) Ensure that executing agency is
methods of work and to express aware of the owner's requirements
views on working procedures and the executing agency's
adopted as may affect safety and responsibilities with respect to
health. safetry practices before starting the
xiii) Ensure that except in an job.
emergency, workers, unless duly 5.0 SAFETY PRACTICES AT
authorised, should not interfere with, WORK PLACES
remove, alter or displace any safety
device or other appliance furnished 5.1. GENERAL PROVISIONS
for their protection or the protection
5.1.1 All openings and other areas likely to
of others, or interfere with any
pose danger to workers should be
method or process adopted with a clearly indicated.
view to avoiding accidents and injury
to health. 5.1.2 Workers & Supervisors should use
the safety helmet and other requisite
xiv) Ensure that workers do not operate Personal Protective Equipment
or interfere with plant and equipment
according to job & site requirement.
that they have not been duly
They should be trained to use
authorised to operate, maintain or personal protective equipment.
use.
5.1.3 Never use solvents, alkalis and
xv) Ensure that workers do not sleep,
other oils to clean the skin.
rest or cook etc in dangerous places
such as scaffolds, railway tracks, 5.1.4 Lift the load with back straight and
garages, confined spaces or in the knees bent as far as possible. Seek
vicinity of fires, dangerous or toxic the help in case of heavy load.
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5.1.5 Ensure the usage of correct and effectively covered or fenced and
tested tools and tackles. Don't allow displayed prominently.
the make shift tools and tackles.
5.4.4 As far as practicable, guardrails and
5.1.6 No loose clothing should be allowed toe-boards should be provided to
while working near rotating protect workers from falling from
equipment or working at heights. elevated workplaces.
5.2 MEANS OF ACCESS AND 5.5 PREVENTION OF
EGRESS UNAUTHORISED ENTRY
Adequate and safe means of access 5.5.1 Construction sites located in built-up
(atleast two, differently located) to areas and alongside vehicular and
and egress from all workplaces pedestrian traffic routes should be
should be provided. Same should be fenced to prevent the entry of
displayed and maintained. unauthorised persons.
5.3 HOUSEKEEPING 5.5.2 Visitors should not be allowed
access to construction sites unless
5.3.1 Ensure: accompanied by or authorised by a
competent person and provided with
i) proper storage of materials and
the appropriate protective
equipment;
equipment.
ii) removal of scrap, inflammable
material, waste and debris at 5.6 FIRE PREVENTION AND FIRE
appropriate intervals. FIGHTING
5.3.2 Removal of loose materials, which
5.6.1 All necessary measures should be
are not required for use, to be
taken by the executing agency and
ensured. Accumulation of these at
owner to:
the site can obstruct means of
access to and egress from i) avoid the risk of fire;
workplaces and passageways. ii) control quickly and efficiently
any outbreak of fire;
5.3.3 Workplaces and passageways, that
iii) bring out a quick and safe
are slippery owing to oil, grease or
evacuation of persons.
other causes, should be cleaned up
iv) Inform unit/fire station control
or strewn with sand, sawdust, ash
room, where construction work
etc.
is carried out within existing
5.4 PRECAUTIONS AGAINST THE operating area.
FALL OF MATERIALS &
5.6.2 Combustible materials such us
PERSONS AND COLLAPSE OF
packing materials, sawdust,
STRUCTURES
greasy/oily waste and scrap wood or
plastics should not be allowed to
5.4.1 Precautions should be taken such as accumulate in workplaces but
the provision of fencing, look-out
should be kept in closed metal
men or barriers to protect any
containers in a safe place.
person against injury by the fall of
materials, or tools or equipment 5.6.3 Places where workers are employed
being raised or lowered. should, if necessary to prevent the
danger of fire, be provided with:
5.4.2 Where necessary to prevent danger,
guys, stays or supports should be i) suitable and sufficient fire-
used or other effective precautions extinguishing equipment, which
should be taken to prevent the should be easily visible and
collapse of structures or parts of accessible;
structures that are being erected, ii) an adequate water supply at
maintained, repaired, dismantled or sufficient pressure meeting the
demolished. requirements of various OISD
standards.
5.4.3 All openings through which workers
are liable to fall should be kept 5.6.4 To guard against danger at places
having combustible material,
OISD-192
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workers should be trained in the d) be operated only by workers who
action to be taken in the event of have been authorised and given
fire, including the use of means of appropriate training.
escape. e) be provided with protective
guards, shields or other devices
5.6.5 At sites having combustible
as required.
material, suitable visual signs
should be provided to indicate ii) Adequate instructions for safe use
clearly the direction of escape in should be provided.
case of fire.
iii) Safe operating procedures should
5.6.6 Means of escape should be kept be established and used for all
clear at all times. Escape routes plant, machinery and equipment.
should be frequently inspected
iv) Operators of plant, machinery and
particularly in high structures and
equipment should not be distracted
where access is restricted.
while work is in progress.
5.7 LIGHTING
v) Plant, machinery and equipment
should be switched off when not in
5.7.1 Where natural lighting is not
use and isolated before any
adequate, working light fittings or
adjustment, clearing or maintenance
portable hand-lamps should be
is done.
provided at workplace on the
construction site where a worker will vi) Where trailing cables or hose pipes
do a job. are used they should be kept as
short as practicable and not allowed
5.7.2 Emergency lighting should be to create a hazard.
provided for personnel safety during
vii) All moving parts of machinery and
night time to facilitate standby
equipment should be enclosed or
lighting source, if normal system
adequately guarded.
fails.
viii) Every power-driven machine and
5.7.2 Artificial lighting should not produce
equipment should be provided with
glare or disturbing shadows.
adequate means, immediately
5.7.3 Lamps should be protected by accessible and readily identifiable to
guards against accidental breakage. the operator, of stopping it quickly
and preventing it from being started
5.7.4 The cables of portable electrical
again inadvertently.
lighting equipment should be of
adequate size & characteristics for ix) Operators of plant, machinery,
the power requirements and of equipment and tools should be
adequate mechanical strength to provided with PPEs, including where
withstand severe conditions in necessary, suitable ear protection.
construction operations.
5.8.2 Hand tools
5.8 PLANT, MACHINERY,
i) Hand tools should be repaired by
EQUIPMENT AND HAND TOOLS
competent persons.
5.8.1 General Provisions ii) Heads of hammers and other shock
tools should be dressed or ground to
i) Plant, machinery and equipment a suitable radius on the edge as
including hand tools, both manual soon as they begin to mushroom or
and power driven, should: crack.
a) be of proper design and iii) When not in use and while being
construction, taking into account carried or transported sharp tools
health, Safety and ergonomic should be kept in sheaths, shields,
principles. chests or other suitable containers.
b) be maintained in good working
order; iv) Only insulated or nonconducting
c) be used only for work for which they tools should be used on or near live
have been designed. electrical installations.
OISD-192
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v) Only non-sparking tools should be c) have devices to stop them from a
used near or in the presence of safe place in an emergency.
flammable or explosive dusts or
vapours. ii) IC engines should not be run in
confined spaces unless adequate
5.8.3 Pneumatic Tools exhaust ventilation is provided.
i) Operating triggers on portable iii) When IC engines are being fuelled:

pneumatic tools should be:
a) so placed as to minimise the risk of a) the engine should be shut off.
accidental starting of the machine. b) care should be taken to avoid
b) so arranged as to close the air inlet spilling fuel;
valve automatically when the c) no person should smoke or have an
pressure of the operator's hand is naked light in the vicinity.
removed. d) a fire extinguisher should be kept
readily available.
ii) Hose and hose connections for
iv) Secondary fuel reservoir should be
compressed air supply to portable
pneumatic tools should be: placed outside the engine room.
a) designed and tested for the

pressure and service for which they 6.0 CONSTRUCTION ACTIVITIES
are intended;
b) fastened securely on the pipe outlet The various common activities in
and equipped with the safety chain, construction are as under:
as appropriate.
Excavation
iii) Pneumatic shock tools should be
equipped with safety clips or
Scaffolding, Platforms & Ladders
retainers to prevent dies and tools Structural Work, Laying of
from being accidentally expelled Reinforcement & Concreting
from the barrel. Road Work (Laying of roads)
iv) Pneumatic tools should be Cutting /Welding
disconnected from power and the
pressure in hose lines released Working in Confined Space
before any adjustment or repair is Proof/Pressure Testing
made.
Working at Heights
5.8.4 Electrical Tools Handling & Lifting Equipments
i) Low voltage portable electrical tools Vehicle Movement

should generally be used. Electrical
ii) All electrical tools should be
earthed, unless they are "all
Offshore
insulated" or "double insulated" tools Demolition
which do not require earthing. Radiography
iii) All electrical tools should get Sand/shot blasting/ spray
inspected and maintained on a painting
regular basis by a competent
electrician and complete records
Work above water
kept. The safe practices to be followed
during the implementation of above
5.8.5 Engines
construction activities are given
i) Engines should: below:
a) be installed so that they can be 6.1 EXCAVATION
started safely and the maximum
safe speed cannot be exceeded. 6.1.1 All excavation work should be
b) have controls for limiting speed. planned and the method of
excavation and the type of support
OISD-192
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work required should be decided its collapse and thereby endanger
considering the following: any person unless precautions such
as the provision of shoring or piling
i) the stability of the ground;
are taken to prevent the sides from
ii) the excavation will not affect
collapsing.
adjoining buildings, structures or
roadways; 6.1.8 Adequately anchored stop blocks
iii) to prevent hazard, the gas, water, and barriers should be provided to
electrical and other public utilities prevent vehicles being driven into
should be shut off or the excavation. Heavy vehicles
disconnected, if necessary; should not be allowed near the
iv) presence of underground pipes, excavation unless the support work
cable conductors, etc., has been specially designed to
v) the position of culvert/bridges, permit it.
temporary roads and spoil heaps
6.1.9 If an excavation is likely to affect the
should be determined;
security of a structure on which
6.1.2 Before digging begins on site, all persons are working, precautions
excavation work should be planned should be taken to protect the
and the method of excavation and structure from collapse.
the type of support work required
6.1.10 Barricade at 1m height (with red &
decided.
white band/self glowing caution
6.1.3 All excavation work should be board) should be provided for
supervised. excavations beyond 1.5m depth.
Provide two entries/exits for such
6.1.4 Sites of excavations should be
excavation.
thoroughly inspected:
6.1.11 Necessary precautions should be
i) daily, prior to each shift and after
taken for underground utility lines
interruption in work of more than
like cables, sewers etc. and
one day;
necessary approvals/clearances
ii) after every blasting operation;
from the concerned authorities shall
iii) after an unexpected fall of
be obtained before commencement
ground;
of the excavation job.
iv) after substantial damage to
supports; 6.1.12 Water shall be pumped/bailed out, if
v) after a heavy rain, frost or snow; any accumulates in the trench.
vi) when boulder formations are Necessary precautions should be
encountered. taken to prevent entry of surface
water in trenches.
6.1.5 Safe angle of repose while
excavating trenches exceeding 6.1.13 During rains, the soil becomes
1.5m depth upto 3.0m should be loose. Take additional precaution
maintained. Based on site against collapse of side wall.
conditions, provide proper slope,
0 6.1.14 In hazardous areas, air should be
usually 45 ,and suitable bench of
tested to ascertain its quality. No
0.5m width at every 1.5m depth of
one should be allowed entry till it is
excavation in all soils except hard
suitable for breathing.
rock or provide proper shoring and
strutting to prevent cave-in or slides. 6.1.15 In case of mechanised excavation,
precaution shall be taken to not to
6.1.6 As far as possible, excavated earth
allow anybody to come within one
should not be placed within one
meter of extreme reach of the
meter of the edge of the trench or
mechanical shovel. The mechanised
depth of trench whichever is greater.
excavator shall be operated by a
6.1.7 Don't allow vehicles to operate too well-trained experienced operator.
close to excavated area. Maintain When not in operation, the machine
atleast 2m distance from edge of shall be kept on firm leveled ground
excavation. No load, plant or with mechanical shovel resting on
equipment should be placed or ground. Wheel or belt shall be
moved near the edge of any suitably jammed to prevent any
excavation where it is likely to cause accidental movement of the
OISD-192
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machine. Suitable precautions as viii) Tubes should be free from cracks,
per manufacturer guidelines should splits and excessive corrosion and
be taken for dozers, graders and be straight to the eye, and tube ends
other heavy machines. cut cleanly square with the tube
axis.
6.1.16 In case of blasting, follow strictly
IS:4081-1986 & Indian Explosive ix) Scaffolds should be designed for
Act and rules for storage, handling their maximum load as per relevant
and carrying of explosive materials code.
and execution of blasting operation.
x) Scaffolds should be adequately
6.2 SCAFFOLDING, PLATFORMS & braced.
LADDERS
xi) Scaffolds which are not designed to
6.2.1 Metal as material of construction be independent should be rigidly
connected to the building at
i) A scaffold should be provided and designated vertical and horizontal
maintained or other equally safe and places.
suitable provision should be made
xii) A scaffold should never extend
where work cannot safely be done
above the highest anchorage to an
on or from the ground or from part of
extent which might endanger its
a building or other permanent
stability and strength.
structure.
xiii) Loose bricks, drainpipes, chimney-
ii) Scaffolds should be provided with
pots or other unsuitable material
safe means of access, such as
should not be used for the
stairs, ladders or ramps. Ladders
construction or support of any part
should be secured against
of a scaffold.
inadvertent movement.
xiv) Scaffolds should be inspected and
iii) Every scaffold should be
certified:
constructed, erected and maintained
so as to prevent collapse or (a) before being taken into use;
accidental displacement when in (b) at periodic intervals thereafter as
use. prescribed for different types of
scaffolds;
iv) Every scaffold and part thereof
(c) after any alteration, interruption in
should be constructed :
use, exposure to weather or
(a) in such a way so as not to cause seismic conditions or any other
hazards for workers during erec- occurrence likely to have affected
tion and dismantling; their strength or stability.
(b) in such a way so as guard rails
xv) Inspection should more particularly
and other protective devices,
ascertain that:
platforms, ladders, stairs or
ramps can be easily put together; (a) the scaffold is of suitable type
(c) with sound material and of and adequate for the job;
requisite size and strength for the (b) materials used in its construction
purpose for which it is to be used are sound and of sufficient
and maintained in a proper strength;
condition. (c) it is of sound construction and
stable;
v) Boards and planks used for scaf-
(d) that the required safeguards are
folds should be protected against
in position.
splitting.
xvi) A scaffold should not be erected,
vi) Materials used in the construction of
substantially altered or dismantled
scaffolds should be stored under
except by or under the supervision.
good conditions and apart from any
material unsuitable for scaffolds. xvii) Every scaffold should be maintained
in good and proper condition, and
vii) Couplers should not cause
every part should be kept fixed or
deformation in tubes. Couplers
secured so that no part can be
should be made of drop forged steel
or equivalent material.
OISD-192
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displaced in consequence of normal more than 100mm apart, to give
use. support to each plank.
xviii) If out-rigger scaffolding is to be x) Platform plank shall not project
used, it should be specifically beyond its end support to a distance
designed and inspected before exceeding 4 times the thickness of
putting in use. plank, unless it is effectively secured
to prevent tipping. Cantilever planks
6.2.2 Lifting appliances on scaffolds
should be avoided.
i) When a lifting appliance is to be xi) The platform edges shall be
used on a scaffold: provided with 150mm high toe board
to eliminate hazards of tools or other
(a) the parts of the scaffold should
objects falling from platform.
be carefully inspected to
determine the additional xii) Erect ladders in the four up-one out
strengthening and other safety position
measures required;
xiii) Lash ladder securely with the
(b) any movement of the scaffold
structure.
members should be prevented;
(c) if practicable, the uprights should xiv) Using non-slip devices, such as,
be rigidly connected to a solid rubber shoes or pointed steel ferules
part of the building at the place at the ladder foot, rubber wheels at
where the lifting appliance is ladder top, fixing wooden battens,
erected. cleats etc.
6.2.3 Prefabricated scaffolds xv) When ladder is used for climbing
over a platform, the ladder must be
i) In the case of prefabricated scaffold of sufficient length, to extend at least
systems, the instructions provided one meter above the platform, when
by the manufacturers or suppliers erected against the platform in four
should be strictly adhered to. up-one out position.
Prefabricated scaffolds should have
xvi) Portable ladders shall be used for
adequate arrangements for fixing
heights not more than 4mt. Above
bracing.
4mt flights, fixed ladders shall be
ii) Frames of different types should not provided with at least 600 mm
be intermingled in a single scaffold. landings at every 6mt or less.
iii) Scaffolding shall be erected on firm xvii) The width of ladder shall not be less
and level ground. than 300mm and rungs shall be
spaced not more than 300mm.
iv) All members of metal scaffolding
shall be checked periodically to xviii) Every platform and means of access
screen out defective / rusted shall be kept free from obstruction.
members. All joints should be
xix) If grease, mud, gravel, mortar etc.,
properly lubricated for easy
fall on platform or scaffolds, these
tightening.
shall be removed immediately to
v) Entry to scaffolding should be avoid slippage.
restricted.
xx) Workers shall not be allowed to
vi) Erection, alteration and removal work on scaffolds during storms or
shall be done under supervision of high wind. After heavy rain or
experienced personnel. storms, scaffolds shall be inspected
before reuse.
vii) Use of barrels, boxes, loose bricks
etc., for supporting platform shall not xxi) Don't overload the scaffolding.
be permitted. Remove excess material and scrap
immediately.
viii) Each supporting member of platform
shall be securely fastened and xxii) Dismantling of scaffolds shall be
braced done in a pre-planned sequential
manner.
ix) Where planks are butt-joined, two
parallel putlogs shall be used, not
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6.2.4 Suspended scaffolds/boatwain's engineering works, formwork,
chair falsework and shoring should be
carried out by trained workers only
i) In addition to the requirements for under the supervision of a
scaffolds in general as regards competent person.
soundness, stability and protection
ii) Precautions should be taken to
against the risk of falls, suspended
guard against danger to workers
scaffolds should meet the following
arising from any temporary state of
specific requirements.
weakness or instability of a
(a) platforms should be designed structure.
and built with dimensions that are
iii) Formwork, falsework and shoring
compatible with the stability of
should be so designed, constructed
the structure as a whole,
and maintained that it will safely
especially the length;
support all loads that may be
(b) the number or anchorage should
imposed on it.
be compatible with the
dimensions of the platform; iv) Formwork should be so designed
(c) the safety of workers should be and erected that working platforms,
safeguarded by an extra rope means of access, bracing and
having a point of attachment means of handling and stabilising
independent of the anchorage are easily fixed to the formwork
arrangements of the scaffold; structure.
(d) the anchorage and other
6.3.2. Erection and dismantling of steel
elements of support of the
and prefabricated structures
scaffold should be designed and
built in such a way as to ensure
sufficient strength; i) The safety of workers employed on
the erection and dismantling of steel
(e) the ropes, winches, pulleys or
and prefabricated structures should
pulley blocks should be
designed, assembled, used and be ensured by appropriate means,
such as provision and use of:
maintained according to the
requirements established for (a) ladders, gangways or fixed
lifting gear adapted to the lifting platforms;
of persons according to national (b) platforms, buckets, boatswain's
laws and regulations; chairs or other appropriate
(f) Before use, the whole structure means suspended from lifting
should be checked by a appliances;
competent person. (c) safety harnesses and lifelines,
6.2.5 Bamboo Scaffolding catch nets or catch platforms;
(d) Power-operated mobile working
platforms.
i) In general, it should be avoided as
far as possible. It should not be ii) Steel and prefabricated structures
used in the unit/off-site areas and should be so designed and made
where hot work is to be done. that they can be safely transported
and erected.
ii) For construction and maintenance of
residential and office buildings, iii) In addition to the need for the
situated outside explosive licensed stability of the part when erected,
area, bamboo scaffold, if used, the design should explicitly take
should conform to provisions given following into account:
in lS-3696 (Part 1)-1987.
(a) the conditions and methods of
6.3 STRUCTURAL WORK, LAYING attachment in the operations of
OF REINFORCEMENT & transport, storing and temporary
CONCRETING support during erection or
dismantling as applicable;
6.3.1 General provisions
(b) Methods for the provision of
safeguards such as railings and
i) The erection or dismantling of
working platforms, and, when
buildings, structures, civil
necessary, for mounting them
OISD-192
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easily on the structural steel or (a) be of such shape and dimensions
prefabricated parts. as to ensure a secure grip
without damaging the part;
iv) The hooks and other devices built in
(b) be marked with the maximum
or provided on the structural steel or
permissible load in the most
prefabricated parts that are required
unfavourable lifting conditions.
for lifting and transporting them
should be so shaped, dimensioned x) Structural steel or prefabricated
and positioned as: parts should be lifted by methods or
appliances that prevent them from
(a) to withstand with a sufficient
spinning accidentally.
margin the stresses to which they
are subjected; xi) When necessary to prevent danger,
(b) Not to set up stresses in the part before they are raised from the
that could cause failures, or ground, structural steel or
stresses in the structure itself not prefabricated parts should be
provided for in the plans, and be provided with safety devices such as
designed to permit easy release railings and working platforms to
from the lifting appliance. Lifting prevent falls of persons.
points for floor and staircase
xii) While structural steel or
units should be located (recessed
prefabricated parts are being
if necessary) so that they do not
erected, the workers should be
protrude above the surface;
provided with appliances for guiding
(c) To avoid imbalance or distortion
them as they are being lifted and set
of the lifted load.
down, so as to avoid crushing of
v) Storeplaces should be so hands and to facilitate the
constructed that: operations. Use of such appliances
should be ensured.
(a) there is no risk of structural steel
or prefabricated parts falling or xiii) A raised structural steel or
overturning; prefabricated part should be so
(b) storage conditions generally secured and wall units so propped
ensure stability and avoid that their stability cannot be
damage having regard to the imperiled, even by external agencies
method of storage and atmo- such as wind and passing loads
spheric conditions; before its release from the lifting
(c) racks are set on firm ground and appliance.
designed so that units cannot
xiv) At work places, instruction should be
move accidentally.
given to the workers on the
vi) While they are being stored, methods, arrangements and means
transported, raised or set down, required for the storage, transport,
structural steel or prefabricated lifting and erection of structural steel
parts should not be subjected to or prefabricated parts, and, before
stresses prejudicial to their stability. erection starts, a meeting of all
those responsible should be held to
vii) Every lifting appliance should:
discuss and confirm the
(a) be suitable for the operations and requirements for safe erection.
not be capable of accidental
xv) During transportation within the
disconnection;
construction area, attachments such
(b) be approved or tested as per
as slings and stirrups mounted on
statutory requirement.
structural steel or prefabricated
viii) Lifting hooks should be of the self- parts should be securely fastened to
closing type or of a safety type and the parts.
should have the maximum
xvi) Structural steel or prefabricated
permissible load marked on them.
parts should be so transported that
ix) Tongs, clamps and other appliances the conditions do not affect the
for lifting structural steel and stability of the parts or the means of
prefabricated parts should: transport result in jolting, vibration or
stresses due to blows, or loads of
material or persons.
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xvii) When the method of erection does placed in position and secured
not permit the provision of other against dislodgment.
means of protection against fall of
6.3.3 Reinforcement
persons, the workplaces should be
protected by guardrails, and if
i) Ensure that workers use Personnel
appropriate by toe-boards.
Protective equipment like safety
xviii) When adverse weather conditions helmet, safety shoes, gloves etc.
such as snow, ice and wind or
ii) Don't place the hand below the rods
reduced visibility entail risks of
for checking clear distance. Use
accidents, the work should be
carried on with particular care, or, if measuring devices.
necessary, interrupted. iii) Don't wear loose clothes while
checking the rods.
xix) Structures should not be worked on
during violent storms or high winds, iv) Don't stand unnecessarily on
or when they are covered with ice or cantilever rods.
snow, or are slippery from other
causes. v) To carry out welding/cutting of rods,
safety procedures/precautions as
xx) If necessary, to prevent danger, mentioned in Item No. 6.5 to be
structural steel parts should be followed.
equipped with attachments for
suspended scaffolds, lifelines or vi) For supplying of rods at heights,
safety harnesses and other means proper staging and/or bundling to be
of protection. provided.
xxi) The risks of falling, to which workers vii) Ensure barricading and staging for
moving on high or sloping girders supplying and fixing of rods at
are exposed, should be limited by all height.
means of adequate collective viii) For short distance carrying of
protection or, where this is imposs- materials on shoulders, suitable
ible, by the use of a safety harness pads to be provided.
that is well secured to a strong
support. ix) While transporting material by
trucks/trailers, the rods shall not
xxii) Structural steel parts that are to be protrude in front of or by the sides of
erected at a great height should as driver's cabin. In case such
far as practicable be assembled on protrusion cannot be avoided behind
the ground. the deck, then it should not extend
rd
xxiii) When structural steel or 1/3 of deck length or 1.5M which
prefabricated parts are being ever is less and tied with red
erected, a sufficiently extended area flags/lights.
underneath the workplace should be 6.3.4 Concreting
barricaded or guarded
xxiv) Steel trusses that are being erected i) Ensure stability of shuttering work
should be adequately shored, before allowing concreting.
braced or guyed until they are ii) Barricade the concreting area while
permanently secured in position. pouring at height/depths.
xxv) Load-bearing structural member iii) Keep vibrator hoses, pumping
should not be dangerously concrete accessories in healthy
weakened by cutting, holing or other conditions and mechanically locked.
means.
iv) Pipelines in concrete pumping
xxvi) Structural members should not be system shall not be attached to
forced into place by the hoisting temporary structures such as
machine while any worker is in such scaffolds and formwork support as
a position that he could be injured the forces and movements may
by the operation. effect their integrity.
xxvii) Open-web steel joists that are
hoisted singly should be directly
OISD-192
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v) Check safety cages & guards with aggregate, shall be provided
around moving motors/parts etc. with PVC hand gloves and rubber
provided in concreting mixers. shoes with legging up to knee joints.
vi) Use Personal Protective Equipment 6.4.6 At the end of day's work, surplus hot
like gloves, safety shoes etc. while bitumen in tar boiler shall be
dealing with concrete and wear properly covered by a metal sheet,
respirators for dealing with cement. to prevent anything falling in it,
vii) Earthing of electrical mixers, 6.4.7 If bitumen accidentally falls on
vibrators, etc. should be done and ground, it shall be immediately
verified. covered by sprinkling sand, to
prevent anybody stepping on it.
viii) Cleaning of rotating drums of
Then it shall be removed with the
concrete mixers shall be done from
help of spade.
outside. Lockout devices shall be
provided where workers need to 6.4.8 For cement concrete roads, besides
enter. site barricading and installation of
warning signs for traffic diversion,
ix) Where concrete mixers are driven
safe practices mentioned in the
by internal combustion engine,
chapter on "Concreting", shall also
exhaust points shall be located
be applicable.
away from the worker's workstation
so as to eliminate their exposure to 6.5 CUTTING/WELDING
obnoxious fumes.
6.5.1 Common hazards involved in
x) Don't allow unauthorised person to
welding/cutting are sparks, molten
stand under the concreting area.
metal, flying particles, harmful light
xi) Ensure adequate lighting rays, electric shocks etc. Following
arrangements for carrying out precautions should be taken: -
concrete work during night.
i) A dry chemical type fire extinguisher
xii) Don't allow the same workers to shall be made available in the work
pour concrete round the clock. Insist area.
on shift pattern.
ii) Adequate ventilation shall be
xiii) During pouring, shuttering and its ensured by opening manholes and
supports should be continuously fixing a shield or forced circulation of
watched for defects. air etc, while doing a job in confined
space.
6.4 ROAD WORK
iii) Ensure that only approved and well-
6.4.1 Site shall be barricaded and maintained apparatus, such as
provided with warning signs, torches, manifolds, regulators or
including night warning lamps at pressure reducing valves, and
appropriate locations for traffic acetylene generators, be used.
diversion.
iv) All covers and panels shall be kept
6.4.2 Filled and empty bitumen drums in place, when operating an electric
shall be stacked separately at Arc welding machine.
designated places.
v) The work piece should be
6.4.3 Mixing aggregate with bitumen shall connected directly to Power supply,
preferably be done with the help of and not indirectly through
bitumen batch mixing plant, unless pipelines/structures/equipments etc.
operationally non-feasible.
vi) The welding receptacles shall be
6.4.4 Road rollers, Bitumen sprayers, rated for 63 A suitable for 415V, 3-
Pavement finishers shall be driven Phase system with a scraping earth.
by experienced drivers with valid Receptacles shall have necessary
driving license. mechanical interlocks and earthing
facilities.
6.4.5 Workers handling hot bitumen
sprayers or spreading bitumen vii) All cables, including welding and
aggregate mix or mixing bitumen ground cables, shall be checked for
OISD-192
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any worn out or cracked insulation xxiv) Do not use matches to light torches,
before starting the job. Ground cable use a friction lighter.
should be separate without any
xxv) Move out any leaking cylinder
loose joints.
immediately.
viii) Cable coiling shall be maintained at
xxvi) Use trolleys for oxygen & acetylene
minimum level, if not avoidable.
cylinder and chain them.
ix) An energised electrode shall not be
xxvii) Always use Red hose for acetylene
left unattended.
and other fuel gases and Black for
x) The power source shall be turned off oxygen, and ensure that both are in
at the end of job. equal length.
xi) All gas cylinders shall be properly xxviii) Ensure that hoses are free from
secured in upright position. burns, cuts and cracks and properly
clamped.
xii) Acetylene cylinder shall be turned
and kept in such a way that the xxix) Avoid dragging hoses over sharp
valve outlet points away from edges and objects
oxygen cylinder.
xxx) Do not wrap hoses around cylinders
xiii) Acetylene cylinder key for opening when in use or stored.
valve shall be kept on valve stem,
xxxi) Protect hoses from flying sparks, hot
while cylinder is in use, so that the
slag, and other hot objects.
acetylene cylinder could be quickly
turned off in case of emergency. xxxii) Lubricants shall not be used on Ox-
Use flash back arrestors to prevent fuel gas equipment.
back-fire in acetylene/oxygen
xxxiii) During cutting/welding, use proper
cylinder.
type goggles/face shields.
xiv) When not in use, valves of all
cylinders shall be kept closed. 6.6 WORKING IN CONFINED SPACES
xv) All types of cylinders, whether full or 6.6.1 Following safety practices for
empty, shall be stored at cool, dry working in confined space like
place under shed. towers, columns, tanks and other
vessels should be followed in
xvi) Forced opening of any cylinder
addition to the safety guidelines for
valve should not be attempted.
specific jobs like scaffolding,
xvii) Lighted gas torch shall never be left cutting/welding etc.
unattended.
i) Shut down, isolate, depressurise
xviii) Store acetylene and oxygen
cylinders separately. and purge the vessel as per laid
down procedures.
xix) Store full and empty cylinders
ii) Entry inside the vessel and to carry
separately.
out any job should be done after
xx) Avoid cylinders coming into contact issuance of valid permit only in line
with heat. with the requirement of OISD-STD-
105.
xxi) Cylinders that are heavy or difficult
to carry by hand may be rolled on iii) Ensure proper and accessible
their bottom edge but never means of exit before entry inside a
dragged. confined space.
xxii) If cylinders have to be moved, be iv) The number of persons allowed
sure that the cylinder valves are inside the vessel should be limited
shut off. to avoid overcrowding.
xxiii) Before changing torches, shut off v) When the work is going on in the
the gas at the pressure reducing confined space, there should always
regulators and not by crimping the be one man standby at the nearby
hose. manway.
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vi) Before entering inside the vessels xix) The gas cylinders used for
underground or located at lower cutting/welding shall be kept
elevation, probability of dense outside.
vapours accumulating nearby
xx) All cables, hoses, welding
should also be considered in
equipment etc., shall be removed
addition to inside the vessel.
from confined space at end of each
vii) Ensure requisite O2 level before work day, even if the work is to be
entry in the confined space and resumed in the same space the next
monitor level periodically or other day.
wise use respiratory devices.
xxi) To the extent possible sludge shall
viii) Check for no Hydrocarbon or toxic be cleared and removed from
substances before entry and monitor outside before entering.
level periodically or use requisite
xxii) No naked light or flame or hot work
Personal Protective Equipment.
such as welding, cutting and
ix) Ensure adequate ventilation or use soldering should be permitted inside
respiratory devices. a confined space or area unless it
has been made completely free of
x) Depending upon need, necessary
the flammable atmosphere, tested
respirator system, gas masks and
and found safe by a competent
suit shall be worn by everyone
person. Only non-sparking tools and
entering confined space. In case of
flameproof hand lamps protected
sewer, OWS or in the confined area
with guard and safety torches
where there is a possibility of toxic
should be used inside such confined
or inert gas, gas masks shall be
space or area for initial inspection,
used by everyone while entering.
cleaning or other work required to
xi) Barricade the confined spaces be done for making the area safe.
during hoisting, radiography,
xxiii) Communication should be always
blasting, pressure testing etc.
maintained between the worker and
xii) Use 24V flameproof lamp fittings the attendant.
only for illumination.
6.7 PROOF/PRESSURE TESTING
xiii) Use tools with air motors or electric
tools with maximum voltage of 24V. 6.7.1 Review test procedure before
allowing testing with water or air or
xiv) House keeping shall be well
any other fluid.
maintained.
6.7.2 Provide relief valves of adequate
xv) Safety helmet, safety shoes and
size while testing with air or other
safety belt shall be worn by
gases.
everyone entering the confined
space. 6.7.3 Ensure compliance of necessary
precautions, step wise loading,
xvi) Don't wear loose clothing while
tightening of fasteners, grouting etc.
working in a confined space.
before and during testing.
xvii) In case of the vessels which are
6.7.4 Inform all concerned in advance of
likely to contain pyropheric
the testing.
substances (like Iron Sulphide),
special care need to be taken before 6.7.5 Keep the vents open before opening
opening the vessel. Attempt should any valve for filling/draining of liquid
be made to remove the pyropheric used for hydrotesting. The
substances. Otherwise, these filling/draining should not exceed the
should be always kept wet by designed rate for pressure testing.
suitable means.
6.7.6 Provide separate gauges of suitable
xviii) The cutting torches should also be range for pressurising pump and the
kept outside the vessel immediately equipment to be tested.
after the cutting.
6.7.7 Provide gauges at designated
locations for monitoring of
pressures.
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6.7.8 Check the calibration of all ii) Roof work should only be
pressurising equipment and undertaken by workers who are
accessories and maintain records. physically and psychologically fit
and have the necessary knowledge
6.7.9 Take readings at pre-defined
and experience for such work.
intervals.
iii) Work on roofs shouldn't be carried
6.8 WORKING AT HEIGHTS
on in weather conditions that
6.8.1 General Provision threaten the safety of workers.
iv) Crawling boards, walkways and roof
i) While working at a height of more
ladders should be securely fastened
than 3 meters, ISI approved safety to a firm structure.
belt shall be used.
v) Roofing brackets should fit the slope
ii) While working at a height of more
of the roof and be securely
than 3 meters, permit should be supported.
issued by competent person before
commencement of the job. vi) Where it is necessary for a person
to kneel or crouch near the edge of
iii) Worker should be well trained on the roof, necessary precautions
usage of safety belt including its
should be taken.
proper usage at the time of
ascending/descending. vii) On a large roof where work have to
be carried out at or near the edge, a
iv) All tools should be carried in tool kits
simple barrier consisting of crossed
to avoid their falling.
scaffold tubes supporting a tubing
v) If the job is on fragile/sloping roof, guardrail may be provided.
roof walk ladders shall be used.
viii) All covers for openings in roofs
vi) Provide lifeline wherever required. should be of substantial construction
and be secured in position.
vii) Additional safety measures like
providing Fall Arrestor type Safety ix) Roofs with a pitch of more than 10
belt, safety net should be provided should be treated as sloping.
depending upon site conditions, job x) When work is being carried out on
requirements.
sloping roofs, sufficient and suitable
viii) Keep working area neat and clean. crawling boards or roof ladders
Remove scrap material immediately. should be provided and firmly
secured in position.
ix) Don't throw or drop
material/equipment from height. xi) During extensive work on the roof,
strong barriers or guardrails and toe-
x) Avoid jumping from one member to boards should be provided to stop a
another. Use proper passageway. person from falling off the roof.
xi) Keep both hands free while xii) Where workers are required to work
climbing. Don't try to bypass the on or near roofs or other places
steps of the ladder. covered with fragile material,
xii) Try to maintain calm at height. Avoid through which they are liable to fall,
over exertion. they should be provided with
suitable roof ladders or crawling
xiii) Avoid movements on beam. boards strong enough and when
xiv) Elevated workplaces including roofs spanning across the supports for the
should be provided with safe means roof covering to support those
of access and egress such as stairs, workers.
ramps or ladders. xiii) A minimum of two boards should be
6.8.2 Roof Work provided so that it is not necessary
for a person to stand on a fragile
i) All roof-work operations should be roof to move a board or a ladder, or
pre-planned and properly for any other reason.
supervised.
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6.8.3 Work on tall chimneys c) haul heavy materials or
equipment up and down by hand
i) For the erection and repair of tall to or from the workplace on the
chimneys, scaffolding should be chimney;
provided. A safety net should be d) fasten pulleys or scaffolding to
maintained at a suitable distance reinforcing rings without first
below the scaffold. verifying their stability;
e) work alone;
ii) The scaffold floor should always be
f) climb a chimney that is not
at least 65 cm below the top of the
provided with securely anchored
chimney. ladders or rungs;
iii) Under the working floor of the g) Work on chimneys in use unless
scaffolding the next lower floor the necessary precautions to
should be left in position as a catch avoid danger from smoke and
platform. gases have been taken.
iv) The distance between the inside x) Work on independent chimneys
edge of the scaffold and the wall of should not be carried on in high
the chimney should not exceed 20 winds, icy conditions, fog or during
cm at any point. electrical storms.
v) Catch platforms should be erected 6.9 HANDLING AND LIFTING
over: EQUIPMENT:
(a) the entrance to the chimney; 6.9.1 General Provisions
(b) Passageways and working
places where workers could be Following are the general guidelines
endangered by falling objects. to be followed with regard to all
types of handling and lifting
vi) For climbing tall chimneys, access equipment in addition to the
should be provided by:
guidelines for specific type of
(a) stairs or ladders; equipments dealt later on.
(b) a column of iron rungs securely
embedded in the chimney wall; i) There should be a well-planned
(c) Other appropriate means. safety programme to ensure that all
the lifting appliances and lifting gear
vii) When workers use the outside rungs are selected, installed, examined,
to climb the chimney, a securely
tested, maintained, operated and
fastened steel core rope looped at
dismantled with a view to preventing
the free end and hanging down at the occurrence of any accident;
least 3 m should be provided at the
top to help the workers to climb on
ii) All lifting appliances shall be
to the chimney.
examined by competent persons at
viii) While work is being done on frequencies as specified in "The
independent chimneys the area Factories act".
surrounding the chimney should be
iii) Check thoroughly quality, size and
enclosed by fencing at a safe
condition of all lifting tools like chain
distance.
pulley blocks, slings, U-clamps, D-
ix) Workers employed on the shackles etc. before putting them in
construction, alteration, use.
maintenance or repair of tall
iv) Safe lifting capacity of all lifting &
chimneys should not:
handling equipment, tools and
a) work on the outside without a shackles should be got verified and
safety harness attached by a certificates obtained from competent
lifeline to a rung, ring or other authorities before its use. The safe
secure anchorage; working load shall be marked on
b) put tools between the safety them.
harness and the body or in
v) Check periodically the oil, brakes,
pockets not intended for the
gears, horns and tyre pressure of all
purpose;
moving equipments like cranes,
OISD-192
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forklifts, trailers etc as per i) Hoist shafts should be enclosed with
manufacturer's recommendations. rigid panels or other adequate
fencing at:
vi) Check the weights to be lifted and
accordingly decide about the crane (a) ground level on all sides;
capacity, boom length and angle of (b) all other levels at all points at
erection. which access is provided;
(c) all points at which persons are
vii) Allow lifting slings as short as
liable to be struck by any moving
possible and check packing at the
part.
friction points.
ii) The enclosure of hoist shafts,
viii) While lifting/placing of the load, no
except at approaches should extend
unauthorised person shall remain
where practicable at least 2mt
within the radius of the boom and
above the floor, platform or other
underneath the load.
place to which access is provided
ix) While loading, unloading and except where a lesser height is
stacking of pipes, proper wedges sufficient to prevent any person
shall be placed to prevent rolling falling down the hoistway and there
down of the pipes. is no risk of any person coming into
contact with any moving part of the
x) Control longer jobs being lifted up hoist, but in no case should the
from both ends.
enclosure be less than 1mt in
xi) Only trained operators and riggers height.
should carry out the job. While the iii) The guides of hoist platforms should
crane is moving or lifting the load,
offer sufficient resistance to bending
the trained rigger should be there for
and, in the case of jamming by a
keeping a vigil against hitting any safety catch, to buckling.
other object.
iv) Where necessary to prevent danger,
xii) During high wind conditions and
adequate covering should be
nights, lifting of heavy equipments provided above the top of hoist
should be avoided. If unavoidable to
shafts to prevent material falling
do erection in night, operator and
down them.
rigger should be fully trained for
night signaling. Also proper v) Outdoor hoist towers should be
illumination should be there. erected on firm foundations, and
securely braced, guyed and
xiii) Allow crane to move on hard, firm anchored.
and leveled ground.
vi) A ladderway should extend from the
xiv) When crane is in idle condition for
bottom to the top of outdoor hoist
long periods or unattended, crane towers, if no other ladderway exists
boom should either be lowered or
within easy reach.
locked as per manufacturer's
guidelines. vii) Hoisting engines should be of ample
capacity to control the heaviest load
xv) Hook and load being lifted shall
that they will have to move.
remain in full visibility of crane
operators, while lifting, to the extent viii) Hoists should be provided with
possible. devices that stop the hoisting engine
as soon as the platform reaches its
xvi) Don't allow booms or other parts of
highest stopping place.
crane to come within 3 meters reach
of overhead electrical cables. ix) Winches should be so constructed
that the brake is applied when the
xvii) No structural alterations or repairs
control handle is not held in the
should be made to any part of a operating position.
lifting appliance, which may affect
the safety of the appliance without x) It should not be possible to set in
the permission and supervision of motion from the platform a hoist,
the competent person. which is not designed for the
conveyance of persons.
6.9.2 Hoists
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xi) Winches should not be fitted with
pawl and ratchet gears on which the
on the platform or cage: the
maximum number of persons
pawl must be disengaged before the to be carried at one time;
platform is lowered.
(c) on hoists for goods only:
xii) Hoist platforms should be capable of
supporting the maximum load that on every approach to the hoist
they will have to carry with a safety and on the platform: prohi-
factor. bition of use by persons.
xiii) Hoist platforms should be equipped xxi) Hoists intended for the carriage of
with safety gear that will hold the persons should be provided with a
platform with the maximum load if cage so constructed as to prevent
the hoisting rope breaks. any person from falling out or being
xiv) If workers have to enter the cage or trapped between the cage and any
go on the platform at landings there fixed part of the structure when the
should be a locking arrangement cage gate is shut, or from being
preventing the cage or platform from struck by the counterbalance weight
moving while any worker is in or on or by articles or materials tailing
it. down the hoistway.
xv) On sides not used for loading and xxii) On each side in which access is
unloading, hoist platforms should be provided, the cage should have a
provided with toe-boards and gate fitted with devices which
enclosures of wire mesh or other ensure that the gate cannot be
suitable material to prevent the fall opened except when the cage is at
of parts of loads. a landing and that the gate must be
closed before the cage can move
xvi) Where necessary to prevent danger away from the landing.
from falling objects, hoist platforms
should be provided with adequate xxiii) Every gate in the enclosure of the
covering. hoist shaft which gives access from
a landing place to the cage should
xvii) Counterweights consisting of an be fitted with devices to ensure that
assemblage of several parts should the gate cannot be opened except
be made of specially constructed when the cage is at that landing
parts rigidly connected together. place, and that the cage cannot be
xviii) Counterweights should run in moved away from that landing place
guides. until the gate is closed.
xix) Platforms should be provided at all 6.9.3 Derricks

landings used by workers. Stiff-leg derricks
xx) Following notices should be posted
up conspicuously and in very legible i) Derricks should be erected on a firm
characters: base capable of taking the
combined weight of the crane
(a) on all hoists: structure and maximum rated load.
on the platform: the carrying ii) Devices should be used to prevent
capacity in kilograms or other masts from lifting out of their
appropriate standard unit of seating.
weight; iii) Electrically operated derricks should
on the hoisting engine: the
be effectively earthed from the sole
plate or framework.
lifting capacity in kilograms or
other appropriate standard iv) Counterweights should be so
unit of weight; arranged that they do not subject
the backstays, sleepers or pivots to
(b) on hoists authorised or certified for
excessive strain.
the conveyance of persons:
v) When derricks are mounted on
wheels:
OISD-192
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a) a rigid member should be used to iii) Gin poles should be fastened at
maintain the correct distance their feet to prevent displacement in
between the wheels; operation.
b) they should be equipped with
iv) Gin poles, which are moved from
struts to prevent them from
place to place and re-erected,
dropping if a wheel breaks or the
should not be taken into use again
derrick is derailed.
before the pole, lifting ropes, guys,
vi) The length of a derrick jib should not blocks and other parts have been
be altered without consulting the inspected, and the whole appliance
manufacturer. has been tested under load.
vii) The jib of a scotch derrick crane v) When platforms or skips are hoisted
should not be erected within the by gin poles, precautions should be
backstays of the crane. taken to prevent them from spinning
and to provide for proper landing.
Guy derricks
6.9.5 Tower cranes
i) The restraint of the guy ropes
should be ensured by fitting stirrups i) Where tower cranes have cabs at
or anchor plates in concrete high level, persons, capable and
foundations. trained to work at heights, should
only be employed as crane
ii) The mast of guy derricks should be
operators.
supported by six top guys spaced
approximately equally. ii) The characteristics of the various
machines available should be
iii) The spread of the guys of a guy
considered against the operating
derrick crane from the mast should
0 requirements and the surroundings
not be more than 45 from the
in which the crane will operate
horizontal.
before a particular type of crane is
iv) Guy ropes of derricks should be selected.
equipped with a stretching screw or
iii) Care should be taken in the
turnbuckle or other device to
assessment of wind loads both
regulate the tension.
during operations and out of service.
v) Gudgeon pins, sheave pins and fool Account should also be taken of the
bearings should be lubricated effects of high structures on wind
frequently. forces in the vicinity of the crane.
vi) When a derrick is not in use, the iv) The ground on which the tower
boom should be anchored to crane stands should have the
prevent it from swinging. requisite bearing capacity. Account
should be taken of seasonal
6.9.4 Gin poles variations in ground conditions.
i) Gin poles should: v) Bases for tower cranes and tracks
for rail-mounted tower cranes should
(a) be straight; be firm and level. Tower cranes
(b) consist of steel or other suitable should only operate on gradients
metal; within limits specified by the
(c) be adequately guyed and manufacturer. Tower cranes should
anchored; only be erected at a safe distance
(d) be vertical or raked slightly from excavations and ditches.
towards the load;
(e) be of adequate strength for the vi) Tower cranes should be sited where
loads that they will be required to there is clear space available for
lift/move. erection, operation and dismantling.
As far as possible, cranes should be
ii) Gin poles should not be spliced and sited so that loads do not have to be
if a gin pole is composed of different handled over occupied premises,
elements, they should be assembled over public thoroughfares, other
in conformity with their intrinsic construction works and railways or
material strength. near power cables.
OISD-192
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vii) Where two or more tower cranes are i) Only ropes with a known safe
sited in positions where their jibs working capacity should be used as
could touch any part of the other lifting ropes.
crane, there should be direct means
ii) Lifting ropes should be installed,
of communication between them
maintained and inspected in
and a distinct warning system
accordance with manufacturers'
operated from the cab so that one
instructions.
driver may alert the other of
impending danger. iii) Repaired steel ropes should not be
used on hoists.
viii) The manufacturers' instructions on
the methods and sequence of iv) Where multiple independent ropes
erection and dismantling should be are used, for the purpose of stability,
followed. The crane should be to lift a work platform, each rope
tested before being taken into use. should be capable of carrying the
load independently.
ix) The climbing operation of climbing
tower cranes should be carried out 6.10 VEHICLE MOVEMENT
in accordance with manufacturers'
6.10.1 Park vehicles only at designated
instructions. The free-standing
places. Don't block roads to create
height of the tower crane should not
extend beyond what is safe and hindrance for other vehicles.
permissible in the manufacturers' 6.10.2 Don't overload the vehicle.
instructions.
6.10.3 Obey speed limits and traffic rules.
x) When the tower crane is left
unattended, loads should be 6.10.4 Always expect the unexpected and
removed from the hook, the hook be a defensive driver.
raised, the power switched off and 6.10.5 Drive carefully during adverse
the boom brought to the horizontal. weather and road conditions.
For longer periods or at times when
adverse weather conditions are 6.10.6 Read the road ahead and ride to the
expected, out of service procedures left.
should be followed. The main jib 6.10.7 Be extra cautious at nights. Keep
should be slewed to the side of the wind screens clean and lights in
tower away from the wind, put into working condition.
free slew and the crane immobilised.
6.10.8 All vehicles used for carrying
xi) A windspeed measuring device workers and construction materials
should be provided at an elevated must undergo predictive/preventive
position on the tower crane with the maintenance and daily checks
indicator fitted in the drivers' cab.
6.10.9 Driver with proper valid driving
xii) Devices should be provided to license shall only be allowed to drive
prevent loads being moved to a the vehicle
point where the corresponding safe
working load of the crane would be 6.10.10 Routes shall be leveled, marked and
exceeded. Name boards or other planned in such a way so as to
items liable to catch the wind should avoid potential hazards such as
not be mounted on a tower crane overhead power lines and sloping
other than in accordance with the ground etc.
manufacturers' instructions. 6.10.11 While reversing the vehicles, help of
xiii) Tower cranes should not be used for another worker should be ensured
magnet, or demolition ball service, at all times
piling operations or other duties, 6.10.12 An unattended vehicle should have
which could impose excessive the engine switched off
loading on the crane structure.
6.10.13 Wherever possible one-way system
6.9.6 Lifting ropes shall be followed
6.10.14 Barriers/fixed stops should be
provided for excavation/openings to
prevent fall of vehicle
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6.10.15 Load should be properly secured xiv) ELCB for all temporary connections
must be provided. Use insulated 3-
6.10.16 The body of the tipper lorry should
pin plug tops.
always be lowered before driving
the vehicle off. xv) All power supply cables should be
laid properly and neatly so that they
6.10.17 Signs/signals/caution boards etc.
don't cause hindrance to persons
should be provided on routes .
working and no physical damage
6.11 ELECTRICAL also takes place to the cables during
various construction activities.
6.11.1 General Provisions
xvi) All Power cables to be properly
i) Only persons having valid licenses terminated using glands and lugs of
should be allowed to work on proper size and adequately crimped.
electrical facilities.
xvii) Use spark-proof/flame proof type
ii) No person should be allowed to electrical fittings in Fire Hazard
work on live circuit. The same, if zones as per area classification
unavoidable, special care and under OISD-STD-113.
authorisation need to be taken. xviii) Check installations of steel
iii) Treat all circuits as "LIVE" unless plates/pipes to protect underground
ensured otherwise. cables at crossings.
iv) Electrical "Tag Out" procedure xix) Don't lay unarmored cable directly
"MUST" be followed for carrying out on ground, wall, roof or trees. All
maintenance jobs. temporary cables should be laid at
least 750 mm below ground and
v) Display voltage ratings prominently cable markers should be provided.
with "Danger" signs. Proper sleeves should be provided
vi) Put caution/notice signs before at road crossings. In case temporary
starting the repair works. cables are to be laid on wooden
poles/steel poles, the minimum
vii) All electrical equipment operating cable heights should be 4.5 M.
above 250V shall have separate and
distinct connections to earth grid. xx) Maintain safe overhead distance of
HT cables as per Indian Electricity
viii) Proper grounding to be ensured for Rules and relevant acts.
all switch boards and equipment
including Portable ones prior to xxi) Don't connect any earthing wire to
taking into service. the pipelines/structures.
ix) Make sure that electrical switch xxii) Don't make any unsafe temporary
boards, portable tools, equipments connections, naked joints/wiring etc.
(like grinding machine etc.) don't get xxiii) Ensure that temporary cables are
wet during their usage. If it happens, free from cuts, damaged insulation,
stop the main supply, make the tools kinks or improper insulated joints.
dry and then only use them. Check
proper earthing. xxiv) Check at periodic intervals that pins
of sockets and joints are not loose.
All temporary switch boards/
KIOSKS put up at work site should xxv) Protect electrical wires/equipments
be suitably protected from rain and from water and naked flames.
the level of same should be high xxvi) Illuminate suitably all the work
enough to avoid contact with water
areas.
due to water logging.
xxvii) All switchboards should be of MS
x) Don't work wet on electrical system. structure only and incoming source
xi) Don't overload the electrical system. should be marked.
xii) Use only proper rated HRC fuses. xxviii) Hand lamps should not be of more
than 24V rating.
xiii) Industrial type extension boards and
Plug sockets are only to be used. xxix) Fire extinguishers (DCP/CO2/Sand
buckets) should be kept near
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temporary switch boards being used ensure suitability for its proposed
for construction purposes. Don't use use.
water for fighting electrical fires.
ii) At the beginning of every shift, the
xxx) Insulating mats shall be provided in person using the electrical
the front and back end of switch equipment should make a careful
boards. external examination of the
equipment and conductors,
xxxi) All parts of electrical installations
especially the flexible cables.
should be so constructed, installed
and maintained as to prevent iii) Apart from some exceptional cases,
danger of electric shock, fire and work on or near live parts of
external explosion. electrical equipment should be
forbidden.
Periodic checking/certification of
electrical safety appliances such as iv) Before any work is begun on
gloves, insulating mats, hoods etc. conductors or equipment that do not
to be done/witnessed along with have to remain live:
maintaining a register at site signed
a) the current should be switched
by competent authority.
off by a responsible authorised
xxxii) A notice displaying following, should person;
be kept exhibited at suitable places: b) precautions should be taken to
prevent the current from being
a) prohibiting unauthorised persons
switched on again;
from entering electrical
c) the conductors or the equipment
equipment rooms or from
should be tested to ascertain that
handling or interfering with elec-
they are dead;
trical apparatus;
d) the conductors and equipment
b) containing directions as to
should be earthed and short-
procedures in case of fire, rescue
circuited;
of persons in contact with live
e) neighbouring live parts should be
conductors and the restoration of
adequately protected against
persons suffering from electric
accidental contact.
shock;
c) specifying the person to be v) After work has been done on
notified in case of electrical conductors and equipment, the
accident or dangerous current should only be switched on
occurrence, and indicating how to again on the orders of a competent
communicate with him. person after the earthing and short-
circuiting have been removed and
xxxiii) No other cables/pipes to be laid n i
the workplace reported safe.
trench used for electrical cables.
xxxiv) Utmost care should be taken while vi) Electricians should be provided with
excavating Earth from cable trench approved and tested tools, and
to avoid damage or any accident. personal protective equipment such
xxxv) Sub-station floor cut-outs meant for as rubber gloves, mats etc.
switch board installations to be
vii) All conductors and equipment
covered wherever installation is
should be considered to be live
incomplete.
unless there is a proof of the
NOTE: A Residual Current Operated Circuit contrary.
Breaker (RCCB) or Earth Leakage
viii) When work has to be done in
Circuit Breaker (ELCB), when
dangerous proximity to live parts the
installed, protects a human being to
current should be cut off. If for
the widest extent. RCCB or ELCB
operational reasons this is not
should be provided as per Indian
possible, the live parts should be
Electricity Rules.
fenced off or enclosed by qualified
6.11.2 Inspection and maintenance staff from the sub-station concerned.
i) All electrical equipment should be

inspected before taking into use to
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6.11.3. Testing 6.12.2 Drilling Rigs
i) Electrical installations should be i) Location of jack up rigs should not

inspected and tested and the results be less than 5 Kms from shipping
recorded. route. Orientation of the rig, wind
direction etc are required for safe
ii) Periodic testing of the efficiency of
landing of helicopter. Information
the earth leakage protective devices
w.r.t. sea currents, wind speed, Hi-
should be carried out.
lo tide etc are required for mooring
iii) Particular attention should be paid to of supply vessels.
the earthing of apparatus, the
ii) Sea bed condition at every location
continuity of protective conductors,
should be ensured for safety of rig.
polarity and insulation resistance,
protection against mechanical iii) Radio and other communication
damage and condition of facilities should be such to maintain
connections at points of entry. contact with base all times.
6.12 OFFSHORE iv) During toeing of rig, the rig deck
should be clear of load, toeing lines
6.12.1 General
should be in good condition and
tensions in various toeing lines
The isolated nature of offshore installations
should be constantly monitored.
are hazardous. They call for greater need for
safety and survival at offshore. Safety at v) Few steps during toeing are:
offshore is safety of installations and safety
a) crane booms should be
of personnel. Safety problems and accidents
secured to their vesta,
at offshore have high risks due to limited
b) all hatches and water tight
space, helicopter operation, sea transport
doors should be closed,
etc. Following are the general safety
c) number of personnel on board
guidelines to be followed in addition to the
should be restricted,
safety guidelines stipulated for specific jobs
d) evacuate in case of emergency
dealt later on:
and operation should be
i) Workers should be well trained to completed preferably in day
do their job independently with high light.
degree of self-control and self-
6.12.3 Drilling
discipline.
ii) On arrival at offshore, everyone i) In view of CO2 and H2S gas cut from
should be briefed about the safety well, effective ventilation should be
rules to be followed at offshore, provided where drilling is in
evacuation system etc. All progress.
personnel should wear overall
ii) Safety alarm shall be checked in
(dangri), helmet and shoes for
advance in view of failure of
personnel protection.
ventilation system.
iii) In case of emergency, workers
iii) Suitable sensors for H2S and
should follow instruction of Field
Methane should be function tested
Production Superintendent (F.P.S.)
time to time and suitable colour
In certain cases instructions may be
code should be given.
given to abandon the offshore
installation and evacuate the iv) Working areas of the crane should
persons to safe location. be illuminated during night to avoid
accident.
iv) To overcome above problems,
offshore personnel must receive v) Clear space should be available for
training for using life saving despatch and receipt of load and, in
appliances and other personal particular, basket transfer of
survival techniques. passengers. Persons engaged in
loading/unloading of materials
v) Any person working at offshore
should be protected from falling into
should have one person as standby
the sea.
for any eventuality.
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vi) Signal light should be fitted at the iii) Surface safety valve or SDV should
top of the jib. be checked for no gas leakage from
vii) Crane hook should be fitted with bleed port / flange etc., in the well
safety latches. head area. It should not be in
"mechanical override" or bypassed
viii) Experienced person should be from panel.
engaged in operation of specific
equipment like winches, cranes etc. iv) High pressure gas lift lines -
blowdown system should be O.K.
ix) At least three cable turns shall
always be there on the winch drum. v) Auto actuation of SDVs in the inlet
of pressure vessels should be O.K.
x) Adequate communication like walkie
talkie, round robin phone should be and in "normal position" from
available between the crane shutdown panels. A record of status
operator, supervisor and helper. of switches normal/bypassed in
auto-con* panels (PSH, PSL, LSL,
xi) Crane operation should be
ILSL) should be maintained.
completely stopped during
helicopter landing/taking off.
Shut Down Panels
xii) Except for helicopter landing deck,
vi) Welders rectifier set and electrical
all decks, platforms, bridges,
connections to it should be checked
ladders should have rigid and fixed
guard rails atleast one meter high and approved by electrical-in-
and should have one intermediate charge for proper electrical safely.
rail midway between the handrail vii) SCADA" telementry system if
and 100 mm toe board. available should be operational for
xiii) Wooden ladders shall not be used remote opening and closing of wells
at offshore. at unmanned platforms (through
RPMC).
xiv) Flow sensor in the flow line should
be ensured for safe working and to viii) Local ESD/FSD (near the work site)
avoid blow out. should be provided for jobs of very
critical nature, so that the persons
xv) Hydrogen sulphuide gas In offshore
working can access it immediately in
is of great risk and at 10 ppm
(0.001%) concentration in air, a emergency for safety. Safety officer
person should not be exposed for should judge the requirement &
more than 8 hours, If concentration inform FPS for the same.
is more, then breathing apparatus ix) Railings and Gratings etc. in and
should be used. Corrosion of around work area should be O.K.
equipment is also caused by H2S. and inspected to avoid slippage of
xvi) Portable H2S gas detector should man into sea.
be continously used. x) Emergency shut down (ESD)
6.12.4 Production Platforms system is initiated when an
abnormal condition is detected.
i) In case hydrocarbon Is released due ESD should be checked once in six
to overpressure, leak, overflow, gas months.
blow etc., shut down process to stop xi) Platform should be manned round
flow of hydrocarbon. Prevent ignition the clock.
of released hydrocarbon and in case
of fire shut in the process complex xii) Welding and cutting work should be
and follow emergency contigency regulated by hot work permit.
plan. xiii) All detectors should be calibrated as
ii) Sub surface safetv valve (SSSV)) per recommendation of the
below the well head should be manufacturer.
actuated during uncontrolled well - xiv) No system should be by-passed
flow and they should be regularly which affects the system of platform.
checked.
OISD-192
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xv) In H2S field platforms, due care shall accommodate twice the number of
be taken as per recommendations. persons onboard installation.
xvi) Follow the instructions of F.P.S. iii) Launching appliances and life boat
during stay at platform equipment should be checked every
week.
6.12.5 Fire Prevention And Control
iv) Boat landing areas should be
i) Provision be made for safe handling adequately illuminated.
and storage of dirty rags, trash, and
v) Life raft has no power and they rely
waste oil. Flammable liquids and
on drift.
chemicals applied on platform
should be immediately cleaned. vi) Life jacket lifts the wearer after
entering water.
ii) Paint containers and hydrocarbon
samples, gas cylinders for welding vii) Life buoys are used to rescue
and cutting should be stored persons if any person accidentally
properly. Cylinders should be falls in the sea.
transported in hand-cart.
viii) All life saving appliances should be
iii) Smoking should be restricted and inspected by the MMD surveyor /sr.
no smoking area should be officials once a year.
identified.
ix) Every life boat shall be inspected
iv) Special attention should be given to once a week.
crude oil pump seals, diesel and
x) Every life boat and life raft should
gas engines which are potential
be serviced once a year by a
source of ignition in the event of
competent authority,
failure.
6.12.7 Safety Precautions during
v) Fire and smoke detectors i.e.
Helicopter Transportation
ultraviolet heat, thermal and smoke
detector should be function tested
i) Passenger briefing regarding safety
once in three months.
rules while travelling in helicopter
vi) Fire is controlled in offshore by should be carried out before
water spraying, Halon, CO2 boarding the helicopter.
flooding, DCP and sprinkler system.
ii) Emergency procedure should be
vii) Foaming agent is applied for briefed to all the passenger In case
controlling fire in liquid hydrocarbon. helicopter is to ditch into the sea.
The system is not effective in gas
iii) Heli-pad should have a non-skid
fire.
surface. Nylon rope net should be
viii) Light weight breathing system stretched on the deck.
should be used.
iv) Proper drainage should be available
ix) The fire control plan at offshore on helideck.
should reveal control station, fire
v) There should be no obstruction on
alarms and fire detectors, deluge
the helideck itself and within 3
valves and sprinkler, fire
extinguishing appliances, fireman meters of its parameter. Closest
super structure above the helideck
outfit and ventilation system.
should have red obstruction light.
x) Fire fighting equipment should be
maintained in ready to use vi) While landing fire crew of two
persons should be standby adjacent
condition.
to helideck.
6.12.6 Life Saving Appliances
vii) Heli-deck should be properly
illuminated for night landing.
i) Life boats with a speed of 6 knots
and carrying capacity upto 50 viii) During switching off helicopter,
persons are used in offshore. persons should not be allowed to go
out/ towards helicopter
ii) No. of life boats on one installation
should have a capacity to
OISD-192
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6.13 DEMOLITION posted. To protect the public a fence
2m high should be erected
6.13.1. General provisions
enclosing the demolition operations
and the access gates should be
i) When the demolition of any building secured outside working hours.
or structure might present danger to
workers or to the public: vi) The fabric of buildings contaminated
with substances hazardous to health
(a) necessary precautions, methods should be decontaminated.
and procedures should be
Protective clothing and respiratory
adopted, including those for the
devices should be provided and
disposal of waste or residues; worn.
(b) the work should be planned and
undertaken only under the vii) Where plant has contained
supervision of a competent flammable materials, special
person. precautions should be taken to
avoid fire and explosion.
ii) Before demolition operations begin:
viii) The plant to be demolished should
(a) structural details and builders' be isolated from all other plant that
drawings should be obtained
may contain flammable materials.
wherever possible;
Any residual flammable material in
(b) details of the previous use should the plant should be rendered safe by
be obtained to identify any
cleaning, purging or the application
possible contamination and
of an inert atmosphere as
hazards from chemicals, appropriate.
flammables, etc.;
(c) an initial survey should be carried ix) Care should be taken not to
out to identify any structural demolish any parts, which would
problems and risks associated destroy the stability of other parts.
with flammable substances and
x) Demolition activities should not be
substances hazardous to health.
continued under adverse climatic
The survey should note the type
conditions such as high winds,
of ground on which the structure
which could cause the collapse of
is erected, the condition of the
already weakened structures.
roof trusses, the type of framing
used in framed structures and the xi) To prevent hazards parts of struc-
load-bearing walls; tures should be adequately shored,
(d) a method of demolition should be braced or otherwise supported.
formulated after the survey and
xii) Structures should not be left in a
recorded in a method statement
condition in which they could be
having taken all the various
brought down by wind pressure or
considerations into account and
vibration.
identifying the problems and their
solutions; xiii) Where a deliberate controlled
collapse technique is to be used,
iii) All electric, gas, water and steam
expert engineering advice should be
service lines should be shut off and,
obtained, and:
as necessary, capped or otherwise
controlled at or outside the (a) it should only be used where the
construction site before work whole structure is to come down
commences. because it relies on the removal
of key structural members to
iv) If it is necessary to maintain any
effect a total collapse;
electric power, water or other
(b) it should only be used on sites
services during demolition
that are fairly level and where
operations, they should be
there is enough surrounding
adequately protected against
space for all operatives and
damage.
equipment to be withdrawn to a
v) As far as practicable, the danger safe distance.
zone round the building should be
xiv) When equipment such as power
adequately fenced off and sign
shovels and bulldozers are used for
OISD-192
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demolition, due consideration should 6.14.9 All personnel working with
be given to the nature of the building radiography sources should wear
or structure, its dimensions, as well appropriate protective equipment
as to the power of the equipment and film badges issued by BARC.
being used.
6.14.10 Protection facilities such as
xv) If a swinging weight is used for manipulator rod, remote handling
demolition, a safety zone having a tongs, lead pots, radiation hazard
width of at least one-and-a-half placards and means of cordon off
times the height of the building or shall be available at each site.
structure should be maintained
6.14.11 The radiography source shall never
around the points of impact.
be touched or handled directly with
6.13.2. Demolition of structural steelwork hands.
6.14.12 The package containing radiography
i) All precautions should be taken to
cameras and sources should never
prevent danger from any sudden
be carried by public transport like
twist, spring or collapse of
bus, train etc.
steelwork, ironwork or reinforced
concrete when it is cut or released. 6.14.13 Radiography sources and cameras,
when not in use, should be stored
ii) Steel construction should be
inside a source pit with lock and key
demolished tier by tier.
arrangement as approved by BARC.
iii) Structural steel parts should be The storage room should preferably
lowered and not dropped from a be located in an isolated area of
height. minimum occupancy and radiation
level outside the storage room
6.14 RADIOGRAPHY
should not exceed 0.25 mR/hr as
per BARC Regulations.
6.14.1 All radiography jobs shall be carried
out as per BARC Safety Regulations 6.14.14 In case of an accident (due to loss
or of damage to radiography
6.14.2 During field radiography, nearby source), action should be taken in
area around the radiation source line with BARC Safety
should be cordoned off. Rules/Guidelines.
6.14.3 If the field radiography is to be done
at the same location repeatedly, it is 6.15 SAND/SHOT BLASTING/ SPRAY
advisable to provide either a wire PAINTING
fencing around or a temporary brick
enclosure. 6.15.1 Sand blasting should be used only
6.14.4 Special permission/permit should be after approval from competent
taken for radiography from area-in- person.
charge. 6.15.2 Air Compressor used for sand/shot
6.14.5 As far as possible, field radiography blasting/painting should have guard
should be done only during night and positioned away from the work
time when there is little or no place.
occupancy there. 6.15.3 Exhaust of the prime mover, if IC
6.14.6 Radiation warning signals should be engine is used, should be directed
pasted all along the cordoned off away from the work place.
area. 6.15.4 In case of motor driven compressor,
6.14.7 Entry into the restricted area by the body of the motor as well as the
unauthorised persons should be compressor to be properly earthed.
strictly prohibited during exposure. 6.15.5 The hoses used for compressed air
6.14.8 The radiation level alongwith the should be of proper quality, and
cordon should be monitored by a health of the same to be ensured
suitable and well-calibrated radiation through regular check/ test.
survey meter.
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6.15.6 The operator of sand/shot iv) All deck openings including those for
blasting/painting should wear buckets should be fenced.
suitable PPE's including mask.
6.16.2 Rescue & Emergency procedures
6.15.7 Adequate measures to be taken to
suppress dust/spray particle.
i) Persons who work over water
6.15.8 Sand used for sand blasting should should be provided with some form
be suitably covered & protected of buoyancy aid. Life jackets should
from to rain/moisture. provided sufficient freedom of
movement, have sufficient buoyancy
6.15.9 When these activities are done in
to bring persons to the surface and
confined places, adequate measure
keep them afloat face upwards, be
to be taken for proper ventilation.
easily secured to the body, be
6.16 WORK ABOVE WATER readily visible by way of self
luminous paint/strip.
6.16.1 General Provisions ii) Nobody should work alone on or
i) Where work is done over or in close above water.
proximity to water & where iii) Each worker should be trained in the
possibility of drowning exists, procedure to be followed in the
provision should be made for: event of an emergency.
a) Preventing workers from falling into
7.0 ADDITIONAL SAFETY
water;
b) The rescue of workers in danger PRECAUTION FOR UNITS
of drowning; WITH HYDROCARBONS
c) Safe and sufficient transport. In addition to general safety
precautions as outlined above for
ii) Provisions for the safe performance the activities in Clause 6.0, following
of work over or in close proximity to additional safety precautions need
water should include, where to be taken for the sites within the
appropriate, the provision and use of operating area or nearby, where
suitable and adequate: presence of Hydrocarbons cannot
be ruled out.
a) fencing, safety nets and safety
i) No job shall be carried out without a
harnesses;
valid permit. Permit should be in
b) lifebuoys, life jackets and manned
line with OISD-STD-105 "Work
boats;
Permit System".
c) protection against such hazards
as reptiles and other animals. ii) Smoking should be prohibited in all
iii) Gangways, pontoons, bridges, places containing readily
footbridges and other walkways or combustible or flammable materials
work places over water should: and "No Smoking" notices be
a) possess adequate strength and prominently displayed.
stability;
iii) In confined spaces and other places
b) be sufficiently wide to allow safe
where flammable gases, vapours or
movement of workers;
dusts can cause danger, following
c) have level surfaces free from
measures should be taken:
tripping hazards;
d) be adequately lit when natural (a) only approved type electrical
light is insufficient; installations and equipment,
e) where practicable and necessary, to including portable lamps, should
prevent danger, be provided with be used;
toe-boards, guard rails, hand ropes (b) there should be no naked
etc. flames or source of ignition;
f) be secured to prevent (c) oily rags, waste and clothes or
dislodgment by rising water or high other substances liable to
winds; spontaneous ignition should be
g) if necessary, be equipped with removed without delay to a safe
ladders which should be sound, of place;
sufficient strength and length and be (d) ventilation should be provided.
securely lashed to prevent slipping.
OISD-192
Page 233 of 674

iv) Regular inspections should be made xi) A dry chemical type fire extinguisher
of places where there are fire risks. shall be made available in the work
These include the vicinity of heating area. Also fire protection facilities
appliances, electrical installations like running hoses etc. as per permit
and conductors, stores of flammable should be complied with.
and combustible materials, welding
xii) Wherever required, welding screens
and cutting operations.
shall be put up to protect other
v) Welding, flame cutting and other hot equipment in adjoining areas
work should only be done after against flying sparks. Material used
issuance of work permit in line with should be metal/asbestos/water
the requirement of OISD-STD-105 curtain.
after appropriate precautions, as
xiii) Welding or cutting of vessels/
required, are taken to reduce the
equipments used in Hydrocarbon/
risk of fire. For carrying out other
hazardous chemicals shall be done
jobs also, OISD-STD-105 should be
after proper gas freeing and
followed strictly.
verifying the same with the
vi) Fire-extinguishing equipment should explosive-meter.
be well maintained and inspected at
xiv) The confined space/equipment shall
suitable intervals by a competent
be gas freed and cleaned.
person. Access to fire-extinguishing
equipment such as hydrants, xv) Absence of any toxic gas and any
portable extinguishers and flammable gas above explosion limit
connections for hoses should be shall be ensured with the help of
kept clear at all times. gas detection instrument and
explosive meter respectively.
vii) All supervisors and a sufficient
number of workers should be trained xvi) Used and hot electrode stubs shall
in the use of fire-extinguishing be discarded in a metal bucket.
equipment, so that adequate trained
personnel are readily available xvii) Use approved and certified flame
arrestors for vehicles.
during all working periods.
xviii) Work permit to be obtained, if
viii) Audio means to give warning in
case of fire should be provided construction work is carried out
within existing operating area.
where this is necessary to prevent
danger. Such warning should be 8.0 FIRST AID
clearly audible in all parts of the site
where persons are liable to work. First aid facilities should be provided
There should be an effective in line with various statutory
evacuation plan so that all persons regulations like factory act etc.
are evacuated speedily without However following care should be
panic and accounted for and all taken:
plant and processes shut down.
ix) Notices should be posted at i) First aid, including the provision of
conspicuous places indicating: trained personnel should be ensured
at work sites. Arrangement should
(a) the nearest fire alarm; be made for ensuring the medical
(b) the telephone number and attention of the injured workers. First
address of the nearest aid box should be as per the Factory
emergency services. rules.
x) The work site shall be cleared of all ii) Suitable rescue equipment, like
combustible materials, as Sparks stretchers should be kept readily
and molten metal coming from the available at the construction site.
welding job can easily ignite
combustible materials near or below iii) First-aid kits or boxes, as
the welding site. If the combustible appropriate and as per statutory
materials cannot be removed from requirements, should be provided at
the area, the same shall be properly workplaces and be protected
shielded. against contamination by dust,
moisture etc.
OISD-192
Page 234 of 674

iv) First-aid kit or boxes should not i) Poster: Posters with safety slogan
keep anything besides material for in humorous, gruesome
first aid in emergencies. demonstrating manner may be used
to discourage bad habits attributable
v) First-aid kits and boxes should
to accidents by appealing to the
contain simple and clear instructions
workers' pride, self-love, affection
to be followed, be kept under the
curiosity or human aspects. These
charge of a responsible person
should be displayed in prominent
qualified to render the first aid and
location(s).
be regularly inspected and stocked.
ii) Safety Sign Boards: Different type
vi) Where the work involves risk of
of message of cautioning, attention,
drowning, asphyxiation or electric
notice etc. should be displayed at
shock, first-aid personnel should be
the appropriate places for learning/
proficient in the use of resuscitation
awareness of the workmen while
and other life saving techniques and
working at site.
in rescue procedures.
iii) Films & Slides: Film(s) narrating
vii) Emergency telephone numbers of
the accident including the causes
nearby Hospitals, Police, Fire
and possible remedial ways of
Station and Administration should
preventing the recurrence of a
be prominently displayed.
similar accident should be displayed
9.0 DOCUMENTATION at regular intervals. Slides consisting
main points of the film show may
The intention of keeping also be shown to workers.
documentation of all types of iv) Talks, lectures & conferences:
accident(s) is to prevent recurrence The success of these events would
of similar accident(s). All accidents depend much on audiences
should be reported as per OISD understandings of the speaker (s).
Guidelines (OISD-GDN-107) and The speakers are to be
Factories act, 1948. knowledgeable and good presenter.
All accidents (major, minor or near Speakers should know to hold the
miss) should be investigated, attention and to influence the
analysed and recommendations audiences.
should be documented along with v) Competitions: Organise
implementation status. competition(s) between the different
All related data should be well- deptts/categories of workers. The
documented and further analysis sense of reward/recognition also will
highlighting the major cause(s) of improve safety awareness and
accidents be done. This will help in result in enhancing safety levels.
identifying thrust areas and training vi) Exhibitions: Exhibitions also make
needs for prevention of accidents. the workers acquainted with hazards
and means of preventive measures.
10.0 SAFETY AWARENESS & vii) Safety Publication: Safety

TRAINING publications including pocket books
dealing with ways of investigation
and prevention in the field of safety
Safety awareness to all section of
and so on, may be distributed to
personnel ranging from site-in-
workers to promote the safety
charge to workmen helps not only
awareness.
preventing the risk but also build up
the confidence. Time and viii) Safety Drives: From time to time,
expenditures also get saved as a an intensive safety drive by
result. organising a safety day or a safety
week etc. should be launched.
Safety awareness basically seeks to
persuade/inform people on safety ix) Training: Training for covering the
besides supplementing skill also. hazards for different trade should be
Awareness programme may include imparted. Training should also
followings: include the specific hazards related
OISD-192
Page 235 of 674

to a job in addition to the general iii) Safety & Health in Construction by
safety training as has been dealt in ILO
various chapters and should include
iv) The Building & Other Construction
all workers. Reference may be
Workers (Regulation, Employment
drawn from OISD-STD-154.
and Conditions of Service) Act 1996
11.0 REFERRENCES
i) Factory Act, 1948
ii) Indian Electricity Rules
OISD-192
Page 236 of 674

ANNEXURE I
LIST OF SAFETY CODES FOR CIVIL WORKS PUBLISHED BY BUREAU OF

INDIAN STANDARDS
Sr.no Code No. Title
01. IS : 818 Code of Practice for Safety and Health Requirements in Electric
and Gas Welding and Cutting Operations First Revision.
02. IS : 875 Code of practice for Structural safety of buildings: Masonry walls
03. IS : 933 Specification for Portable Chemical Fire Extinguisher, Foam
Type Second Revision.
04. IS : 1179 Specification for Equipment for Eye and Face Protection during
Welding First Revision.
05. IS : 1904 Code of practice for Structural safety of buildings: Shallow
foundations
06. IS : 1905 Code of practice for Structural safety of buildings: Masonry walls
07. IS : 2171 Specification for Portable Fire Extinguishers, Dry Powder Type
Second Revision.
08. IS : 2361 Specification for Building Grips First Revision.
09. IS : 2750 Specification for Steel Scaffoldings.
10. IS : 2925 Specification for Industrial Safety Helmets First Revision.
11. IS : 3016 Code of Practice for Fires Precautions in Welding and Cutting
Operations First Revision.
12. IS : 3521 Industrial safety belts and harnesses
13. IS : 3696 Part I Safety Code for Scaffolds and Ladders : Part I Scaffolds.
14. IS : 3696 Part II Safety Code for Scaffolds and Ladders : Part II Ladders.
15. IS : 3764 Safety Code for Excavation Work.
16. IS : 4014 -Part I & II Code of practice for Steel tubular scaffolding
17. IS : 4081 Safety Code for Blasting and Related Drilling Operations.
18. IS : 4082 Recommendations on staking and storage of construction
materials at site
19. IS : 4130 Safety Code for Demolition of Buildings First Revision.
20. IS : 4138 Safety Code Working in Compressed Air-First Revision
21. IS : 4756 Safety code for Tunneling works
22. IS : 4912 Safety requirements for Floor and Wall Openings, Railings and
toe Boards First Revision.
23. IS : 5121 Safety Code for Piling and other Deep Foundations.
24. IS : 5916 Safety Code for Construction involving use of Hot Bituminous
Materials.
25. IS : 5983 Specification for Eye Protectors First Revision.
26. IS : 6922 Structures subject to underground blasts, criteria for safety and
design of
27. IS : 7155 Code of recommended practices for conveyor safety
28. IS : 7205 Safety Code for Erection on Structural Steel Works.
OISD-192
Page 237 of 674

Sr.no Code No. Title
29. IS : 7069 Safety Code for Handling and Storage of Building Materials.
30. IS : 7293 Safety Code for Working with Construction Machinery.
31. IS : 7323 Guidelines for operation of Reservoirs
32. IS : 7969 Safety code for handling and storage of building material
33. IS : 8758 Recommendation for Fire Precautionary Measures in
construction of Temporary Structures and Pandals.
34. IS : 8989 Safety Code for Erection of Concrete Framed Structures.
35. IS : 9706 Code of Practices for construction of Arial ropeways for
transportation of material
36. IS : 9759 Guidelines for de-watering during construction
37. IS : 9944 Recommendations on safe working load for natural and man-
made fibre roap slings
38. IS : 10291 Safety code for dress divers in civil engineering works
39. IS :10386 Part I Safety Code for Construction, Operation and Maintenance for
River Valley Projects.
40. IS :10386 Part II Safety Code for Construction, Operation and Maintenance of
River Valley Projects.
41. IS : 11057 Code of practice for Industrial safety nets
42. IS : 13415 Code of Practice on safety for Protective barriers in and around
building
43. IS : 13416 Recommendations for preventive measures against hazards at
working places
OISD-192
Page 238 of 674

OISD GDN 207
FOR RESTRICTED
CIRCULATION ONLY
OCTOBER 2002
CONTRACTOR SAFETY
OISD GUIDELINES 207
Oil Industry Safety Directorate

Government of India
Ministry of Petroleum & Natural Gas
Page 239 of 674

CONTRACTOR SAFETY
CONTENTS
SECTION DESCRIPTION
1.0 INTRODUCTION
2.0 SCOPE
3.0 DEFINITIONS
4.0 DUTIES / RESPONSIBILITIES
4.1 Owner
4.2 Contractor
4.3 Consultant
4.5 Designer
5.0 SAFETY MANAGEMENT
5.1 Job Safety Analysis (JSA)
5.2 Criteria of a Selection of a Contractor
5.3 Site Planning and Layout
5.4 Gate Entry Procedure
5.5 Training
5.6 Inspection / Audit
5.7 Penalties for non-compliance
5.8 Incident Reporting and Investigation System
5.9 Safety Committee Meetings
5.10 Safety Equipment / Personnel Protective Equipment
6.0 REFERENCES
ANNEXURE I List of BIS codes / Statutory Regulations
ANNEXURE II Checklist for Safety Inspection / Audit
Page 240 of 674

CONTRACTOR SAFETY
1.0 INTRODUCTION on its behalf, for supervising / co-ordinating

the activities of the contractor/execution
Oil and Gas operations like Drilling, agency.
Production, Refining, Transportation and
Distribution are inherently hazardous. A Contractor / Executing Agency
large number of contractor workforce is
deployed to carry out construction, A physical or legal person/entity having
maintenance and other jobs. The analysis of contractual obligation with the owner, and
the incidents in the Petroleum Sector who deploys one or more worker on the site.
indicates that a large number of incidents
involved contractor workforce and have Contractor Worker
resulted in either casualty or injury besides
leading to property damage and operational It covers all workmen who are either self-
interruptions and environmental degradation. employed or employed through contractor,
the casual workers and includes contractors
In order to improve the safety levels of oil supervisor, working at a location / site
installations, the contractor safety is of employed directly by Owner or through their
utmost importance and there is a need to contractor.
institute a good contractor safety system.
Incident
2.0 SCOPE
An incident is an unplanned, uncontrolled,
This standard covers broadly the guidelines unintended or unforeseen event, caused by
on the management system for enhancing unsafe acts and / or unsafe conditions,
the safety levels of the contractor workforce resulting in or having the potential to result in
deployed in construction, maintenance and personal injury and/or property damage.
operation activities in the hydrocarbon
industry. Consultant
The safety precautions to be taken while Consultant is a physical or legal

carrying out different activities during person/entity engaged by owner to provide
construction / maintenance have separately the consultancy services to owner for
been covered in OISD-GDN-192 on "Safety management of the contract on their behalf
Practices during Construction". or as specified.
3.0 DEFINITIONS Designer
Work station/Work site Designer is a physical or legal person / entity

engaged by owner to provide design
A place/unit where the job is carried out by services of a work site.
contractor/executing agency in specified
manner with safety, during construction Owner's Representative / Engineer In
phase or in operation phase. Charge
Owner The Owners representative/Engineer-in-

charge is the one, who has been designated
Any physical or legal person/entity for whom
by the owner to manage the contract.
prescribed job is carried out.
Owner's Safety Officer
It shall also include owner's designated
representative / consultant /nominee / agent,
A properly trained person designated by
authorised from time to time to act for and
owner who ensures safety at work site.
Page 241 of 674

viii) To specify the requirements of
Health, Safety and Environment (HSE)
4.0 DUTIES/ RESPONSIBILITIES (commensurate with the nature of job)
in Pre- Qualification criteria.
4.1 OWNER
ix) To designate Engineer-in-charge
4.1.1 Owners Management and safety officer.
The commitment to safety has to be x) To arrange for a multi-

emphasised by the owner by practice by its disciplinary safety audit team to
own management and employees at all conduct surprise / regular safety
levels. The duties and responsibilities of audits and monitor the implementation
owner should include: of the recommendations.
i) To institute a mechanism for xi) To introduce suitable schemes

identification and compliance of all for motivation of the contractor worker
applicable statutory rules & to adhere to safety guidelines.
regulations (Refer Annexure I for a list
of few important Bureau of Indian xii) To review safety practices & their
Standards & statutory regulations). implementation through periodic
surprise visit of the work sites and
ii) To provide specific information to monthly review meeting.
contractors and make workers aware
on the hazards associated with job xiii) To develop the HSE plans and
assigned. incorporate the same in the tender
document.
iii) To provide information about
Risk Mitigation measures available at xiv) To liaise with external agencies
the place of work. like press, public etc and with law
enforcement, regulatory, statutory
iv) To provide the contractor with agencies etc.
information on Owners Safety Plan &
Regulations, Emergency Management xv) To report to statutory agencies
Plan, lockout/ tag out procedure, on safety compliance and accidents, if
confined space entry, work permit any.
system, excavation/trench permit
system etc. 4.1.2 Owner's Representative/Engineer-
in-charge
v) To specify rules (e.g. for security
including access arrangements) and The duties & responsibilities of engineer-in-
safety rules such as fire protection, charge should include:
first aid arrangements, Work Permit
systems etc. i) To ensure that all Contract
requirements including Health, Safety,
vi) To provide comprehensive list of Environment & Security are complied
statutory regulations / standards and with.
specification, to be complied with
during execution of contract, in the ii) To ensure that contractor workforce
tender document itself. deployed is adequately qualified,
trained and in state of health to
vii) To ensure training of the commensurate with the requirements
contractor workforce, medical of the job.
examination, and proper usage of
safety equipment. iii) To ensure that the Tools / Tackles and
Machinery being used are properly
Page 242 of 674

tested and are in sound working contracts), which is to be considered
conditions and necessary resources in future when selecting contractors.
proposed for providing safe place of
work and necessary PPE are being xii) To ensure that the Consultant,
used. contractor and sub-contractor employ
/ designate qualified & trained Safety
iv) To take the required necessary Engineer / Officer commensurate with
corrective action immediately upon requirement of the job.
noticing or receipt of a report on
noncompliance or any such condition 4.1.3 Owner's Safety Officer
which poses a threat to health, safety The duties & responsibilities of the Owner's
or environment. If during the course of Safety Officer should include:
execution of the contract, any
situation of non-compliance with the i) To assess the hazards associated
contractor's safety and health plan are with jobs in consultation with all
noticed / reported, the same will be concerned and establish safe working
taken up with the contractor for procedure including identification of
correction. In the event of repeated the escape routes.
non compliance, suitable action to be ii) To establish a written record of factors
initiated as per the contract. which can cause injuries and
illnesses.
v) To ensure that the incidents are
reported to all concerned within iii) To undertake routine/surprise
stipulated timeframe. inspections of all work sites and
identify unsafe conditions & practices,
vi) To ensure submission of a plan for if any. Check for compliance of the
safe working (Method Statement) safety practices being followed with
from contractor and approval of the approved HSE Plan.
same by competent person / iv) To investigate promptly the incidents
department. (including near-miss) in order to
advise corrective and/or preventive
vii) To ensure that Work Permit action.
System in line with OISD-STD-105 is
adhered to. v) To maintain statistical information for
use in analyzing all phases of
viii) To ensure availability of all the incidents and events involving
documentation needed for the contract personnel.
execution of contract. vi) To provide the means for complying
with the reporting requirements for
ix) To ensure that the quality controls occupational injuries and illnesses.
have been maintained during
vii) To check whether the proposed
fabrication/erection and all jobs
working arrangements are safe and
required for safe commissioning have
satisfactory, particularly at the
been carried out.
interface between the contractor's
planned work and owners existing
x) To ensure safe dismantling of all
facilities.
temporary facilities/connections put
up by the contractor, after completion
viii) To communicate to the
of work.
Contractor the imposed restrictions
which may affect the work/personnel
xi) To compile a report on the safety
such as the temporary closure of a
performance (at the conclusion of
corridor or electrical isolation of
each contract or periodically such as
equipment.
annually for renewable and long-term
Page 243 of 674

ix) To review and monitor the contractor's iii) To nominate qualified & trained Safety
adherence to approved HSE plan and Engineers / Officers reporting to the
all applicable environmental, health, Site in charge, for supervision, co-
and safety requirements. ordination and, liaison for the
implementation of the safety plan.
x) To ensure that Consultant,
Contractors Managers, Supervisors Similar HSE Plan should be
and workmen at all levels (who will implemented at the sub- contractors
plan, monitor, oversee and carry out or suppliers site /office. However the
the work) undergo Health, Safety and compliance with the HSE Plan is to be
Environmental training in their the sole responsibility of the
respective responsibilities with Contractor.
respect to conducting work safely and
with due regard for the protection of iv) To arrange suitable facilities in liaison
the environment. with the owner for drinking water,
toilets, lighting, canteen, crche etc as
xi) To identify areas of operations where applicable as per Laws/ Legislation at
specialized training is required to deal site and also arrange for workmen
with potential dangers. compensation insurance, third party
liability insurance, registration under
xii) To document and to bring to the ESI / PF act etc as applicable.
attention of the Owner's Supervisor
and Contractor any non- v) To arrange for fire protection
compliance/violation of the safety equipment as per the advice of owner.
norms against approved safety and
health plan or safety and health vi) To ensure that its employees have
requirements and also raise these completed appropriate health and
issues in the Safety Committee safety training as required by the
Meetings. statute / regulation and also as per
requirements of the Owner /
xiii) To take part in Tool Box Consultant. The documentation of
Meetings at random and to ensure such training imparted to all its
maintenance of records. employees should be maintained and
produced for verification as required.
4.2 CONTRACTOR
vii) To comply with all the security
4.2.1 Contractor's Management arrangements of owner.
Duties & responsibilities of the contractor viii) To ensure that the plant and
should include the following: equipment used on-site by him / his
employees is correctly registered,
i) To implement safe methods and controlled and maintained in sound
practices, deploy appropriate working condition.
machinery, tools & tackles,
experienced supervisory personnel ix) To ensure availability of First Aid
and skilled work force etc. required for boxes and First Aid trained attendant.
execution.
x) To ensure that all incidents including
ii) To prepare a comprehensive and near misses are reported to all
documented plan for implementation, concerned immediately.
monitoring and reporting of Health,
Safety and Environment (HSE) and In construction projects where sub-
implement the same after its approval. contractors are engaged, the contractor
should set out the responsibilities, duties
and safety measures that are expected of
Page 244 of 674

the sub-contractors workforce. These vi) To take immediate action to correct
measures should include the provision and any violation of safety rules observed
use of specific safety equipment, methods of or reported.
carrying out specific tasks on safety and the
inspection and appropriate use of tools. vii) To ensure that the workers likely
to be exposed to hazardous
The responsibilities indicated separately chemicals/materials have access to
under contractors Supervisor, Safety Officer appropriate Material Safety Data
and contract worker are contractually that of Sheets (MSDS), wherever applicable,
the Contractor and legally binding on the and provide necessary mitigation
Contractor only. However the specific measures.
detailing as above has been given
separately for guidance and operational viii) To ensure inspection and
convenience. certification of all tools (hand operated
as well as mechanically operated)
The selection of sub contractors, if being used. Defective tools shall be
employed, should be approved by the immediately removed.
owner. Sub-contractor should comply fully
with all safety rules and conditions ix) To ensure that appropriate warning
applicable to the main contractor. signboards or tags are displayed.
4.2.2 Contractors Supervisor / Safety x) To ensure that workers have proper

Officer training for their job assignments,
including use of appropriate PPE and
Duties & responsibilities of the Contractors first aid fire fighting equipment.
supervisor/Safety Officer should include the
following: xi) To comply with all applicable safety
and health standards, rules,
i) To ensure strict compliance with work regulations and orders issued by
permit system by carrying out work competent authority pertaining to the
only with appropriate work permits assigned activities.
and after ensuring that all safety
precautions / conditions in the permit xii) To ensure that sick and/or
are complied with and closing the injured workers receive appropriate
same after job completion. first aid and/or medical attention.
ii) To ensure that required guards and xiii) To report each incident and/or
protective equipment are provided, injury in accordance with established
used, and properly maintained. procedures and assist in investigation.
iii) To ensure that tools and equipment xiv) To take necessary action for
are properly maintained and tested. correction of any unsafe act /
condition at the workplace. However,
iv) To plan the workload and assign in case the same is outside the limits
workers to jobs in commensuration of authority, it should be reported to
with their qualification, experience and Owners Engineer-in-charge
state of health. immediately.
v) To ensure that the workers xv) To conduct daily inspections to

understand the work to be done, the ensure compliance with safety
hazards that may be encountered, standards, codes, regulations, rules
and the proper precautions/procedure and orders applicable to the work
for carrying out the work safely. concerned.
Page 245 of 674

xvi) To ensure that workers under iii) To wear PPE as stipulated and
their supervision are aware of their necessary for the job.
responsibilities.
iv) To inform promptly to their supervisor
xvii) To arrange daily tool box regarding all work related incidents
meeting and regular site safety resulting in personal injury, illness
meetings and maintain records in the and/or property damage.
required formats. (Refer Clause 5.9.1)
v) To take all necessary and appropriate
xviii) To arrange stand-by supervisor/ safety precautions to protect
worker where situations so demand. themselves, other personnel and the
environment.
xix) To develop methods and display
banners/posters to inculcate safety 4.3 CONSULTANT
consciousness.
The activities and responsibilities covered
xx) To attend training and ensure under the scope of the Owner may be
participation of his workers for training delegated to the consultant in those cases
as per schedule arranged by the as applicable, based on the respective
Owner / Consultant and keeps himself contract conditions. The primary
updated. responsibility of Consultant is to ensure
compliance with agreed HSE plan for the
xxi) To keep records of number of contract by the Contractor. However those
persons working at the site. responsibilities conferred on Owner as
Principal employer cannot be delegated to
xxii) To keep a constant liaison with consultant.
Engg-in-charge / owners
representative on safety issues. Where the consultants scope involves
Engineering and Design, those factors under
xxiii) To maintain accident & nearmiss Designer should also be applicable.
record in a register.
In all cases, the Consultant's scope should
xxiv) To ensure that only PPE of the include submission of latest HSE plans for
approved type by owner is used at work under his and Contractor's purview and
site. implementing the same till job completion. It
should conform to owner's overall HSE plan.
A separate Safety Officer should be This should include Guidelines and
assigned, where more than 100 workers are Implementation and Reporting Methodology
employed at site. For smaller jobs, the to be followed with required report formats.
supervisor should assume the role of the
safety officer also. Adequate number of Safety Officers shall be
provided by the Consultant with necessary
4.2.3 Contract workers skills required for the work to be performed.
The duties & responsibilities of the The Consultant shall review the documents
contractor worker should include the submitted by the contractor and advise
following: owner on acceptance as well as advise
suitability and number of Contractor's safety
i) To perform work safely as per the job officers / supervisors.
requirement and instructions.
4.4 DESIGNER
ii) To inform all concerned regarding
unsafe conditions/acts. The Process Designer should identify all
hazards and risks likely to be encountered
during fabrication, erection including
Page 246 of 674

dismantling, Pre-commissioning, accident, causes of injuries and personal
commissioning and Performance run to experience) and determine the
meet the Guarantees and advise the risk preventive measures to overcome these
mitigation measures. hazards
Apply the controls to the hazards
All the hazards and safety measures to be Evaluate the controls
adopted while handling Dangerous
chemicals and Catalysts should be detailed 5.2 CRITERIA OF SELECTION OF A
by the Process Licensor and the same CONTRACTOR
should be again included in the scope of the
suppliers. Specific write ups/MSDS should Contractor Safety can be ensured to a
be obtained from Patented single source large extent if competent agency for
suppliers also. execution of assignment or job, based on
HSE system agreed upon by owner, is
Designs should recognize, include and apply selected. It is necessary to assess his
safe practice during preparation, capabilities and competencies to perform
construction and subsequent operational work safely.
use and maintenance after completion of the
Project. A databank should be developed for all the
contractors for their past performance on
All documents including drawings and HSE aspects. An attempt should also be
calculations are to be originated, checked made to get similar data from other similar
and approved in accordance with latest industries.
international codes, standards,
specifications and design basis philosophy. The data required will depend upon
complexity involved in the job and type / size
Preferred use of low risk materials, policy of resources required. Format needs to be
on hazardous substances, preferred use suitably developed depending upon size,
of low noise and dust-suppressed nature of the job & hazard associated
equipment etc. should be encouraged. therein. The format designed should also
take care of the skill required to carry out the
5.0 SAFETY MANAGEMENT job.
5.1 JOB SAFETY ANALYSIS (JSA) Performance review is essential for all type
of contractors. It helps in recording actual
Job safety analysis (JSA) provides a performance/experience with contractors
mechanism by which the contractor, safety while the contract is in progress. It is
officer or supervisor take a detailed look at essential that resources agreed as per the
how an individual task is performed and its contract are reviewed at mobilization stage
inherent hazards and preventive measures. for ensuring compliance from the day one
This procedure helps in integrating accepted and thorough effective supervision /
safety and health principles and practices monitoring system are at place.
into a particular operation. In a JSA, each
step of the job is examined to identify This activity also helps in taking timely action
potential hazards and to determine the in case of unsatisfactory performance to
safest way to do the job. correct the situation and ensure safe work
during execution period and deciding about
A job safety analysis includes five steps as suitability of the contractor for future jobs.
below:
The periodicity of such performance review
Select a job will depend upon size/type/complexity of
Break the job down into a sequence of contract. However, the performance should
steps be reviewed at least at mobilisation stage
Identify the hazards against each of and at the end of the contract.
these steps (based on knowledge of
Page 247 of 674

5.3 SITE PLANNING AND LAYOUT vii) Pedestrian pathways and routes
for vehicular traffic (light/heavy
Before starting the construction/maintenance vehicles including material handling
job at existing workplace in operation or equipment) should be earmarked.
green field locations, following should be
ensured: - viii) Artificial lighting to be provided at
places where work continues or
i) Details regarding location of workers pass by after sunset or in
workshop/ fabrication yard, site office, case natural light is insufficient like
stores, laboratory, electrical confined spaces.
installations, placement of
construction machinery, medical and ix) Keep all equipment /machines under
welfare facilities, lighting underground cover to prevent them from dust,
and above ground piping route, cable rain/flood water, heat etc. and follow
route etc. should be decided prior to storage instructions as applicable for
commencement of the work in each of them.
consultation with owner / Consultants
and implementation should be 5.4 GATE ENTRY PROCEDURE
ensured. Layout should be displayed
at strategic locations. Gate entry at any site / workplace / unit is to
be restricted to ensure entry of only
ii) The resources required to meet any authorised persons / vehicles.
emergency situations like fire fighting,
first aid etc. should be planned and 5.4.1 Entry procedure for all contractor
mobilized as per the job requirement. worker should be as follows:
iii) The sequence or order in which work A. Issuance of Pass

to be done and any hazardous
operations or processes should be i) The passes are to be issued after the
identified. owners representative/engineer-in-
charge forwards the application of the
iv) Free access to site shall be provided contractor providing complete details
with clear roads, passage, gangways, of the workers being engaged. The
staircases etc. Access to construction contractor may be asked to submit
site should be leveled, open and free Character & Antecedents (C&A)
from any obstructions like verification of individual worker from
construction material or scrap/waste, concerned authorities.
exposure to hazards such as falling
materials, material handling ii) With regard to issuance of passes for
equipment and vehicles. Any pit or all vehicles including material
ditch shall be covered or barricaded. handling equipment, owners
representative / engineer-in-charge
v) Arrangements should be made to should forward the application only
maintain good housekeeping at site. after ensuring that all documents
Scrap and debris generated out of pertaining to the fitness of the
construction work should be vehicle/equipment and valid driving
removed/disposed off at a regular license of the driver etc. are available.
interval as directed. Emergency exit
should be provided in case of iii) The passes should be serially
blockade of primary exit. numbered with address, contractor
name, identification mark, signature of
vi) Suitable warning notices and also the the worker etc.
routes to and from welfare facilities
should be displayed prominently. iv) Special colour code for passes should
be used for persons entering different
Page 248 of 674

areas like Administrative Block, Unit taken with two copies (one for
area, Project Area (wherever preparing the pass and other for
applicable). attachment with gate register).
Specific advice and recommendation
v) Contractor workers engaged on of User Department may be given due
routine basis for long periods should cognizance. Relevant details are to
be provided with monthly photo pass. be written. The pass should be
collected back at the gate after days
vi) Special permit is required separately work.
for working beyond normal working
hours and holidays. 5.4.2 Tank Truck Loading (TTL)
Operation :
B. Gate Entry
At the loading / unloading location, a large
i) Entry of the contractors employees no. of Tank Trucks of petroleum products
should be permitted with valid gate enter the installation. Crew members are
passes only. generally not regular entrants. The
procedure should be as follows:
ii) Entry of contractors workers should
be allowed in presence of authorized i) The gate pass should be issued to the
representative of contractor. individual crew members on written
request of the transporter
iii) Records of persons at the time of mentioning TT registration nos.,
entry/exit should be maintained. License and certificate of training as
per MV rule 9.
iv) At the entry gate of the location, a
physical checking for non-carrying of ii) Character & Antecedent (C & A)
lighter, matchboxes, explosives etc. verification of the TTL crew through
should be carried out. local police is to be done preferably
and record maintained.
v) Gate passes/Identity Cards should be
displayed on persons at all the times. iii) For loading/unloading purpose,
register entry at security gate is
vi) For Mega-projects at existing / made before allowing entry into the
operating installations, it is preferable premises with recording of names of
to have a separate gate for entry of crew members, time of entry, pass
contractor workers and also the Sr. No., TT no. etc.
project areas should be segregated
fencing from operational area by iv) For loading/unloading, crew is allowed
fencing / other physical means. entry alongwith TT only, after
checking of TT from
vii) No vehicle should be allowed to explosive/security point of view.
enter in an operational area without
proper flame arrestor. v) Out time, invoice no., Destination etc.,
are recorded while TTs go out of the
viii) Awareness on Safety through security gate.
training / posters etc. highlighting Do's
and Don'ts should be spread within 5.5 TRAINING
entire contractor workforce.
Video/Audio tapes on Safety Topics Training is to educate contractor workforce
should be played preferably. on various hazards associated with the
job/workplace and on the respective
ix) For occasionally engaged labourers preventive / mitigation measures to avoid
such as for material handling etc., untoward incidents.
spot photograph may be preferably
Page 249 of 674

i) Workers should be adequately and equipment and protective
suitably: clothing provided to the worker;
(a) informed of potential safety and (f) general measures for personal
health hazards to which they may hygiene and health protection;
be exposed to at their workplace;
(g) fire precautions to be taken;
(b) instructed and trained in the
measures available for the (h) action to be taken in case of an
prevention, control and protection emergency;
against those hazards.
(i) requirements of relevant safety
ii) No person should be employed in any and health rules and regulations.
work at a workplace unless that
person has received the necessary Copies of the relevant safety and health
information, instruction and training so rules, regulations and procedures should be
as to be able to do the work available to workers upon the
competently and safely. The commencement of and upon any change of
competent authority should, in employment.
collaboration with employers, promote
training programs to enable all the
workers to read and understand the
information / instructions related to 5.5.1 Training Techniques
safety and health matters.
a) Lectures
iii) The information, instruction and
training should be given in a language This technique should be applied when it is
understood by the worker and written, required to transfer information in local
Oral, visual and participative language to a large contractor workforce
approaches should be used to ensure with controlled content and time.
that the worker has assimilated the
information. b) Case Study
iv) Every worker should receive This is an effective technique based on the
instruction and training regarding the presentation of case of real events by
general safety and health measures Trainer to highlight probable causes like
common to the workplace. This Human Error, ignorance about the job etc.
should include:
c) Videos
(a) general rights and duties of
workers at the workplace; Videos, an effective technique of
communication, should be used to display
(b) means of access and egress the right techniques of performing a task in a
both during normal working and safe manner and hazards associated with a
in an emergency; job.
(c) measures for good d) Demonstration at site

housekeeping;
Right way to do a job should invariably be
(d) location and proper use of demonstrated to workers at the site itself.
welfare amenities and first aid The right way is also a safe way. Hazards
facilities provided; due to wrong procedures, short cuts and
their adverse effects etc. should also be
(e) proper use and care of the items highlighted.
of personnel protective
Page 250 of 674

5.5.2 Training/Awareness Module and
Frequency iii) Importance of First Aid fire
fighting equipment, their use &
A. General Safety Training to all operations
categories of contractor employees
should be imparted before induction iv) Communication system at the
and annually thereafter. No person installation
should be allowed to enter the
installation without undergoing this v) Fire / Accident Reporting
training. This training program may procedure
cover:
vi) General Safety rules
i) Mandatory uses of PPE like Cotton
clothes, Helmet, Safety Shoes, Safety vii) Safety Measures during
Belts etc. execution of job such as:
ii) Probable Hazards - Welding / Cutting / Grinding

- Working at height
iii) Important Telephone No / Escape - Confined space entry
route - X ray / radiation
- Erection / Dismantling of
iv) First Aid scaffolding
- Tank construction and repairs
v) Use of Fire extinguisher - Handling of chemicals etc.
The contractor workers, if engaged in viii) Importance & use of PPE

operation of the plants/facilities, should be
trained in line with Clause No. 4.6 of OISD- ix) Emergency Routes
GDN-206 on Safety Management System.
For other categories of contractor workers, x) Assembly Points
training modules for different category
employees are as follows: xi) Job Specific Training
B. Contractor Supervisor D. Consultant / Contractor
Contractor Supervisor should be trained in Awareness program should be carried out

accordance with the provision of clause no. for Consultant / Contractor at the time of
5.1.1.2, 5.2.7, 5.3.10, 5.6.12 and 5.7.8 of induction. This program should cover at
OISD-STD-154 on 'Safety Aspects in least the following:
Functional Training'
i) Responsibility of contractor for safety
C. Contractor Worker of their personnel and work area
Yearly training programme should be carried ii) Hazardous property of Petroleum

out for contractor worker and the records products and chemical used
should be maintained. The training
programme should cover at least the iii) Communication system
following:
iv) Fire / Accident Reporting procedure
i) Worker responsibility for safety
of himself and work area. v) Medical facility available
ii) Associated hazards with the job vi) Statutory requirements

and job area including
electrical shock hazards.
Page 251 of 674

vii) Importance of First Aid equipment and through site inspection using ready-made
required at the site check lists to ensure that contractors /
agencies abide by the safety rules and
viii) Work Permit system norms while working at operating /
construction sites.
ix) Direct/ Indirect losses due to accident
A checklist, while carrying out different type
x) Safety Measures while executing the of jobs, should be developed based on
jobs such as: hazards associated with the job being
performed and requirements as per OISD-
- Welding / Cutting / Grinding GDN-192 on "Safety Practices during
- Working at height Construction". Typical format is enclosed at
- Confined space entry Annexure II, which should be modified to suit
- X ray / radiation the requirement of the site / job to be done.
- Erection / Dismantling of
scaffolding Before starting the work and at regular
- Tank construction and repairs intervals thereafter, Contractors
- Handling of chemicals etc. Supervisor/safety Officer and Owner's
- electrical jobs representative / Engineer-in charge/safety
Officer should inspect as per the checklist so
xi) Safety training needs of their prepared to ensure that contractor has
supervisors and workers prepared to start the work with all safety
precaution required for safe execution of job.
xii) Importance & Use of PPE at the site
5.7 PENALTIES FOR NON-
xiii) General Safety rules at the installation COMPLIANCE
Financial or other type of penalties like

seizure of gate passes, stoppage of work for
E Security Personnel a limited period etc. may be levied on the
contractors or their workers for non-
Training program should be carried out for compliance of safety rules. A provision of
Security personnel at the time of induction suitable accident severity based penalty
and annually thereafter and the records clause for contractor may be incorporated to
should be maintained. The training program ensure adherence of systems and
should cover at least the following: procedures. A few of the usual non-
compliance are as follows:
i) Layout of Plant and Facilities
ii) Vulnerable locations -- Non-usage of PPEs like Safety helmet /
iii) Safety regulations (Statutory and in Safety shoes / Safety goggles /
company) Respiratory protection etc. by the
iv) Fire Protection Facilities and contractor personnel
Locations
v) Role in case of Fire / Disaster -- Non-usage of the safety belt and life line
vi) Emergency Procedure and Drills by the workers while working at height
vii) Industrial First Aid
viii) Use of Personnel Protective -- Non-provision of basic safety
Equipment requirement such as 24 V lamp for
ix) Disaster Management Plan working in confined space, uncertified /
non standard lifting tools, earth leakage
5.6 INSPECTION / AUDIT protection & earthing connections for
electrical appliances as per Indian
Inspection / Audit is a tool to evaluate Electricity Rules, emergency isolation
compliance of all safety requirements. Most switches etc.
of the information could be gathered
Page 252 of 674

-- Violation of Safety Permit conditions like attend these meetings on random basis.
Fire fighting equipment Tool box meeting should be conducted more
frequently depending upon circumstances.
-- Non-barricading of area while rigging, Record of the same can be maintained in
digging etc. the following typical format.
-- Working without valid work permit TOOLBOX MEETING FORM
-- Unauthorised road closure/blockage SUBJECT :

PRESENTER :
5.8 INCIDENT REPORTING AND DATE :
INVESTIGATION SYSTEM TIME : From.. To..
CONTENT IN BRIEF :
All the incidents including near-miss should
be reported immediately by contractors Participants Name Signature
Supervisor to Contractor and owners
Supervisor/Engineer-in-charge, who should -------------------- ---------------------
inform to Owners Safety Officer and owners -------------------- ---------------------
Management. Owners Safety Department -------------------- ---------------------
will be required for onward reporting as per
OISD, Statutory requirements. 5.9.2 Site Safety Committee Meeting
All accidents regardless of the extent of Primary purpose of this safety committee is
injury or damage should be investigated in to enable owner, contractor and workers to
order to find probable causes, lessons learnt work together to monitor the site safety and
thereof and remedial measures required to health plan so as to prevent accidents and
prevent its recurrence. improve working condition on site. Its size
and membership will depend on the size and
The incident investigation should be done as nature of job.
per provision of clause no. 4.12 of OISD-
GDN-206 on 'Safety Management System' . The safety committee should include
All the recommendations of investigation / representatives of owner, consultant,
Enquiry Report need to be monitored closely contractor identified as safety
for its implementation. A proper record officer/supervisor. It should be headed by
needs to be maintained to ensure Engineer-in-charge.
implementation of all the recommendations
and same should be reviewed from time to The safety committee should have regular
time. and frequent meetings, atleast fortnightly, to
discuss the safety and health program on
5.9 SAFETY COMMITTEE MEETINGS site and to make suggestions for
improvement. The meetings should be
Following three type of safety committee documented with a time bound action plan.
meetings should be held aiming at raising The functions carried out by safety
the level of safety consciousness at the site: committee should include:
5.9.1 Toolbox meeting i) Review compliance of pending items

of last Safety meetings.
To maintain awareness, update training and
convey important safety and health ii) Consideration of the reports of safety
information, contractor supervisors should personnel.
conduct tool box meetings at least weekly
and also prior to start of any work. All the iii) Discussion of accident/near-miss and
contractor workers should attend this illness reports in order to make
meeting. The owners supervisor/Engineer- appropriate recommendation for
in-charge and safety officers should also prevention.
Page 253 of 674

iv) Examination/evaluation of suggestions 2) OISD-GDN-192 on Safety During
made by workers. Construction
v) Dissemination of acquired knowledge 3) OISD-STD-155 Part(I&II) on

through training programs and Personnel Protective Equipment
information sharing sessions.
4) Building & Other Construction
vi) Discussion & review of Fire Prevention workers (Regulation of Employment
& Disaster Management Plan. & Condition of Service) Act 1996
vii) To send recommendation to

Apex Body for
consideration/approvals.
5.9.3 Safety Review Meeting by

Location Head
This meeting should be headed by the

Location head and attended by Owners
Supervisor/Engineer-in-charge, owners
safety Officer and all concerned department
heads. Prime purpose of this review is to
ensure that all the recommendations of
various committees are being complied with
and to take decisions on critical points
raised. This meeting should take place at
least once in every quarter. All the
investigation reports/ audit findings with
status of implementation of
recommendations should be discussed.
5.10 SAFETY EQUIPMENT /

PERSONNEL PROTECTIVE
EQUIPMENT
The type of safety equipment to be used is

decided based on the job requirement.
Selection should be made based on OISD-
GDN-192, OISD-STD-155 (Part I & II) and
the job requirement. Safety equipment /
Personnel Protective Equipment (PPE) shall
be of approved make. Contractor shall
provide necessary training to each employee
regarding proper usage and upkeep of PPE
including its limitation.
A register showing stock and issue of PPE

should be maintained by the contractor at
site and must be available for inspection.
6.0 REFERENCES
1) OISD-GDN-206 on Safety
Management System
Page 254 of 674

ANNEXURE I
LIST OF SAFETY CODES FOR CIVIL WORKS PUBLISHED BY BUREAU OF
INDIAN STANDARDS
Sl.no. Code No. Title

1 IS: 818 Code of Practice for Safety and Health Requirements in Electric
and Gas Welding and Cutting Operations First Revision.
2 IS: 875 Code of practice for Structural safety of buildings: Masonry

walls
3 IS: 933 Specification for Portable Chemical Fire Extinguisher, Foam

Type Second Revision.
4 IS: 1179 Specification for Equipment for Eye and Face Protection during
Welding First Revision
5 IS: 1904 Code of practice for Structural safety of buildings: Shallow

foundations
6 IS: 1905 Code of practice for Structural safety of buildings: Masonry

walls
7 IS: 1989 Part II Leather Safety Boots and shoes for heavy metal industry
8 IS: 2171 Specification for Portable Fire Extinguishers, Dry Powder Type
Second Revision
9 IS: 2361 Specification of Building Grips First Revision
10 IS: 2750 Specification for Steel Scaffoldings
11 IS: 2925 Specification for Industrial Safety Helmets First Revision
12 IS: 3016 Code of Practice for Fires Precautions in Welding and Cutting
Operations First Revision
13 IS: 3521 Industrial Safety Belts and harnesses
14 IS: 3696 Part I Safety Code for Scaffolds and Ladders: Part I Scaffolds
15 IS: 3696 Part II Safety Code for Scaffolds and Ladders: Part II Ladders
16 IS: 3764 Safety Code for Excavation Work
17 IS: 4014 Part I & II Code of Practice for Steel Tubular Scaffolding
18 IS: 4081 Safety Code for Blasting and Related Drilling Operations
19 IS: 4082 Recommendations on stacking and storage of construction

materials at site
20 IS: 4130 Safety Code for Demolition of Buildings First Revision
21 IS: 4138 Safety Code for working in compressed air First Revision
Page 255 of 674

22 IS: 4756 Safety Code for Tunneling works
23 IS: 4912 Safety requirements for Floor and Wall openings, Railings and
toe boards First Revision
24 IS: 5216 Part I & II Recommendations on safety procedures and practices in

electrical work
25 IS: 5121 Safety code for piling and other deep foundations
26 IS: 5916 Safety Code for Construction involving use of Hot Bituminous
materials
27 IS: 6994 Part I Specifications for safety gloves: Part I Leather and Cotton
gloves
28 IS: 5983 Specification for Eye Protectors First Revision
29 IS: 6922 Criteria for safety and design of structures subject to

underground blasts
30 IS: 7155 Code of recommended practices for conveyor safety
31 IS: 7205 Safety Code for Erection on Structural Steel Works
32 IS: 7069 Safety Code for Handling and Storage of Building Materials
33 IS: 7293 Safety Code for Working with Construction Machinery
34 IS: 7323 Guidelines for operation of Reservoirs
35 IS: 7969 Safety Code for handling and storage of building materials
36 IS: 8758 Recommendation for Fire Precautionary Measures in

construction of Temporary Structures and Pandals
37 IS: 8989 Safety Code for Erection of Concrete Framed Structures
38 IS: 9706 Code of Practices for construction of Arial ropeways for

transportation of material
39 IS: 9759 Guidelines for de-watering during construction
40 IS: 9944 Recommendations on safe working load for natural and

manmade fibre rope slings
41 IS: 10667 Guide for selection of industrial safety equipment for protection
foot and leg
42 IS: 10291 Safety Code for dress divers in civil engineering works
43 IS: 10386 Part I Safety Code for Construction, Operation and Maintenance for
River Valley Projects
44 IS: 10386 Part II Safety Code for Construction, Operation and Maintenance for
Page 256 of 674

River Valley Projects
45 IS: 11057 Code of Practice for Industrial Safety Nets
46 IS: 13415 Code of Practice on safety for Protective barriers in and around
building
47 IS: 13416 Recommendations for preventive measures against hazards at

working places
Statutory Regulations
Latest Statutory Acts and Rules, as given below, may be referred:-
1. The Petroleum Acts 1934 and Petroleum Rules 2002

2. The Factory Act, 1948 (As amended by Factory Amendment Act 1987) and concerned
Factory Rules
3. The Water (Prevention and Control of Pollution) Act 1974 & Rules 1975
4. The Environment (Protection) Act 1986
5. The Manufacturing, Storage and Import of Hazardous Rules 1989
6. The Hazardous Wastes Management (Management & Handling) Rules 1989
7. The Indian Electricity Act 1901 and Rules 1956
8. The Indian Explosive Acts, 1884 & The Indian Explosive Rules 1983
9. The Gas Cylinder Rules 1981and the static & Mobile Pressure Vessels (Unfired) Rules 1981
10. The Indian Boiler Act 1923 and Regulations 1950
11. The Public Liability Act 1991 as amended in 1992
12. The Motor Vehicle act 1988 and Central Motor Vehicle rules 1989
13. Building & Other Construction workers (Regulation of Employment & Condition of Service)
Act 1996
In addition to above, various other statutory acts like EPF, ESIS, Minimum wage act and other
local statutory requirements shall also be complied with.
Page 257 of 674

ANNEXURE II
CHECK LIST FOR SAFETY INSPECTION / AUDIT
Job ___________ Location _______________ Date of Audit______Frequency _____________
Inspected by __________________ Contractor (s) __________________________
Sl.no. ITEM YES NO NA REMARKS /

ACTION
1.0 PERSONNEL PROTECTIVE EQUIPMENT (PPE):
Are following PPEs being used as per the job requirements?
1.1 Safety Helmets
1.2 Safety Shoes
1.3 Gum Boots
1.4 Safety Belts with life line
1.5 Gloves
1.6 Ear Plug
1.7 Goggles
1.8 Shield Glass
1.9 Face Protection
1.10 Breathing Apparatus
1.11 Canister Mask
1.12 Hand wash / Eye wash/ Respirating filter /

cloth
1.13 Boiler Suit
1.14 Others
2.0 HOUSE KEEPING
2.1 Whether Waste Bins are provided / used
2.2 Are Passageways / Walkways clear?
2.3 Is General neatness O.K.?
2.4 Is the Ground free from oil, grease etc.

and is not found to be slippery?
2.5 Others
Page 258 of 674

3.0 EXCAVATION
3.1 Whether soil stability is checked?
3.2 Whether proper shoring for the excavation

is provided to prevent cave-in for side of
slope >45 Degree?
3.3 Whether proper precautions have been

taken if the excavation is adjoining to
heavy structure like building, street and
roadways?
3.4 While excavating whether proper slope

usually 450 & suitable benches of 0.5 m
width at each 1.5 m depth are provided?
3.5 Whether barricading of 1m height with

glowing caution board is provided for
excavation beyond 1.5m depth?
3.6 Whether excavating earth is placed

beyond 1m of the edge of the trench?
3.7 Whether heavy vehicle movement is

restricted to come too close to the
excavating area?
3.8 Whether necessary precaution is taken

for underground pipes, sewers, cables by
contractors?
3.9 Whether excavation hot work permit is

taken?
3.10 Whether extra precaution is taken for

bailing out water properly while
excavating?
3.11 During rains whether the excavation is

done with extra precaution to prevent
caving in?
3.12 Whether two separate entry/ exit points

with necessary ladders / steps, as per
requirement, have been provided?
3.13 Whether one person is available at all the

time to communicate any hazards noticed
with workers working in deep trenches or
excavation?
3.14 Whether necessary precautions like
Page 259 of 674

regular gas testing are being taken in
areas having hydrocarbons and LPG so
that no gas accumulation takes place in
the trenches.
3.15 Whether IS: 4081-1986 & Indian

Explosive act & rules for storage, handling
& carrying of explosive material and
execution of blasting operation is
followed?
3.16 Whether in case of mechanised

excavation, caution board is provided for
dos and donts like Nobody to enter
within one meter of the extreme reach?
3.17 Whether the following are inspected

during excavation work :-
a) Boulder formation encountered
b) Collapsing / development of cracks of
sides
c) Marked damage to support
d) Unexpected fall of ground
e) Inspection of site after each blast.
3.18 Others
4.0 PERMITS
4.1 Whether valid work permit is issued to

start any work?
4.2 Whether all conditions of the permit are

fulfilled before starting the job?
4.3 As noted in the permit, whether

compliance of all the recommendations
are ensured?
4.4 Whether permits are available at work site

all the times?
4.5 Whether hot work permit registered in fire

station?
4.6 Whether permits are being closed after

the completion of job?
4.7 Others
5.0 SAFETY IN CUTTING / WELDING/GRINDING
5.1 Whether LPG / Oxygen / Acetylene/ Gas
Page 260 of 674

cylinders are kept outside only while
working in confined space?
5.2 Are Acetylene /LPG cylinders kept in

upright position and secured at
designated places under shed wet
gunny bags wrapped around it if the same
is under sun at designated place?
5.3 Check cylinder and cylinder valves for any

kind of damage?
5.4 Whether protective valves are kept on

cylinder while not in use?
5.5 Whether proper means and method for

transportation of cylinders to avoid
dropping and rolling are being adopted /
followed?
5.6 Whether gas cylinders, regulators are

kept away/free from oil and grease?
5.7 Whether all hoses were found to be free

of any damage or crack?
5.8 Whether oxygen and acetylene cylinders

are stored separately?
5.9 Whether color coding is being used for

easy identification of different type of
cylinders and hoses?
5.10 Whether cylinder keys are available near

the cylinder?
5.11 Whether gas torches with NRV with flash

back arrestor of approved make are only
being used?
5.12 Whether pressure gauges are in working

condition and checked from time to time?
5.13 Whether welding shields are used while

welding?
5.14 Whether proper earthing for welding

machines are provided?
5.15 Whether power is taken from approved

sources (welding receptacles)?
5.16 Whether welding receptacles are properly

grounded?
Page 261 of 674

5.17 Whether welding cables are maintained in
good condition and without any joints/
cuts?
5.18 Whether to avoid short circuit, welding

machines are protected against rain?
5.19 Whether earth connectors are securely

connected to the job and not to the
adjoining pipeline or structure?
5.20 Whether flame arrestor of DG set is of

approved make and quality?
5.21 Others
6.0 SAND / SHOT BLASTING
6.1 Whether sand blasting is used only after

getting approval from competent
authority?
6.2 Whether air compressor used for sand /

shot blasting are positioned away from
work place?
6.3 Whether exhaust of the prime mover is

directed away from the work place?
6.4 Whether in case of motor driven

compressor, the body of the motor as well
as the compressor is properly earthed?
6.5 Whether line operator of sand/shot

blasting wear suitable PPEs including
mask?
6.6 Whether adequate measures are adopted

to confine dust/spray particles?
6.7 Whether adequate measures are taken

for proper ventilation while the work is
done in confined space?
6.8 Others
7.0 SAFETY WHILE WORKING AT HEIGHTS / SCAFFOLDING / LADDERS
7.1 Whether work permit is obtained to take

up work at height above 3 mts?
7.2 Whether steel pipes scaffoldings are used

in unit/off site areas?
Page 262 of 674

7.3 Whether provision for suitable platform
with all scaffoldings are made? Whether
its construction is as per specification with
toe board and railing?
7.4 Whether the area below working at height

is cordoned?
7.5 Whether suitable platform is provided?
7.6 Whether ISI approved quality and good

condition safety belts are used while
working at heights?
7.7 Whether life line of safety belt is

Anchored to an independent secured
support capable of withstanding load of a
falling person?
7.8 Whether the area around the scaffold is

cordoned off to prohibit the entry of
unauthorized person?
7.9 Whether ropes used are of good condition

and adequate strength free of defects?
7.10 Whether ladder is placed at secured and

leveled surface?
7.11 Whether it is extended 1.5 Mts. Above the

landing point?
7.12 Whether ladder used are of adequate

length and tying short ladder is avoided?
7.13 Whether metallic ladders are placed away

from electrical system?
7.14 Whether tools or materials are removed

after completion of the days job at
heights?
7.15 Whether a valid permit is obtained before

taking up work on asbestos or fragile
roof?
7.16 Whether sufficient precaution is taken

while working on fragile roof?
7.17 Whether provision is made to arrange

duck ladder, crawling board for working at
fragile roof?
7.18 Whether scaffolding has been erected on

rigid / firm / levelled surfaces only?
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7.19 Whether scaffold has been inspected by
competent person prior to being put in
use?
7.20 Whether the scaffolding has been

designed for the load to be borne?
7.21 Whether the erection and dismantling of

the scaffolding is being done only by
trained persons and under supervision?
7.22 Whether safety net with proper working

arrangement and life line has been
provided?
7.23 Others
8.0 SAFETY IN CONFINED SPACE
8.1 Whether a permit is obtained to enter a

confined space?
8.2 Whether gas test for hydrocarbon, toxic

gas, oxygen level is obtained before
entering any confined space?
8.3 Whether adequate oxygen level is

ensured in confined space before
entering? If not, whether all precaution
like using of Breathing Apparatus set is
ensured?
8.4 Whether, in case of chance of ingress of

hydrocarbon gases / toxic gases,
Personnel Monitoring System (PMS) is
used or not?
8.5 Whether only in presence of a supervisor,

worker enters in confined space?
8.6 Whether provision of sufficient means of

entry and exit is available?
8.7 Whether provision of ventilation to remove

welding fumes, dust, exhaust gases are
made?
8.8 Whether provision of 24V (Hand lamps

with cage as per OISD-STD-155) light for
working inside space is made?
Page 264 of 674

8.9 Is it strictly ensured that a stand-by
trained person is standing outside before
a person enters a confined space and
communication is being maintained all the
time with workers working inside?
8.10 Whether life belt with one end under

control of stand-by person outside is kept
while working in confined space?
8.11 Whether Personnel protective Equipment

are in good condition as specified in the
permit?
8.12 Whether absence of Hydrogen Sulfide,

CO or other toxic gas is ensured before
entering into a confined space? If yes,
whether proper required PPE like BA,
Gas Mask are used.
8.13 Whether boxing up is being done only as

per the approved procedures and by
competent persons?
8.14 Whether all the safety precautions listed

in OISD-GDN-192 are taken while
working in sewers, OWS etc.?
8.15 Whether proper house keeping is being
maintained inside the confined space?
8.16 Whether training has been provided to

workers working in the confined space
and the workers only of sound health are
being asked to work in the confined
space?
8.17 Others
9.0 SAFETY IN MATERIAL HANDLING
9.1 Whether all lifting tools, tackles,

machines, chains, ropes etc. are of sound
construction, made of sound material and
maintained in good condition?
9.2 Whether safe working load, date of testing

visibly marked/painted on the equipment?
9.3 Whether lifting tools, tackles are of

adequate strength for the load to be
handled?
9.4 Whether all parts including the working

gears fixed or movable of every lifting
machine, chain, rope, tackles specify the
Page 265 of 674

following condition:
a) Thoroughly examined by competent

person at least once a year or such
interval as required by statutory
authority.
b) Document of such examination are

maintained and produced to owner
supervisor before use of particular
equipment?
9.5 Whether chain blocks and cables are

inspected before each use to assure their
sound condition?
9.6 Whether hoist and lift if used are:
a) Properly maintained and thoroughly

examined by competent authority at
least once in every year.
b) A register to be maintained to record

particulars of such examination in
prescribed forms and shall be
produced to the owner supervisor
before use.
9.7 Whether area below the movement of

boom of crane is cleared to avoid injury
from falling objects?
9.8 Whether it is ensured that crew of truck

leave the truck in crane handling area
before starting loading / unloading, if not
involved in rigging operation?
9.9 Whether transporting material from one

place to another is done by suitable
means?
9.10 Whether carrier with sufficient capacity

without projecting parts is used for
transporting materials?
9.11 Whether riggers engaged are well trained

and conversant with signaling procedures
including night signalling if required?
9.12 Whether permission of authorized person

is obtained before working on or near an
overhead crane?
9.13 Whether trained riggers are available all

the time along with crane?
Page 266 of 674

9.14 Whether barricading has been done to
ensure no unauthorised person enters in
the working area of the crane?
9.15 Whether lifting plan has been prepared

and approved before start of the work?
9.16 Whether route of crane movement has

been planned before the crane moves out
of the garage?
9.17 Whether it has been ensured that no

electrical cable come within 3 metres or
safe distance from the boom of the
crane?
9.18 Whether boom is being kept in the

horizontal position or locked while idling?
9.19 Whether material is being stacked /

destacked in trucks with the help of
wedges to ensure no slippage while
loading / unloading takes place?
9.20 Whether the forklift / crane is being

operated only by trained person?
9.21 Others
10.0 ELECTRICAL SAFETY
10.1 Has the Electrical Line Clearance

procedure been followed involving
electrical and other concerned Dept. and
filling of formats?
10.2 Have Danger Signs with Voltage rating/

Men at work signboards been displayed
at both Sub Station as well as the work
site?
10.3 Has the contractor worker understood the

electrical circuit on which he is going to
work with probable electrical hazards and
mitigation measures to be adopted?
10.4 Whether contractor has engaged

electrician (s) having valid electrical
licence in line with provisions in Indian
Electricity Rules?
Page 267 of 674

10.5 Have all checks prior to switching
operation been carried out and
authorisation of owner/ user section
obtained subsequently?
10.6 Have all earthing links on electrical

conductors removed before charging the
line/ apparatus?
10.7 Have PPE as prescribed under Indian

Electricity Rules been in place, kept
healthy and used?
10.8 Are earthing and bonding arrangement of

non-current carrying metallic parts in line
with provisions of Indian Electricity Rules
1956 amended time to time as IS:
3043?
10.9 Have electrical part of OISD-GDN-192

and Clause No. 9.0 for Temporary
installations in OISD-173 been
understood and followed wherever
applicable?
10.10 Are flexible wires having voltage of 240

volts above earth potential taken through
PVC conduits?
10.11 Whether portable hand lamps with a

voltage rating of not more than 24 volts
used with flameproof enclosures in
confined spaces within columns, vessels
etc?
10.12 Have the Switches, MCBs, fuses etc.

been inspected for proper ratings?
10.13 Has Earth Leakage Circuit Breaker (

ELCB) been used on the incoming side to
protect against leakage of current? Is the
device tested every time the work is
started?
10.14 Whether all portable appliances are

provided with insulated Three pin Plugs
and socket arrangement?
10.15 Whether industrial type extension boards

and plug sockets are used?
10.16 Has the electrical equipment brought to

site by contractor been inspected by
owners supervisor/ safety officer for
damage/cuts/abrasion etc? Is record of
Page 268 of 674

Insulation Resistance, wherever required ,
being kept?
10.17 Have standard practices for termination of

conductors/ cables been followed (e.g.
use of proper lugs, crimping tool, cable
glands etc)? Is cable armour in continuity
from feeding point to load?
10.18 Are the Contractor supervisor and

workmen well acquainted with first aid for
electrical shock?
10.19 Are the wires/ cables identifiable along

their route towards the load by using
colour coding and/or markers?
10.20 Others
11.0 ROAD WORK
11.1 Whether site is barricaded and provided

with warning signs including night warning
lamps/ self glowing markers at
appropriate location for diversion of
traffic?
11.2 Whether mixing aggregates with bitumen

is done with the help of batch mixing
plants? If no, whether adequate
precautions have been taken?
11.3 Whether road rollers, bitumen sprayers,

pavement finishers are driven by
experienced drivers with valid driving
licenses?
11.4 Whether the worker handling hot bitumen

sprayers or spreading bitumen aggregate
mix or mixing bitumen with aggregate are
provided with PVC hand gloves rubber
shoes with pegging upto knee joints?
11.5 Others
12.0 FORM WORK, REINFORCEMENT
12.1 Whether form work, shuttering, shoring

etc. are adequately designed and
provided to erect the structure and to
support the expected load?
Page 269 of 674

12.2 Whether staging (support) for shuttering is
designed for loads like worker movement,
impact load and other incidental loads
during construction?
12.3 Whether workers use PPEs at work site?
12.4 Whether all safety procedures are

adopted while cutting rod?
12.5 Whether proper staging and bundling is

provided for supplying rods at height?
12.6 Whether sufficient cross bracings are

provided for high staging works at
vulnerable points?
12.7 Others
13.0 CONCRETING
13.1 Whether the concreting area is

barricaded?
13.2 Whether vibrator hoses, pumping

concrete accessories are in healthy
condition and mechanically strong?
13.3 Whether it is ensured that no pipe line in

concrete pumping system is attached to
any temporary strut such as scaffolds
etc.?
13.4 Whether it is checked that safety guards

around moving parts are provided in
concrete mixer/ machines?
13.5 Whether earthing of electrical mixers,

vibrator etc. are checked?
13.6 Whether entry of unauthorised person in

the concreting area is restricted?
13.7 Whether adequate lighting arrangement is

made in the concreting area if working
during night?
13.8 Whether PPEs like gum boots, gloves and

dust masks etc. are being used?
13.9 For overhead or underground work,

whether form work and shuttering have
been checked so that the same do not
collapse during concreting?
Page 270 of 674

13.10 Others
14.0 DEMOLISHING (DEMOLISHING BY BLAST NOT CONSIDERED)
14.1 Has the stability of structure been

examined by competent person and found
OK?
14.2 Are non-sparking tools being used, if

required?
14.3 Is intermittent clearing operation being

done to keep the area reasonably tidy and
clean?
14.4 Whether effective barricading has been

provided?
14.5 Whether Electrical and other facilities like

water, oil, gas pipelines have been
isolated/protected?
14.6 Whether the plan of demolition (including

sequence of activities) has been prepared
and approved prior to start of the work?
14.7 Others
15.0 RADIOGRAPHY
15.1 Are safety precautions for handling of

source as per guidelines of BARC being
followed?
15.2 Is the potency of the source being used

within acceptable limits as per the BARC
regulations?
15.3 Is the area being cordoned with proper

signs during radiography?
15.4 Does proper place exist as per BARC

regulations for storage of source /
Personnel safety equipment?
15.5 Does the radiographer has valid

certificate of radiography from competent
authority (BARC)?
15.6 Is radiographer using Exposure Meter /

Dosi Meter?
15.7 Whether minimum occupancy of the
Page 271 of 674

premises / workplace is being ensured
while radiography is in progress?
15.8 Is permit system being followed?
15.9 Others
16.0 ADDITIONAL SAFETY PRECAUTION FOR UNITS WITH HYDROCARBONS
16.1 Are jobs being carried out with a valid

work permit only as per OISD-STD-105
"Work Permit System".
16.2 Is smoking prohibited in all places

containing combustible or flammable
materials and "No Smoking" notices
prominently displayed.
16.3
Are only approved type electrical
installations and equipment, including
portable lamps, being used?
16.4 Are oily rags, waste, wooden materials

and clothes or other substances liable to
spontaneous ignition being removed?
16.5 Are the combustible materials properly

shielded in case same cannot be
removed from the area?
16.6 Has welding screens (like metal/asbestos/

water curtain) been put up to protect other
equipment / facilities/ OWS/ drains in
adjoining areas against flying sparks, as
may be required?
16.7 Is Gas-testing being done with the means

of a calibrated Gas detection Meter prior
to start of Hot work and being done
subsequently at regular intervals as per
the requirement?
16.8 Are regular inspections being done of
places where there are fire risks like in the
vicinity of heating appliances, electrical
installations and conductors, stores of
flammable and combustible materials,
welding and cutting operations?
16.9 Are fire-extinguishing equipment being

placed at strategic locations and are kept
well maintained and inspected at suitable
intervals by a competent person.
16.10 Are access to fire-extinguishing

equipment such as hydrants, portable
Page 272 of 674

extinguishers and connections for hoses
kept clear at all times?
16.11 Are all supervisors and a sufficient

number of workers trained in the use of
fire-extinguishing equipment?
16.12 Are audio means, to give warning in case

of fire provided, audible in all parts of the
site where persons are liable to work?
16.13 Is there an effective evacuation plan in

place so that all persons are evacuated
speedily without panic?
16.14 Others
17.0 EMERGENCY PROCEDURES
17.1 Is signaling / siren system effective?
17.2 Is arrangement for rescuing affected

person adequate?
17.3 Are signs showing emergency exit route

installed?
17.4 Is emergency exit route clear of

obstacles?
17.5 Is communication system adequate?
17.6 Whether emergency vehicle with driver

has been provided to meet any
emergency situation?
17.7 Does any tie-up with hospitals or local

doctors exist?
17.8 Has the assembly point for workers in

case of emergency been identified and
earmarked?
17.9 Has training been provided to a few

workers for First Aid?
17.10 Others
18.0 WELFARE FACILITIES
18.1 Is hygienic conditions prevailing at labour

camps?
18.2 Are First Aid facilities available?
Page 273 of 674

18.3 Does proper sanitation exist at site office
and labour camps?
18.4 Does any arrangement of medical

facilities like tie ups with nearby hospital
exist?
18.5 Is proper drinking water facility available

for workmen & staff?
18.6 Are crches provided for children (if

applicable)?
18.7 Is any proper place/canteen/restroom

provided for eating food and taking rest?
18.8 Is any place earmarked for storing /

keeping clothing?
18.9 Is Adequate washing facility available?
18.10 Does proper ventilation at working place

exist?
18.11 Others
19.0 GENERAL
19.1 Are illumination levels at workplace and

passages adequate?
19.2 Is communication system adequate?
19.3 Are display and caution boards provided

at strategic locations?
19.4 Are road barriers being used for blocking

any roads/passage?
19.5 Has the structure been adequately

secured against storm/high winds during
construction/ erection?
19.6 Are the equipment properly earthed?
19.7 Are vehicles being checked like brakes,

oil, lights etc. on regular basis?
19.8 Is compressed air being used only for its

intended purpose and not for any other
purpose?
19.9 Are only proper clothes and not loose

clothes being used while working around
Page 274 of 674

machinery?
19.10 Are nails or other sharp objects being

removed or bent?
19.11 Are machine guards over moving parts of

machinery such as coupling, pulley, wheel
etc. installed?
19.12 Whether after maintenance of machinery

the guards are securely fitted before
putting into operation?
19.13 Are working platforms / gangways

provided with hand rails & toe guards?
19.14 Are swing platforms provided with chains

& secured adequately when not in use?
19.15 Are the approaches to work sites being

maintained & kept clear of obstacles?
19.16 Whether engines of equipment entering

into the operating area have exhaust and
muffler system with approved spark
arrestor?
19.17 Whether vehicles/engine driven

equipment, electrical equipment and tools
used are certified?
19.18 Whether contractors inform his workers

about hazards and safe procedures?
19.19 Whether sufficient care is taken so that

spark do not go outside working
enclosure & falls below?
19.20 Whether contractors qualified / trained

supervisor is present?
19.21 Whether all exhausts of engines are

provided with approved type of flame
arrestors and exhaust is not facing toward
the place where the workers are working?
19.22 Others
Signature of the Auditor
Page 275 of 674

44NC-4600 SPECIAL CONDITIONS OF CONTRACT CPCL. Manali Refinery
EPCC-1 Safety Regulation Part I : Section 2.2
Revision : 0 Page 2 of 42
Index
Clause No. Name

1.1 General
1.2 First Aid and Industrial Injuries
1.3 Carrying Match Boxes / Lighters and No Smoking
1.4 Work Permits
1.5 Safety Permit
1.6 Vessels Entry Permit
1.7 Entry Pass for Men and Machinery
1.8 Owners Fire Fighting Facilities
1.9 Operation of Vehicles
1.10 Contractors Barricades
1.11 Working at Heights and Scaffolding
1.12 Excavation and Trenching
1.13 Demolition
1.14 Personal Protective Equipment
1.15 Bombs, Unattended Baggages / Objects
1.16 Risky Places
1.17 Use of Hoisting and Heavy Equipment
1.18 Electrical Equipment and System
1.19 Maintenance of Safety Devices
1.21 Personal Conduct
1.22 Housekeeping
1.23 Enforcement of Safety Regulations
1.24 Radiography
1.25 Temporary Structure / Fixtures
1.26 Compressed Gas Cylinders
1.27 Actions for compliance by Contractors
1.29 Compensation in case of accidents
1.30 Emergency Response Plan
1.31 Special Conditions of Contract of Environmental Management System
1.32 Details of HSE Management System by Contractor
\\Nmumfil01\project\WIP\4401-4600\4401-4600_Procurement\draft_tenders\EPCC_1-Draft\Final_After incorporation of CPCL Comments\23_SCC_Apppendix 6_sAFETY DOCS..doc
Page 276 of 674

Revision : 0 Appendix - 6 Page 3 of 42
1.1 General
1.1.1 The Contractors employees and labour, engaged in the performance of the Work,
shall adhere to safe construction practice and guard against hazardous or unsafe
working conditions and shall comply with the Owners Safety Rules as set forth herein.
The safety rules specified herein are in addition to and not in substitution of the
applicable provisions of the Factories Act, 1948, The Contract Labour Act 1970, and
other statutory provisions, which in all cases shall apply.
1.1.2 Contractors employees shall abide by the Fire & Safety rules and regulations of the
Refinery since the job is to be done in the operational area. The contractor shall
ensure smooth construction activities/ hot works may be suspended temporarily as per
the instruction of the Engineer-in- Charge / Site Engineer / Fire & Safety Engineers.
Any extra claim for whatsoever reasons for such suspension of the work will not be
entertained.
1.1.3 The Contractor shall not be entitled to any extra or additional payment or other
compensation for the compliance with all applicable safety rules.
1.1.4 The requirement to comply with all applicable safety rules shall not entitle or justify the
Contractor to demand or claim any time or cost overrun.
1.1.5 Contractor shall post a qualified and experienced Safety Manager and provide Safety
Engineers / Officers / Supervisors in every shift, to exclusively oversee and ensure
compliance with all applicable safety rules. Contractor shall notify the name of the
safety manager / officer along with their bio-data to the head of F&S department of
owner.
1.1.6 "The contractor/his workmen/supervisor shall fully adhere to the security instructions
issued by Management from time to time.
1.1.7 It shall be the responsibility of the Contractor to keep those engaged in the Work duly
and promptly informed of any patent and latent dangers at the work sites. The
Contractor shall undertake safety talks with his staff and labourers each day before the
commencement of the work and outline dangers on site.
1.1.8 The Contractors shall not employ minors (persons below the age of 18 years) in any
part of the refinery. Also, the women workers shall not be engaged in hazardous
areas. Notwithstanding the requirement under any applicable law, the Owner or the
Engineer-in-charge, may at any time require the Contractor to subject any contract
workman, to a medical examination, generally or in relation to specific jobs such as in
canteen, tank cleaning, work at height, etc.
1.1.9 Female employee shall not be allowed to bring their child to workplace inside Refinery
premises. Contractor shall make suitable arrangement in case need, outside Refinery
premises at his own cost.
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1.1.10 The weekly safety report should be submitted in the prescribed format.
1.1.11 For any damage done by the contractors employees to the existing facilities of the
Refinery, the contractor shall be solely responsible to make good as per the instruction
of the Engineer-in-Charge / site engineer.
1.1.12 For any overhead work contractor has to arrange necessary safety belt for his
workman at his own cost.
1.1.13 Contractors are prohibited from using Cellular phones within the Refinery premises,
except to the extent permitted by the Owner by special or general order / instruction.
1.1.14 Contractors personnel shall abide by the applicable instructions as may be issued
from time to time to handle any emergency situations, such as explosion, fire, terrorist
attacks, major accident, etc. In the event of such emergencies, the Contractors
personnel shall stop their work and proceed to a safe designated place assembly point
in the area of their work and inform the Engineer-in-Charge immediately. If needed,
they shall be safely evacuated.
1.1.15 The contractor/his workmen/supervisor shall fully adhere to the security instructions
issued by management from time to time.
1.1.16 The contractor shall ensure that the workmen working with him comply with safety
rules mentioned in the Safety booklet for Contractor and their employee. Booklet can
be had free of cost from CPCLs Fire & Safety Dept.
1.1.17 Contractor personnel shall stop their work and proceed to a safer area in the event an
emergency arises they are working like, in case of fire, oil spillage, power failure, etc.
Before re-commencement of the job they should obtain fresh clearance of supervisor
of area involved.
1.1.18 List of electronic equipments/gadgets brought inside refinery by contractor for official
purpose shall be submitted to the security at Main Gate.
1.1.19 Storage of hazardous / flammable / Radio-active material in the contractor shed is

prohibited unless permitted by CPCL Engineer-in-charge.
1.2 First Aid and Industrial Injuries :
1.2.1 Contractor shall ensure maintenance of first aid facilities for his employees and those
of his sub-contractors. However, if practicable and available, emergency first-aid
treatment may be obtained from Owners First Aid Center / Emergency Care Center.
1.2.2 The contractor has to maintain the following at job site : First Aid Box with required
medicines, Safety Register, Injury Record, Records of weekly staff safety meeting,
Record for safety briefing / Training at site by contractor
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1.2.3 Contractor shall make his own arrangements for the transportation and treatment of
his employees and those of his sub-contractors suffering injuries. Name and telephone
numbers of those providing such services shall be prominently displayed in
Contractors Site Office.
1.2.4 All cases of personal injury sustained by the Contractors personnel within the
premises of the Owner shall be promptly reported in writing to the Engineer-in-charge /
Emergency Care Center / Owners Safety Department, if occurring during normal
working hours and to the Shift Manager or Emergency Care Center of the Owner if
occurring at other times. The date on which the injured workmen returned back to work
shall be reported to Engineer-in-charge / CLM cell / Owners Safety Department
1.2.5 The Contractor shall be solely responsible for any and all liability under the Workmens
Compensation Act, and other applicable laws with respect to all those engaged by the
Contractor or any sub-contractor.
1.2.6 All personnel injuries sustained by contractor personnel and damages to vehicle and
property, no matter how slight they are, shall be promptly reported to the concerned
department and safety department during normal working hours and to the Refinery
Shift Manager (RSM), other than normal working hours.
1.2.7 Medical treatment for injured contractor personnel will be entirely the responsibility of
contractors.
1.2.8 Any questions or doubts on the safety regulations enumerated in this booklet or the
generally accepted safety working practices may be clarified with the concerned
department of safety section.
1.3 Carrying Match Boxes / Lighters and No Smoking :
1.3.1 Carrying / Striking of matches, lighters inside the Owners premises or smoking within
the refinery, tank farm or dyke limits are strictly prohibited. Owners regulatory officials
shall be entitled to forthwith remove, using force if necessary, anyone violating the No
Smoking and other fire safety rules.
1.3.2 Any contractors employee who is found smoking or in the possession of matchbox or
lighter or any other means of ignition in a prohibited area will be turned out from the
premises of the Refinery. Suitable action as decided by the Management will also be
taken against the contractor/contractors employees.
1.4 Work Permits:
1.4.1 Contractor shall obtain the necessary entry permits for all his labour before
commencing the job and abide by the instructions in this regard.
1.4.2 A hot work permit issued by the concerned department or area-in-charge must cover
any work carried out within Refinery. In addition a clearance must be obtained from the
Page 279 of 674

concerned departments officer or supervisor prior to commencement of any job. A hot

permit is required for:
Any work involving open flames, spark such as welding, gas cutting, soldering,
grinding, concrete breaking, use of hurricane lamps and internal combustion driving
vehicles / Radiography / Crane lifting / Vessel entry.
Sand blasting, Trucks, Jeeps, Cranes, Lifts, Cars or any kind of vehicle driven by an
internal combustion engine or by batteries
Entry of vehicles inside battery limits of process area within tank dykes and adjacent
to pump houses and loading gantries etc.
1.4.3 The contractor shall ensure that all labourers / supervisors engaged by him will carry
identify Card/Photo Pass displayed on their person during working hours at the work
place in/out side Refinery for their easy identification
1.4.4 The contractor shall not commence the job without the valid permit for the area and for
the job. The following are the types of permits / clearances to be obtained by the
contractor as per the requirement of the job: Clearance from the area-in-charge and
shift engineer, Cold work / excavation permit, hot work permit, working at height /
depth permit, working in confined area / vessel entry permit, Electrical isolation &
Energisation permit, any other permits
1.4.5 Before starting any work, contractor shall apply at least one day ahead for fire & safety
permit for excavation, electrical, gas welding and cutting work to Engineer-in-Charge of
work/ works who in turn will arrange for such permits. The contractor shall take all the
precautions given in the permit before starting of the work to the full satisfaction of the
Engineer-in-Charge of the sections. On account of operational problem it is possible
that the clearance and permit may get delayed for which the contractor shall not ask
for the idle charges. Fire equipment such as fire extinguishers, fire hoses, control type
nozzles, personal protective equipment, Blow man air apparatus etc required for safety
precautions are to be arranged by contractor himself. However in case of emergency
on authorization from Engineer-in-Charge those items will be issued from the
Refinerys Fire Station on chargeable basis and shall be returned after completion of
the work / works in working conditions, to the full satisfaction of the Fire & Safety
Officer. In case of any damage to the fire & safety equipments issued or used by the
contractor, the contractor shall bear the cost of such damage in full and the same will
be recovered from his bills.
1.4.6 Safety measures stipulated in the respective Work Permits shall be strictly complied at
all times when within the premises of the Owner.
1.4.7 Owner reserves the right to cancel a work permit without assigning reasons. When
called upon to stop the work by the Engineer-in-charge, the Contractor shall
Page 280 of 674

immediately cease to continue the work. Before re-commencement, fresh work permit
must be obtained.
1.4.8 The Engineer-in-Charge reserves the right to terminate the contract and forfeit any or
all amounts due to him in case he finds that the precautions written on the permit are
not strictly adhered to by the Contractor.
1.4.9 Open fire such as burning of wood, coal etc. is strictly prohibited inside the battery
area.
1.4.10 While carrying out the hot job, the contractor and his workmen must ensure the
following safety measures and job should not be carried out without these :
provision of running fire water hose at work place.
1.4.11 All Flammable / combustible materials should either be removed from the work place
or should be properly protected.
1.5 Safety Permit

1.5.1 The contractors must obtain the safety permit from the area in-charge of the
concerned department, prior to the starting of the job as stated below:
a) Entry of personnel into any process area of storage facilities that has been in
service.
b) Entry into hazardous area where chemicals and hazardous materials are either in
use or stored.
1.6 Vessels Entry Permit

1.6.1 Contractor must obtain this permit prior to the start up of the job, column, vessels,
tanks or any enclosed area where the chemicals or hazardous materials is either used
or stored into it. It is the contractors duty to see that daily, the above permits are
obtained from the area-in-charge till the completion of the job. All points stipulated in
the permit must be strictly complied with.
1.6.2 Contractor shall ensure the following at the time of entry into the vessels: Stand by
persons, provision of exhaust fan & use of breathing apparatus
1.7 Entry Pass for Men and Machinery

1.7.1 Refinery is an operational area, therefore, contractor and his employee shall observe
all fire & safety regulations of the refinery and shall so organise his work as not to
interfere with the running of the Refinery in any manner whatsoever. The contractor
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shall ensure that their staff/workmen carry with them valid passes/work permits etc for
proper identification inside the battery area.
1.7.2 Contractor shall arrange to apply for and secure valid gate passes for the entry and
exit of his men, materials and equipment, including those of the sub-contractors, from
the concerned authorities of the Owner.
1.7.3 The complete job is to be carried out within the running unit of Refinery. The
Contractor shall take all necessary safety precautions and obtain required certificates/
fire permits / safety/ work permits etc. from the competent authority before carrying out
any hot works during the execution of the entire works covered by this tender. Safety
barricade wherever necessary are to be put up at his own cost.
1.7.4 The Contractor shall make his own arrangements of Gate Pass with photo for his
employees as prescribed and instructed by the Security dept. i.e. CISF, and Contract
Labour Management Cell (CLM) at his own cost, each gate pass has to be endorsed
by the Security Officer of the Refinery before the pass be used by any employee. In
case of termination of the service of any of his employee during the contractual period,
the contractor shall have to surrender the Gate Pass issued to the employees to the
Security Dept. At the end of the project all the gate passes endorsed by the Security
Dept. for use of the contractors employees shall have to be returned.
1.7.5 The contractor shall ensure that their workmen/ supervisors shall not move to other
places other than their work premises without proper permission / authorisation.
1.7.6 The contractor shall ensure verification of antecedents of the labourers/ supervisors
from Polices / Sarpanch/ other officials before they are engaged by him. No person
having adverse antecedent shall be employed by the contractor. The contractor shall
be held responsible for all the acts carried out by his workmen.
1.8 Owners Fire Fighting Facilities :

1.8.1 Fire hydrant water shall never be used by the Contractor, directly or indirectly, for any
purpose other than putting out any fire, unless otherwise permitted by the Engineer-in-
charge.
1.8.2 CPCL will provide fire protection equipment wherever it is required. The concerned
department will instruct contractor personnel the operation of such standby fire
protection equipment who are working on such jobs. In the event of an accidental fire,
it is expected of such personnel to make efforts to extinguish the fire with the standby
equipment made available and the contractor personnel should immediately get in
touch with any CPCL personnel available or, inform (Phone 101 / 3630 / 3663) or
break the nearest fire alarm points glass. In all cases accidents fires shall be reported
to the Engineer-in-charge of the area concerned.
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1.8.3 Contractor or their workmen shall not remove the fire hose / extinguishers from their
locations under any circumstances.
1.8.4 A work permit must be obtained prior to contractor personnel drawing water from the
Refinery firewater loop through Engineer-In-Charge.
1.8.5 All efforts should be made by contractor personnel to prevent occurrence of any
unwanted fire. Gasoline driven engines, trucks, tractors etc. shall not be filled with fuel
while the motor is still running.
1.8.6 Gasoline, naphtha, benzene or toluene must not be used as a cleaning agent or
solvent.
1.9 Operation of Vehicles

1.9.1 Contractor shall ensure that all State traffic rules and regulations are complied with
while motor vehicles are driven inside the refinery premises. In addition, the following
points are also outlined for compliance:
i) Speed Limit: The speed limit of all vehicles within the refinery is limited to 25
KM per hour. All vehicles must be mechanically sound and have an efficient
exhaust, silencer, horn, brakes and filler cap. Approved type of spark arrestor
shall be fitted on exhaust of vehicles. In any case, vehicle drivers should take
cognizance of load, vehicle conditions and adjusts their driving accordingly.
ii) Vehicles driven inside the refinery premises should have effective brakes
horns, lights, fuel cap, mufflers, flame arrestors etc
iii) Vehicle drivers shall always check overhead and side clearance while driving
vehicles inside refinery
iv) Overtaking of vehicle in side refinery is prohibited
v) PARKING: Park vehicles only in approved area. Vehicles must be parked in
such manner that they will not move while unattended. As a general rule,
vehicles should not be parked at road bends; in front of fire equipment sheds
and fire fighting equipment thereby blocking access to them.
vi) Vehicles shall be parked only in designated areas. No vehicle shall be parked
opposite fire hydrants or at the intersection of roads or within 10 meters of
any road corner or in front of the Fire Station.
1.9.2 No vehicles should enter into any operating area without valid fire permit followed by a
safety clearance from the area-in-charge (this includes process areas, tank farms and
loading racks).
1.9.3 Vehicles shall carry only the number of passengers or weight of load it is authorised to
carry as per law. Loads carried in trucks shall be properly secured so that they will not
accidentally fall off while vehicle is in motion.
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1.9.4 Any kind of repair work on Contractor's vehicle is not allowed inside the Battery area.
1.9.5 The contractors shall prominently display the name of their company on all the
vehicles including tractor trolleys, trucks, open jeeps, cranes which are allowed by the
Engineer-in-charge to enter inside the Refinery for carrying out the job. The display
board shall be put on front and rear side of each of the vehicle.
1.9.6 Hand cart, tractor-trolley etc should also bear the name of the contractor clearly.
1.9.7 Only open type of vehicles like jeep etc are allowed inside the Refinery having fitted
with approved spark arrestor
1.9.8 Vehicles such as tractors, cranes or forklifts shall not be used to transport people.
1.9.9 Contractors vehicles, trucks, tractor, cranes and other portable equipments e.g. Air
Compressor, DG Set, Dewatering pumps etc. used inside Refinery premises (where
Hydrocarbon is used as fuel) for execution of the job must be mechanically sound and
have an approved spark arrester and have exhaust complying pollution norms. Idle
running of those vehicles and equipments shall be avoided.
1.9.10 Photocopy of the vehicle gate pass along with the drivers photo shall be pasted on the
1.9.11 No Contractors material should be spread or stacked on any of the roads, unless it is
in the performance of the Work.
1.9.12 The Work shall, as far as is practicable, be carried out by the Contractor so as not to
interfere with the normal activities of the Owner and the normal use of all facilities in
the Owners premises.
1.10 Contractors Barricades
1.10.1 Contractor shall erect and maintain suitable barricades to guard or protect :
a) Excavations, demolitions
b) Hoisting areas
c) Areas adjudged hazardous by Contractors or Owners inspectors
d) Owners existing property liable to damage by Contractors operations, in the

opinion of the Engineer-in-charge
e) Railroad unloading spots.
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1.10.2 Contractors employees and those of its Sub-contractors shall become acquainted with
Owners barricading practice and shall respect the provisions thereof.
1.10.3 Barricades and hazardous areas situated in passages, pathways, or roads and in
areas adjacent thereto shall be conspicuously indicated including by red flasher
lanterns at night.
1.11 Working at Heights and Scaffolding
1.11.1 Suitable scaffolding should be provided for workmen for all works that cannot safely be
done from the ground or from solid construction except such short period work as can
be done safely from ladders. When a ladder is used, an extra mazdoor shall be
engaged for holding the ladder and if the ladder is used for carrying materials as well,
suitable footholds and handholds shall be given in inclination not steeper than 1 in 4 (1
horizontal and 4 vertical).
1.11.2 While working at height, at more than 2 mtrs. from floor level, following safety
precautions has to be followed:
(i) Contractor has to obtain the permit for working at height duly approved by
competent authority
(ii) Proper type of scaffolding / platform /ladder should be made to facilitate the
job at height. Minimum 2 nos. of ladders should be provided at opposite
sides.
(iii) Use of bamboo scaffolding is strictly prohibited inside the Battery area. Only
steel scaffolding shall be used for work inside the Refinery. The steel
scaffolding material and it's erection shall be done as per relevant IS
specification
(iv) The contractor shall ensure the use of safety belts by the person who is
working at heights. Safety belt to be used should be of good quality (IS
marked) and shall be hooked up with firm support.
(v) Full body safety belt, horizontal & vertical fall arrestor are to be used
(vi) Safety nets also to be used as per site conditions
(vii) Before starting the job, scaffolding shall be inspected by competent person
and a record of the same shall be kept at site.
1.11.3 All scaffolding material used shall be as per relevant IS specifications and tested
periodically as per statutory requirements.
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1.11.4 Scaffolding or staging more than 12 meters above the ground or floor, swing or
suspended from an overhead support or erected with stationery support shall have a
guard rail properly attached, bolted, braced and otherwise guarded at least 1 meter
above the floor or platform of such scaffolding or staging and extending along the
entire length of the outside and ends thereof with only such openings as may be
necessary for the delivery of materials. Such scaffolding or staging shall be so
fastened as to prevent from swaying from the building or structure.
1.11.5 Working platform, gangways and stairways should be so constructed that they should
not sag unduly or unequally and if the height of the platform or the gangway or the
stairway is more than 12 meters above ground level or floor level, they should be
closely guarded, should have adequate width and should be suitably fastened as
described in clause 1.11.4 above.
1.11.6 Any opening in the floor of a building or in working platform be provided with suitable
means to prevent the fall of persons or materials by providing suitable grills, fencing or
railing having a minimum height of 1 meter.
1.11.7 Safe means of access shall be provided to all working platforms and other working
places. Every ladder shall be securely fixed. No portable single ladder shall be over
900 cms. in length, while the width between the side rails in rung ladder shall in no
case be less than 30 cms. for ladder upto and including 300 cms. in length. For longer
ladders, this width should be increased at least 6 mm for each additional foot of length.
Uniform step spacing shall not exceed 30 cms. Adequate precautions shall be taken to
prevent danger from electrical equipment. No materials on any of the sites of work
shall be so stacked or placed as to cause danger or inconvenience to any person or
public. Contractor shall also provide all necessary fencing and lights to protect the
workers and staff from accidents, and shall be bound to bear the expenses of defense
of every suit, action or other proceedings, as law that may be brought by any person
for injury sustained owing to the neglect of the above precautions and to pay any
damages and costs which may be awarded in any such suit or action or proceedings
to any such persons or which may be with the consent of the Contractor be paid to
compromise any claim by any such person.
1.11.8 Scaffolding must be inspected and certified fit by the Contractors Safety Manager
weekly or more frequently in the event of adverse weather. Such inspections shall be
recorded.
1.12 Excavation and Trenching
1.12.1 All trenches 1.2 meters or more in depth, shall at all times be supplied with at least one
ladder for each span of 30 meters length.
1.12.2 Ladder shall be extended from bottom of the trench to at least 100 cms. above the
surface of the ground. The site of the trenches which are 152 cms. or more in depth
shall be stepped back to give suitable slope or securely held by timber bracing, so as
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to avoid the danger of sides to collapse. The excavated material shall not be placed
within 152 cms. of the edge of the trench or half of the trench depth whichever is more.
Cutting shall be done from top to bottom. Under no circumstances undermining or
under cutting be done.
1.12.3 All the areas where the existing grading is disturbed in the course of work by the
contractor, shall be made good by him to the full satisfaction of the Engineer-in-
Charge.
1.12.4 This job must be executed only after obtaining a valid excavation permit for the
particular area where the excavation is required to be done. The permit shall be
considered valid only when it is signed by the authorized person of CPCL in addition to
other signatories like F&S officer, Civil Engineer, the electrical section and supervising
Engineer-in-Charge of the particular area where the excavation is to be carried out
1.12.5 If any excavation job is being done at the depth, then following precaution needs to be
taken up.
Contractor has to obtain the permit "Working at Depth" duly authorised by competent
authorities.
Proper barricading shall be provided at all sides of the opening.
Excavation shall be done with adequate slop instead of vertical to avoid collapse of
wall.
Proper shoring / strutting shall be provided without fail.
At least two no. of escape ladders shall be provided at two sides.
Adequate illumination shall be provided as per site requirement.
Minimum person shall be kept inside the pit. All idle workers should be removed from
there.
Heavy machinery like crane etc. should not be used near the pit.
1.12.6 This job must be covered by an excavation permit, which must be signed by the
concerned authorities as mentioned in the permit. In addition to excavation work
permit, specific work permit shall be required to be obtained depending upon the
nature of work. The company reserves the right to cancel a permit without assigning
any reasons. When called upon to stop the work by any personnel of the company,
contractor shall immediately cease to continue the work. Before re-commencement, a
fresh permit must be obtained.
1.13 Demolition:
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1.13.1 Immediately prior to the commencement of any demolition work and also during the
process of demolition the following additional precautionary steps shall be observed.
(i) All roads and open areas adjacent to the particular site shall either be closed
or suitably controlled.
(ii) All underground / overground power / telephone cables or water / sewerage

lines in the vicinity of the particular site shall be either suitably diverted or
made non-functional for the duration of the demolition activity.
(iii) All practical steps shall be taken to prevent danger to persons employed from
risk of fire or explosion or flooding. No floor, roof or other part of the building
shall be overloaded with debris or materials as to render it unsafe.
1.14 Personal Protective Equipment:

1.14.1 The Contractor shall ensure ready availability at the respective work site of necessary
personal protective equipment for use by persons employed at the site and such
equipment shall be maintained in a condition suitable for immediate use. The
Contractor shall ensure proper use of such equipment by those concerned. Contractor
shall use material handling equipment and tools such as chain pulley blocks, wire
ropes, lifting machines etc. and scaffolding materials only if they are duly certified as
per statutory requirements.
1.14.2 For the safe conduct of certain job, the supervisor of the area concerned will stipulate
personnel protective equipment. Contractors shall provide such equipment to their
personnel. However, in certain cases, personnel protective equipment maintained by
the Refinery will be made available for this purpose. Such equipment shall be returned
to the authorities in working condition to the full satisfaction of fire & safety officer. In
case any damage, to the Fire Protective equipment i.e. Fire hoses, safety helmets,
nozzles, fire extinguishers etc., the contractor shall bear the cost of such damage in
full as decided by the Fire & Safety dept. and will be recovered from his bill. Personnel
working in the process area and those engaged in any type of work shall wear
helmets, safety shoes. When working at height they shall use full body safety belt.
They should use, proper goggles when engaged in working or gas cutting, Mask and
suit while vend entries, valve pits, confined spaces.
1.14.3 Workers engaged in mixing asphalt materials, cement and lime mortar shall wear
protective foot ware (Gumboot) and protective gloves.
1.14.4 Contractor shall arrange all Non-Respiratory Type of Personal Protective Equipment
(PPE) (e.g. Safety Goggles, Welding Helmets, Belts etc.) at their own cost and shall
ensure use of these PPE by their workmen/ personnel during execution of the job as
per Fire & Safety Rules and Regulations of the Refinery and as directed by the Site
Engineer-in-Charge. Fire & Safety Dept. may be contacted for any clarification on
Safety Regulations.
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1.14.5 Workers engaged in white washing and mixing or stacking of cement bags or any
materials which are injurious to eyes shall be provided with protective goggles / dust
masks.
1.14.6 Those engaged in welding and cutting works, shall be provided with protective face
and eye-shields, hand gloves, apron etc.
1.14.7 Stonebreakers shall be provided with protective goggles, hand gloves, safety shoe and
protective clothing.
1.14.8 When workers are required to work in sewers and manholes, which are in use, the
Contractor shall ensure that the manhole covers are opened, ventilated, gas tested for
hydro carbon / toxic gas / oxygen and obtain vessel entry permit and the manholes so
opened shall be cordoned off with suitable railing and provided with warning signals or
boards to prevent accidents. Respiratory protective equipment shall be used as
advised by Engineer-in-Charge / Fire & Safety Dept.
1.14.9 Special precautions and personal protection shall be taken as per Refinery Safety
Regulation during the following jobs:
(i) Handling of Hazardous Chemicals, gases and Materials etc. (e.g. Hydrogen
Sulphide, Carbon Monoxide, Acids, Chlorine, Ammonia, Pyrophoric Iron etc.);
(ii) Working in presence of Suspended Solids (e.g. Catalyst, Refractory, Sand,

Dust etc.);
(iii) Cleaning / Maintenance of equipments in Lead/ Sulphur/ Phenol rich

Hydrocarbon service;
(iv) Cleaning/ handling of oily sludge;
(v) Welding/ Grinding/ Gas cutting jobs;
(vi) Radiography of Mechanical jobs.
1.14.10 Contractor personnel shall not wear loose clothing while working around moving or
rotating machinery and equipment, and must wear helmets and safety shoes while
working in Refinery area.
1.14.11 Any questions or doubts on the safety regulations enumerated in this tender or the
generally accepted safety working practices may be clarified with the concerned
department of safety section.
1.15 Bombs, Unattended Baggages/Objects:

1.15.1 The following actions shall be taken by the contractor and his employees/workmen
about Bombs, Unattended baggages / Objects lying in secluded places in the Plant :
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(i) On noticing any bomb/ unattended baggage or object lying in the plant area,
they should immediately inform the CISF control room on Telephone No.3685
& 3660 and CPCL Fire Control Room No. 3630 & 3663.
(ii) They should not touch the object or try to open the baggage or fiddle with the
wires or battery if found attached to the object.
(iii) They should move away to a safety distance of approximate 300 mtrs.
without creating any panic.
(iv) In case of unattended baggage, they should help CISF personnel in

identifying the claimant.
(v) They should not move to the area unless clearance is given by security
personnel.
Dos & Donts in case of Bomb/Unattended baggages lying secluded places in the
Plant.
Sl. Sl.
Dos Donts
No. No.
1. On noticing any bomb or 1. Do not touch the bomb /
unattended baggage, in form CISF unattended baggage.
Control Room by quickest possible
means or on Intercom Telephone 2. Do not lift any attended baggage
No. 3685 / 3660 and CPCL Fire
Control Room on 101 / 3630 /
3663. 3. Do not go very close to the object
2. Move away from the 4. Do not create panic.

bomb/unattended baggage.
3. Help security personnel in 5. Do not fiddle with wires or battery
identifying unattended baggage. if found attached with any object.
4. Help ladies and injured person 6. Do not open any unattended
during evacuation process from baggage.
the affected area.
5. Move back to your place of work 7. Do not try to defuse any bomb or
after clearance has been given by explosive material
CISF.
1.16 Risky Places:
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1.16.1 If there is risk of drowning or such like danger at or near the work site, adequate safety
equipment shall be positioned at such site(s) in ready-to-use condition. Steps
necessary for prompt rescue of any person in danger shall be taken.
1.16.2 When work is required to be performed in areas where H2S / CO gas is likely to be
present, the Contractor should ensure with the Permit Issuing Authority on the total
gas free atmosphere. Care should be exercised when work in a contaminated area up-
to the Threshold Limit Value (TLV) is undertaken, by wearing a Self Contained
Breathing Apparatus (SCBA) or using a Blow Man Apparatus. Such work should not
be performed by a single worker and should always be done under close supervision.
1.17 Use of Hoisting and Heavy Equipment:
1.17.1 All hoisting machines and tackles including their attachments, anchorage and supports
shall be as per relevant IS specifications, standards and tested / inspected periodically
by the concerned competent authorities. Necessary records / certificates etc., in this
regard shall be maintained as per statutory requirements.
1.17.2 If hoists, cranes, derrick, mixer machine, pumps etc. are used by the contractor, the
following are to be ensured by the contractor and his workmen:-
Testing of crane for its capacity;
Inspection & maintenance logs;
Crane operation logs;
Safety latch is provided on the hooks;
The area is notified through display of Sign boards/ barricades;
Over head power cables is removed or kept at a safe distance;
The exhaust of machines should have a proper flame arrester;
Carrying material by hydra inside refinery;
No change of boom length beyond permissible limit.
1.17.3 These shall be of good mechanical construction, sound materials, and adequate
strength and free from patent defect and shall be kept in good repair and in good
working order.
1.17.4 Ropes used in hoisting or lowering materials or as a means of suspension shall be of

durable quality, of adequate strength and free from defects.
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1.17.5 Every crane driver or hoisting appliance operator shall be properly qualified. No
person under the age of 21 years shall be in charge of any hoisting machine
including any scaffolding winch or for giving signals to the operator.
1.17.6 In case of every hoisting machine and of every chain ring hook, shackle swivel and
pulley block used in hoisting or lowering or as means of suspension, the safe
working load shall be ascertained by appropriate means. Every hoisting machine and
all gear referred to above shall be prominently marked to show the safe working
load. In case of a hoisting machine having a variable safe working load, each safe
working load and the respective conditions under which it is applicable shall be
clearly indicated. No part of any machine or any gear shall be loaded beyond the
safe working load except for the purpose of testing.
1.17.7 In respect of machines made available by the Owner, the safe working load shall be
notified by the Engineer-in-charge. As regards Contractors machines, the contractor
shall notify the safe working load of the machine to the Engineer-in-charge,
whenever he brings any machinery to site of work and cause it to be verified by the
Engineer-in-charge.
1.17.8 Hoisting appliances should be provided with such means as will reduce to the
minimum, any risk of accidental descent of the load.
1.17.9 Adequate precautions should be taken to avoid the risk of any part of a suspended
load becoming accidentally displaced.
1.18 Electrical Equipment and System:
1.18.1 The Contractor shall deploy a competent Engineer / Electrician to attend to electrical
matters. All temporary power supply boards shall conform to IE Regulations.
1.18.2 Contractor or his nominated subcontractor should have valid electrical contractors
license for working in State. Contractor shall furnish a copy of the same to Engineer-
in-Charge before commencement of any work pertaining to Electrical System. In any
case, no work shall be permitted to be executed at site without a valid Electrical
Contractors License, and the decision of the Engineer-in-charge in this regard shall
be final and binding and no claim / compensation whatsoever shall entertained on
this account.
1.18.3 Motors, Gearing, Transmission, Electric wiring and other dangerous parts of hoisting
appliances should be provided with efficient safeguards.
1.18.4 The contractor should ensure that the portable electrical equipment like grinding
machine, drilling machine etc. is in healthy condition. The contractor should take all
precautionary safety action, as providing of earth leakage circuit breakers for their
portable electric machines, also double insulated portable equipment may be used.
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1.18.5 All portable electrical apparatus shall be regularly examined, tested and maintained
to ensure the apparatus and leads are in good order. Temporary jointing of extension
wire, power cables etc. is not allowed.
1.18.6 Ensure that all portable appliances are provided with 3 pin plug and socket
connections and that the metal body of the apparatus is effectively earthed. All loose
wiring such as flexible cables for portable lamps, tools & trailing cables and other
portable and transportable apparatus, shall be tested regularly at frequent intervals
to ensure safety. All temporary board shall have ELCB of 30 ma sensitivity for
personnel safety and double earthed / double insulated hand tools.
1.18.7 When workers are employed on electrical installations, which are already energised,
insulating mats, wearing apparel, such as tested rubber gloves, sleeves and boots as
may be necessary, shall be provided. The workers should not wear any metallic
rings, watches, keys or other materials, which are conductors of electricity.
1.18.8 While working on electrical system, the contractor and his workmen shall ensure that
the following safety measures are in place:-
Proper & valid Electrical line clearance is obtained for the equipment;
The cables are properly insulated and are without any temporary joint;
All Flammable / combustible materials should either be removed from the work
place or should be properly protected;
Suitable Earth leakage Circuit Breaker (ELCB) is provided for incoming and all
outgoing feeders;
Proper earthing is provided to distribution board and other electrical equipments

like welding machines & grinding machines etc.;
Pipe sleeves are provided for road crossings of temporary cables laid by the
contractor for his work;
The power connection should not be overloaded and suitable overload protection
should be provided;
The tools used by the contractor personnel should be properly insulated and in
good condition;
The grinding machine & other power tools should have proper guard.
1.18.9 Do not attempt to work on electrical apparatus unless authorized by an electrical

department, and without obtaining clearance or permit from the area-in-charge. Use
only approved electrical fitting gadgets or equipment. Obtain clearance from
electrical personnel and produce the clearance to area-in-charge prior to obtaining
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permit to start the work. Electrical personnel will check the norms and should sign
the register/permit. Keep the register/permit at the site. Times to time the equipment
are to be checked by contractors authorized electrical supervision and necessary
entry shall be made in the register. If any kind of norms are found violated, the work
of those equipment to be stopped till the equipment is either rectified or replaced, the
norms are as below:
i) Contractor should use approved quality earth leakage circuit breakers (ELCB)
on their portable distribution board for all type of electrical equipment used
including welding sets etc.
ii) Also use ELCB on their main distribution board for each feeders. Contractor
should ensure the healthiness of their Electrical Portable Apparatus by
competent electrical supervisors. Contractor shall provide proper earthing for
their distribution board.
iii) Contractor should engage Licensed electrical supervisors for certifying their
equipment and ensuring safety of their connection.
1.18.10 The work area shall always be kept accessible for switching off power supply in case
of emergency. Before leaving the work place, the Contractor shall ensure power
supply is switched off properly. For this purpose a record shall be maintained of the
last person leaving the concerned work site on all days of activity.
1.18.11 No dry battery or accumulator type of electric hand lamp or torch which is not of the
flame proof safety type shall be taken inside the Refinery.
1.19 Maintenance of Safety Devices:
1.19.1 All scaffolds, ladders and other safety devices mentioned or described herein shall
be maintained in safe conditions and no scaffold, ladder or equipment shall be
altered or removed while it is in use. Adequate washing facilities should be provided
at or near places of work.
1.20 Display of Safety Instructions :
1.20.1 The Contractor shall display a Safety Policy at a prominent place at his site office
and each work spot.
1.20.2 The safety provisions covered herein should be brought to the notice of all
concerned by display on a notice board at a prominent place at the work spot(s).
1.20.3 At all work sites, contractor has to display a board containing following information:-
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CPCL site in-charge name;
1.20.4 The contractor has to maintain the following at job site :-
First Aid Box with required medicines;
Safety Register;
Injury record;
Records of Weekly Staff safety meeting;
Record for Safety briefing / Training at site by contractor.
1.21 Personal Conduct:
1.21.1 Gambling, fooling on the work, horseplay, mock fighting or fighting is strictly
forbidden in the Refinery premises Project area.
1.21.2 Horseplay:
a) Fooling on the job, mock fighting or fighting within the Refinery premises will
not be tolerated.
b) Gambling within the Refinery premises is strictly forbidden.
c) Entering the Refinery premises while in possession of weapons such as

knives & gun etc. is prohibited.
d) Contractor personnel shall not pick up quarrel or get into arguments with
Refinery personnel or act in any misunderstanding, such problems should be
referred to appropriate Refinery personnel.
1.21.3 Working under influence of alcohol/ narcotics and entering Refinery premises while
in the influence of alcohol/ narcotics is strictly forbidden. The contractor should
ensure compliance of above by him and all his workmen.
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1.21.4 Unsafe Practices: Any unsafe practices or disregard of normal safe working
practices by contractor personnel when pointed out by company personnel shall be
immediately corrected.
1.22 Housekeeping:
1.22.1 The contractor personnel must practice good housekeeping at all times while within
the plant. During and after completion of the work, they are to ensure that their work
area is kept clean and tidy. Materials and equipment should be stored in a safe and
orderly manner so that they will not block exit to roads, building, arises, passage and
approach to fire fighting equipment such as fire hydrants, fire hose and fire
extinguishers or area where emergency safety showers, electrical switch panels and
switch panels and switch rooms are located.
1.22.2 Records of routine housekeeping inspection shall be maintained.

1.22.3 Materials and equipment should be stored in a safe and orderly manner so that they
will not block exits to roads, buildings, aisles, passages and approach to fire fighting
equipment such as fire hydrants, fire hoses, fire extinguishers or areas where
emergency safety showers, electrical switch panels and switch rooms are located.
1.22.4 The work / construction sites are to be cleaned daily and all debris / scrap generated
is to be kept at the designated place only every day by the contractor as directed by
the Engineer-In-charge. The scrap / debris so generated shall be disposed off to the
designated places once a week as per the direction of Engineer-in-charge.
1.22.5 A job will not be considered completed until all surplus material, scrape and debris /
rubbish are removed from the job site.
1.22.6 In case the Contractor does not clear the area within 5 days of completion of work ,
the same shall be got done by CPCL and recoveries shall be made from the bills of
the Contractor at double the rate at which the CPCL has got it done.
1.22.7 Any failure by the contractor in maintaining good housekeeping / clearing the site as
above shall be recorded in the performance report of the contractor.
1.23 Enforcement of Safety Regulations:
1.23.1 To ensure effective enforcement of the rules and regulations relating to safety
precautions, the arrangements made by the Contractor shall be open to inspection
by the Engineer-in-Charge or Safety Engineer of the Owner or their representatives.
1.23.2 Contractors and their supervisory staff shall undergo a one-day training programme
annually by CPCL on Safe Working Practices in the Refinery Premises so as to
familiarize themselves with the safety rules, regulations and practices. Contractor
Page 296 of 674

shall be in possession of valid safety training badge while working in the Refinery
premises.
1.23.3 The Contractors shall ensure that their supervisors must undergo Fire & Safety
Training & subsequent Test at Fire Station before starting the job. All contractors
must disclose to CLM Cell the name of supervisors and arrange safety training at
Refinery Fire Station, before obtaining a gate pass. CISF will issue the gate pass
meant for supervisor, only after getting the confirmation from Fire & Safety. It is the
duty of supervisor to train his work force in Fire & Safety on regular basis. The
1.23.4 Under no condition shall any contractor personnel tamper with or use any property
belonging to the refinery without obtaining prior sanction from the supervisor of area
concerned.
1.24 Radiography:
1.24.1 The radiography agency employed by the contractor shall be duly approved by
BARC.
1.24.2 Specific approval from the Engr.-in-charge for the radiography agency shall be
obtained by the Contractor prior to any radiography work.
1.24.3 The contractor shall ensure the following safety precautions for the work to be done
by the radiography agency:-
(i) The radiography work shall be carried out under the supervision & guidelines
of their site in-charge duly approved by BARC.
(ii) As far as possible, field radiography should be done only during night time
when there is little or no occupancy around.
(iii) Field radiography during day time may be permitted with due permission of
EIC when the occupancy around is minimum i.e. during lunch interval or on
holidays.
(iv) A suitable area around the radiography job should necessarily be cordoned
off, so that the radiation level outside the area does not exceed the
permissible radiation level. The radiation level along the cordon should be
monitored by suitable & calibrated survey meter.
(v) Radiation warning symbol during daytime & red warning light during the night
to be prominently displayed while carrying the radiography work.
(vi) The concerned radiographer shall remain physically present outside the
cordoned area during exposure.
1.25 Temporary Structure/Fixtures:
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1.25.1 Before erecting temporary shelters like sheds anywhere within the Refinery
premises, written permission of the Engineer-in-charge be obtained.
1.25.2 Temporary fixtures like sheds, tents, etc. shall be erected in conforming with normal
safety standards. Thatched roof to such fixtures will not be permitted.
1.25.3 Temporary piping, hose connections and electrical wiring must be laid in such
manner that they do not cause tripping or hitting hazard
1.25.4 Temporary sheds can be constructed only for the storing of the material / site office.
It should not be used for any other purpose.
1.25.5 However, for all jobs having value more than Rs. One crore, no temporary sheds
shall be allowed for office / stores of the contractor and instead the contractor shall
arrange for portal cabin for site office / stores.
1.25.6 Following information shall be clearly written on the shed:- Name of the contractor;
Work Order No.; Working under the Department; Name of the Engineer-in-charge;
Permit No. & it's validity period.
1.25.7 The shed shall be made of safe construction material and good aesthetic view. The
shed shall be made strictly at the authorised location and size.
1.25.8 All windows shall be either of wire mesh or glass.
1.25.9 Company has the right to open or break the door at any time to inspect the shed.
1.25.10 After completion of the job shed must be demolished within 10 days and area must
be cleaned.
1.25.11 All precautions should be taken to ensure that any temporary electrics wiring used
within the Refinery will not cause sparks or shock
1.26 Compressed Gas Cylinders:
1.26.1 Compressed gas cylinders should be used in upright position. They must be firmly
located on the ground or to a sturdy stand and the cylinder should be chained to
prevent accidental fall.
1.26.2 Rolling or throwing of cylinders is strictly prohibited. Cylinders shall be handled

carefully and transported through hand trolleys.
1.26.3 Cylinders shall be stacked properly. Empty cylinders shall be stacked separately and
filled cylinders separately. After completion of job, all cylinders must be removed.
Page 298 of 674

1.27 Actions for compliance by contractors

S.No. Clause Ref Actions for Compliance by Contractors
1. 1.20.3 A. The contractor has to display the following
information at the job site on a notice board:
i. Name of the Contractor;
ii. Name of the Work & Contract No.;
iii. Job site warning instructions;
iv. Emergency telephone Number;
v. Do's and Dont on Safety & Security
1.20.4 B. The contractor has to maintain the following at job site :

i. First Aid Box with required medicines;
ii. Safety Register;
iii. Injury record;
iv. Records of Weekly Staff safety meeting;
v. Record for Safety briefing / Training at site by
contractor
2. 1.4.1 The contractor shall not commence the job without the valid
permit for the area and for the job. The following are the types
of permits / clearances to be obtained by the contractor as per
the requirement of the job:
i. Clearance from the Area Incharge and Shift
1.4.4 Engineer;
ii. Cold work;
iii. Hot work permit / excavation permit;
iv. Working at height / depth permit;
v. Working in confined area / Vessel entry permit;
vi. Electrical isolation & Energisation permit;
vii. Any other permits.
3. 1.14 The contractor shall ensure that he and all his workmen shall
use the following (minimum) personal protective equipment:
i. Helmet - while working in the Refinery or any other
hard hit area;
ii. Safety Belt - Working above 2.00 m height;
iii. Eye shields / goggles & Face protecting equipment
while welding / grinding etc;
iv. Hearing Aid - while working in noisy area;
v. Hand gloves and aprons - as per job requirement;
vi. Any other as required
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4. 1.10 While carrying out excavation or working at depth in pit,

trench etc, the following safety measures are to be followed:
i. Proper barricading for the floor opening / excavated
1.12 area;
ii. Adequate side slope;
iii. Proper shoring / strutting;
iv. Provision of escape Ladder;
v. Provision of Sufficient lighting arrangement
vi. Respiratory PPE;
5. 1.11 While working at height, the contractor and his workmen shall
ensure that the following safety measures are taken:
i. Sufficient approach to work area and proper
scaffolding;
ii. The person working at height is wearing the full
body safety belt which is firmly secured to a proper
place.;
iii. The Scaffolding shall be made of steel as per
norms.;
iv. The ladder / scaffolding shall be properly secured to
prevent sliding / failing;
v. The clamps and tiring are properly secured;
vi. The Safety net is provided;
vii. Inspection of final scaffolding before use has been
done by competent authority and the inspection
report in this regard should be available with the
contractor.
6. 1.6 in a confined space the contractor and his workmen shall
ensure the following:
i. Provision of Exhaust fan on the confined place;
ii. A standby man should always be available standing
near the confined space entry / exit point when the
other worker is carrying on job inside the confined
space;
iii. Use of breathing apparatus.
7. 1.4.10 While carrying out the hot job, the contractor and his workmen
must ensure the following safety measures and job should not
be carried out without these:
i. Valid hot job permit;
ii. Availability of Tested and proper Fire Extinguisher
at the work places;
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iii. Provision of Running fire water hose at the work

place;
iv. All Flammable / combustible materials should either
be removed from the work place or should be
properly protected.
8. 1.18.8 While working on electrical system, the contractor and his

workmen shall ensure that the following safety measures are
in place:
i. Proper & valid Electrical line clearance is obtained
for the equipment;
ii. The cables are properly insulated and are without
any temporary joint;
iii. All Flammable / combustible materials should either
be removed from the work place or should be
properly protected;
iv. Suitable Earth leakage Circuit Breaker (ELCB) is
provided for incoming and all outgoing feeders;
v. Proper earthing is provided to distribution board
and other electrical equipments like welding
machines & grinding machines etc.;
vi. Pipe sleeves are provided for road crossings of
temporary cables laid by the contractor for his work;
vii. The power connection should not be overloaded
and suitable overload protection should be
provided;
viii. The tools used by the contractor personnel should
be properly insulated and in good condition;
ix. The grinding machine & other power tools should
have proper guard.
9. 1.17 If hoists, cranes, derrick, mixer machine, pumps etc. are used
by the contractor, the following are to be ensured by the
contractor and his workmen :
i. Testing of crane for its capacity;

ii. Inspection & maintenance logs;
iii. Crane operation logs;
iv. Safety latch is provided on the hooks;
v. The area is notified through display of Sign boards /
barricades;
vi. Over head power cables is removed or kept at a
safe distance;
Page 301 of 674

vii. The exhaust of machines should have a proper

flame arrester;
viii. Carrying material by hydra inside refinery;
ix. No change of boom length beyond permissible limit.
10. 1.22 The contractor shall maintain good house keeping at his area
of work and must ensure the following:
i. Passage, walkway and working area should be free
from any blockage are maintained neat and clean;
ii. Debris, scrap etc is removed daily and put to a
proper place;
iii. The temporary structure are removed after
completion of job.
11. 1.9 A. The contractor's vehicles like jeep, cars, trucks and
tractors should maintain the prescribed speed limits and
should not over speed.
B. Obstacles for fire fighting and blockage of road etc.
The contractor has to follow all Safety, Health and Environment rules & regulations of
the Refinery. In case of non-compliance of any of these rules and regulations by
contractor or his employees, the contractor shall be held responsible. If any violation or
non-fulfillment of these Safety, Health and Environment rules and regulation is
observed by Refinery authorities during checking at any time, a penalty of Rs. 5000.00
( Rs. Five Thousand Only ) shall be imposed on the contractor for each occasion of
non-compliance to these rules and regulations by him or his employees. The decision
of Refinery authorities shall be final and binding on to the contractor in this regard. The
amount of penalties so imposed shall be recovered from the next R.A. Bill of the work
or any other dues payable to the contractor by Refinery
Event Penalty
Absence of Resident / safety Engineer of Rs 1000 per meeting
Contractor in CPCLs safety meeting
Failure to have regular site safety Inspection (by Rs 1000 / week
contractors themselves) every week
Failure to conduct Health / Safety / Environment Rs 1000/month
(HSE) meetings by Contractor at site (in-house)
and maintain records
Failure to submit HSE reports/check Lists, etc., by Rs 1000 /month and Rs 100 /
5th of every month to CPCL day for further delay
Page 302 of 674


For not providing shoring / strutting / proper slope Rs 5000 / occasion
and not keeping the excavated earth at least 1.5M
away from the excavated area
1.28.1 In case the violation / non-compliance of above Safety, Health & Environment rules
results in results in any Physical Injury or Fatal Accident, an additional penalty as given
below shall also be imposed on to the Contractor:
1.28.2 For any reportable physical injury as per Indian Factories Act - 1948: Additional
penalty of 0.5 % of the contract value subject to a maximum of Rs.2,00,000 (Rs. Two
Lakhs Only) per injury in addition to the penalty of Rs.5000 as per cl.No.1.28.1 above
1.28.3 For Fatal accident: Additional penalty of 1 % of the contract value subject to a
maximum of Rs.10,00,000 (Rs. Ten Lakhs Only) per fatality in addition to the penalty
of Rs.5000 as per cl.No.1.28.1 above.
1.29 Compensation in case of Accidents:
In case of any accidents/injury of a contractor's workmen, the contractor shall pay a

suitable compensation (subjected to the minimum compensation as mentioned below)
to the affected person / his family members in the presence of Engineer-in-charge and
in consultation with Chief Medical Officer of the Refinery. The said compensation shall
depend on the seriousness of injury, etc, and shall be in addition to the hospitalization /
treatment charges and Group Insurance Amount payable to the effected person. The
following are the minimum compensation shall be paid to the affected person / his
family as stated above:
1.29.1 In case of fatal accidents: Rs.1.0 lacs (Rs. One Lakhs) within 5 days of accident.
1.29.2 In case of loss of both the limbs (hand / legs/eyes/ ears) : Rs.50,000/- (Rs. Fifty
Thousand ) within 1 week.
1.29.3 In case of loss of one limb (hand / legs/eyes/ ears) : Rs.25,000/- (Rs. Twenty Five
Thousand ) within 1 week.
1.29.4 In case of any injury not specified above, Rs.1000/- (Rs. One Thousand) to Rs.5000/-
(Rs. Five Thousand )as directed by Engineer-in-charge within 1 week.
1.30 Emergency Response Plan
1.30.1 Contractor has to adhere and respond to the on-site emergency plan and coordinate
with the site main controller of Refinery
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1.30.2 Contractor personnel shall stop their work and proceed to a safe area in the event an
emergency arises in the area where they are working like, in case of fire, oil spillage,
power failure etc. Before re-commencement of the job they should obtain clearance of
supervisor of area involved.
1.30.3 In view of the hazards associated with Hydrocarbon processing, on site emergency
plan has been prepared in the event of major accident occurring on site. The plan
envisages handling emergency situation, which shall be communicated through siren,
based on nature of emergency as mentioned below.
1.30.4 In case of major emergency, it is the responsibility of the contractor to head count his
personnel and take them out with the help of concerned Refinery Co-ordinator.
Contractor must confirm the safe evacuation of his personnel to Refinery Co-ordinator.
In case of any missing person, it must be brought into the notice of Refinery authorities
immediately.
1.30.5 Types of Communication, In Case of Emergency:
Type of
Siren
Emergency
Minor Fire No Siren
Major Fire Wailing type siren for two minutes. Sirens will be sounded for
30 seconds with an interval of 15 seconds in between
Disaster Same type of siren as in the case of Major Fire except that it
will be sounded three times at the interval of two minutes.
All clear Sounding of fire sirens continuously for two minutes
1.30.6 Evacuation and Sheltering:
In case of emergency/major accident or disaster, following 8 Nos. of Muster points

have been identified for assembling of people for head counting / transportation to a
safe place. The contractor site-in-charge shall coordinate with Site Main Controller for
sheltering and evacuation and advise his workmen to rush o the identified locations of
muster points as given below
1.30.7 Muster Points
S. No. Affected Area Location

1. ETP - I
2. Road 2, Near Crude2 Feed Pump
3. LEB / DHDS Control Room
4. OM&S Control Room
5. Refinery - I
Page 304 of 674

6. Water Treatment Plant

7. LPG
8. Maintenance
9. Refinery - II
10. Refinery - III
11. Near Indco Office
EVACUATION
CENTRE
1 Fire Station
2 East Gate
1.31 Special Conditions of Contract on Environmental Management System
1.31.1 Contractor shall inculcate environmental awareness among their workmen/ personnel
and strive for enhancement of systems and skills for minimizing the environmental
impact out of their activities/ services.
1.31.2 Contractor shall avoid wastage of water, compressed Air and Steam supplied to them
from owners source of supply for execution of the job and close the supply valves
properly while not in a use.
1.31.3 Contractor shall ensure that while carrying out Modification/ Repair/ Replacement jobs
of any equipment of pipeline, the spillage of Hydrocarbon Oily sludge etc. are cleaned
and routed to nearby OWS, at regular interval as well as after completion of jobs.
Contractor must ensure that the spillage of hydro-carbon oily sludge etc. are not
drained in Storm water channel or open channel.
1.31.4 Before attending any blinding/ de-blinding jobs, all tools, tackles and spares shall be
kept ready at site in order to minimise Hydrocarbon spillage.
1.31.5 Contractor shall clear and level the job-site and remove all metallic and nonmetallic
surplus materials, scrap and other waste materials generated out of his job, from time
to time as well as after completion of job to a specific location as per Engineer-in-
charge.
1.31.6 Contractor shall ensure to avoid idle running of all electrical equipments e.g. welding
machines etc. used for execution of the job.
1.32 DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR
1.32.1 On Award of Contract
The Contractor shall prior to start of work submit his Health, Safety and Environment
Manual or procedure and HSE Plans for approval by CPCL. The Contractor shall
Page 305 of 674

participate in the pre-start meeting with CPCL to finalise HSE plans including the
following:
Job procedure to be followed by Contractor for activities covering. Handling of

equipment, scaffolding, electric installation, describing the risks involved actions
to be taken and methodology for monitoring each activity.
CPCL / Owner review / audit requirement.
Organisation structure along with responsibility and authority, records / reports

etc on HSE activities.
1.32.2 During job execution
Implement approved Health, Safety and Environment Management procedure

including but not limited to as brought out under para 3.0. Contractor shall also ensure
to.
Arrange workmen compensation insurance, registration under ESI Act, third party
liability insurance etc, as applicable.
Arrange all HSE permits before start of activities (as applicable) like hot work,
confined space, work at heights, storage of chemical / explosive materials and its
use and implement all precautions mentioned therein.
Submit timely the completed checklist on HSE activities, Monthly HSE report,
accident report and investigation reports etc as per CPCL requirements.
Compliance of instructions on HSE shall be done by Contractor and informed
urgently to CPCL.
Ensure that Resident Engineer / Site-in-charge / safety officer of the contractor

shall attend all the Safety Committee/HSE meetings arranged by CPCL/Owner.
Only in case of his absence from site that a second senior most person shall be
nominated by him in advance and communicated to CPCL/Owner.
Display at site office and work locations caution boards, list of hospitals,
emergency services available.
Provide posters, banners for safe working to promote safety consciousness

Carryout audits/inspection at sub contractor works as per approved HSE
document & submit the reports for CPCL review.
Assist in HSE audits by CPCL and submit compliance report
Generate & submit HSE records/report as per HSE Plan.
Appraise CPCL on HSE activities at site.
Page 306 of 674

RELEVANT IS CODES FOR PERSONAL PROTECTION
IS: 2925 1984 Industrial Safety Helmets

IS: 4770 1968 Rubber gloves for electrical purposes
IS : 6994 1973 (Part-I) Industrial Safety Gloves (Leather & Cotton Gloves)
IS : 1989-1986 (Part-I & III) Leather safety boots and shoes
IS : 3738-1975 Rubber knee boots
IS : 5557-1969 Industrial and safety rubber knee boots
IS : 6519-1971 Code of practice for selections, care and repair of Safety footwear
IS : 11226-1985 Leather Safety footwear having direct molding Sole
IS : 5983 1978 Eye protectors
IS : 9167 1979 Ear protectors
IS : 3521 1983 Industrial Safety belts and harness
Page 307 of 674

1.0 HEALTH, SAFETY & ENVIRONMENT (HSE) PLAN
NAME OF WORK : _______________________________________________

CONTRACTOR : _______________________________________________
DATE : ___________________________
(To be prepared by each Construction Agency)

ACTIVITY PERFORMING FUNCTIONS AUDIT FUNCTION
DESCRIPTI PROCEDUR CODE OF
ON E/W.I/GUID CONFOR- CUSTOMER REVIEW/
E-LINES MANCE PERFORMER CHECKER APPROVER AUDIT REQUIRE-
MENTS
--------------------- --------------------- ---------------------

PREPARED BY REVIEWED BY APPROVED BY
Engineer-in-charge
Page 308 of 674

2.0 MONTHLY HSE CHECKLIST CUM COMPLIANCE REPORT
PROJECT : __________________________
CONTRACTOR : __________________________
DATE : ___________________________
OWNER : ___________________________
INSPECTION BY : ___________________________
Note: Write `NA wherever the item is not applicable

ITEM YES NO REMARKS ACTION
HOUSE KEEPING
Waste containers provided and
used
Sanitary facilities adequate and
clean
Passageways and Walkways Clear
General neatness of working areas
Other
PERSONNEL PROTECTIVE
EQUIPMENT
Goggles, Shields
Face Protection
Hearing Protection
Safety helmet
Safety Shoes Provided
Hand protection
Respiratory Masks etc
Full Body Safety Belts
Other
Page 309 of 674

MONTHLY HSE CHECKLIST CUM COMPLIANCE REPORT (Cont.)

EXCAVATIONS/OPENINGS
Openings properly covered or
barricaded
Excavation barricaded
Overnight lighting provided
Other
WELDING, CUTTING
Gas cylinders chained upright
Cables and hoses not obstructing
Screens or shields used
Flammable materials protected
Other
SCAFFOLDING
Fully decked platforms
Guard and intermediate rails in
place
Toe boards in place
Adequate shoring
Adequate access
Other
LADDERS
Extension side rails 1 m above
Top of landing
Properly secured
Angle + 70 from horizontal
Other
Page 310 of 674


HOISTS, CRANES AND
DERRICKS
Condition of cables and sheaves
OK
Condition of slings, chains, books
and eyes O.K.
Inspection and maintenance logs
maintained
Outriggers used
Signs / barricades provided
Signals observed and understood
Qualified operators
Other
MACHINERY, TOOLS &
EQUIPMENT
Proper instruction
Safety devices
Proper cords
Inspection and maintenance
Other
VEHICLE AND TRAFFIC
Rules and regulations observed
Inspection and maintenance
Licensed drivers
Other
TEMPORARY FACILITIES
Emergency instructions posted
Fire extinguishers provided
Fire-aid equipment available
Secured against storm damage
General neatness
In accordance with electrical
requirements
Other
Page 311 of 674


FIRE PREVENTION
Personnel instructed
Fire extinguishers checked
Smoking is banned
Hydrants clear
Other
ELECTRICAL
Proper wiring
ELCB's provided / double earthing
Ground fault circuit interrupters
Protection against damage
Prevention of tripping hazards
Other
HANDLING AND STORAGE OF
MATERIALS
Properly stored or stacked
Passage ways clear
Other
FLAMMABLE GASES AND
LIQUIDS
Containers clearly identified
Proper storage
Fire extinguishers nearby
Other
WORKING AT HEIGHT
Erection Plan
Safety nets
Full body safety belts and lanyards,
chutelines
Horizontal / vertical fall arrestors
Other
Page 312 of 674


ENVIRONMENT
Chemical and other Effluents properly
disposed
Cleaning liquid of pipes disposed off
properly
Seawater used for hydro-testing
disposed off as per agreed procedure
Lubricant Waste/Engine oils properly
disposed
Waste from Canteen, Offices,
Sanitation etc disposed properly
Disposal of surplus earth, stripping
materials, Oily rags and combustible
materials done properly
Green belt protection
Hygienic conditions at labour camps
O.K.?
Availability of First Aid facilities
Proper sanitation at site, office and
labour camps
Arrangement of medical facilities
Measures for dealing with illness
Availability of Potable drinking water for
workmen & staff
Provision of crche for children.
________________________________
Signature of Site-in-charge
Page 313 of 674

3.0 ACCIDENT CUM FIRE REPORT
(To be submitted by contractor after every accident within 6 hours of accident)
Report : ______________
Name of Work : ___________________________
Date : ______________
CONTRACTOR : ____________________________________
NAME OF THE INJURED : ------------------------------------------------------------
FATHER' NAME : -------------------------------------------------------------
SUB-CONTRACTOR : M/S.
DATE & TIME OF ACCIDENT : -------------------------------------------------------------
LOCATION : -----------------------------------------------------------------
_________________________________________________________________________
BRIEF DESCRIPTION OF ACCIDENT:

_________________________________________________________________________
CAUSE OF ACCIDENT
_________________________________________________________________________
NATURE OF INJURY / DAMAGE

_________________________________________________________________________
MEDICAL AID PROVIDED /

ACTIONS TAKEN
_________________________________________________________________________
INTIMATION TO LOCAL AUTHORITIES

_________________________________________________________________________
DATE: SIGNATURE OF CONTRACTOR WITH SEAL
Page 314 of 674

4.0 SUPPLEMENTARY ACCIDENT & INVESTIGATION REPORT
Name of Work: __________________ Supplementary to Report No._______________

(Copy enclosed)
Site:______________________ Dated : ___________________
CONTRACTOR : __________________________________________
________________________________________________________________________
NAME OF THE INJURED : ----------------------------------------------------------

FATHER' NAME : ----------------------------------------------------------
SUB-CONTRACTOR : M/s. .
DATE & TIME OF ACCIDENT : -----------------------------------------------------------
LOCATION : ------------------------------------------------------------
BRIEF DESCRIPTION & CAUSE OF ACCIDENT :
NATURE OF INJURY / DAMAGE :
COMMENTS FROM MEDICAL PRACTICETIONER, WHO ATTENDED THE

VICTIM/INJURED :
_________________________________________________________________________
SUGGESTED IMPROVEMENT IN THE WORKING CONDITION, IF ANY :

_________________________________________________________________________
LOSS OF MANHOURS AND IMPACT ON SITE WORKS :
ANY OTHER COMMENT BY SAFETY OFFICER
DATE:
SIGNATURE OF CONTRACTOR WITH SEAL
Page 315 of 674

5.0 MONTHLY HEALTH, SAFETY & ENVIRONMENT (HSE) REPORT

(To be submitted by each Contractor)
Actual work start Date:_____________ For the Month of: :_______________
Name of Work:_________________ Report No._______________________
Name of the Contractor:________________ Status as on:________________
Name of safety officer:_______________
ITEM THIS MONTH CUMULATIVE

Total Strength (Staff + Workmen)
Number of HSE meetings organised at site
Number of HSE awareness programmes
conducted at site
Whether workmen compensation policy taken Y/N
Whether workmen compensation policy is Y/N
valid
Whether workmen registered under ESI Act Y/N
Number of Fatal Accidents
Number of Loss Time Accidents (Other than
Fatal)
Other accidents (Non Loss Time)
Total No. of Accidents
Total man-hours worked
Man-hour loss due to fire and accidents
Compensation cases raised with Insurance
Compensation cases resolved and paid to
workmen
Remarks
Safety Officer/Resident Engineer

(Signature and Name)
TO: CPCL ENGINEER-IN-CHARGE
CM (F&S)
Page 316 of 674

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This drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited
MATERIAL REQUISITION (TOP SHEET)
ITEM DESCRIPTION: COKE DRUM STRUCTURE ELEVATOR (LIFT) (HAZARDOUS AREA)
GROUP ITEM CODE: DESTINATION: As per Commercial Documents
MR CATEGORY: II DELIVERY PERIOD: As per Commercial Documents
DOCUMENT NUMBER
( Always quote the Document Number given below as reference )
A133 086 LZ MR 4140 B 18/09/2013 16 44

JOB NO. UNIT/ MAIN DOC. SR. NO. REV. DATE DIVN. DEPT.
AREA COST CODE
CENTRE ORIGINATOR
or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use. EIL-1641-515 Rev.1 A4-210x297.
NOTES :
1 This page is a record of all the Revisions of this Requisition.
2 The nature of the Revision is briefly stated in the "Details" column below, the
Requisition in its entirety shall be considered for contractual purposes.
3 Vendor shall note the MR category and shall submit his offer in line with the
requirements included in attached 'Instructions to Bidders'.
REV. DATE BY CHK. APPD. DETAILS
A 11/01/2011 NJ/RKP SPC/PB MK ISSUED FOR BIDS

B 18/09/2013 DK/SD SPC PB REVISED AND ISSUED FOR BIDS
This is a system generated approved document and does not require signature.
Project: RESID UPGRADATION PROJECT-COKER BLOCK

16 Client: CPCL
Page 322 of 674

Sheet 1 of 4
File Name: C:\Documents and Settings\C031\Desktop\4140.pdf
TAG NO/
SR. NO. ITEM CODE/ [ ID. NO. ] DESCRIPTION QUANTITY
01.00 Design, engineering, manufacture,

procurement of materials and bought out
components, assembly at shop, inspection,
shop painting, testing at manufacturer's
works, packing and supply of the
following, including supply of all
commissioning spares, special tools and
tackles, first fill of lubricants, oils
including supply of erection material
and drawings and documents as per the
enclosed job specifications, data sheets,
standard specifications, etc. and other
codes and standards attached or referred.
01.01 86-LZ-20 COKE DRUM STRUCTURE ELEVATOR (LIFT) 1 Lot
(HAZARDOUS AREA)
02.00 << DELETED >>
03.00 Handling and transportation from

purchaser's store to work site, storage
at work site, assembly at work site,
installation, testing, site painting,
pre-commissioning, commissioning,
testing, handing over to purchaser and
other field works including minor civil-
structural works for the following, as
per the enclosed job specifications,
data sheets, standard specifications,
etc.
03.01 {03}86-LZ-20 For Sr. No. 01.01 1 Lot
04.00 Supply of Mandatory Spares as per clause
no. 4.1.19 of job specification no. A133-
086-16-44-SP-4140. (Separate lump sum
price to be quoted)
04.01 {04}86-LZ-20 For Sr. No. 01.01 1 Lot
05.00 Quotation for supply of recommended Lot
spares for two(2) years' normal operation
and maintenance including those required
for electrical and instrumentation &
control with itemised price list.
06.00 Unit Rates for addition/ deletion
purpose.
06.01 Per meter cost for increase/decrease in 1 m
elevator shaft length.
06.02 Cost for increase/decrease per landing. 1 Lot
07.00 << DELETED >>
08.00 << DELETED >>
09.00 Drawings and documents as per attached Lot
Vendor Data requirement for all supplies
and services covered above in Sr.Nos.1.00
to Sr.No.8.00
Vendors shall quote prices in EIL Price Schedule except for Sr.No.9.00. Price for
documentation is implied to be included in the prices quoted against Sr.No.1.00 to
Sr.No.8.00
Vendor to note that the numbers given in square '[]' and curly '{}' brackets are
not for their use and meant for store purpose only. Items shall be tagged as per
main equipment Tag No. only.

ENGINEERS INDIA LIMITED REQUISITION NO. REV.
16 Client: CPCL A133-086-LZ-MR-4140 B
Page 323 of 674

Sheet 2 of 4
SR. NO.
16
Page 324 of 674
TAG NO/
Client:
ITEM CODE/ [ ID. NO. ]

CPCL
DESCRIPTION
Sheet
A133-086-LZ-MR-4140
REQUISITION NO.
3 of 4
B
QUANTITY
REV.
LIST OF ATTACHMENTS
REVISION
SL. REV. REV. REV. REV.
DOCUMENT TITLE DOCUMENT NO.
No.
DATE DATE DATE DATE
1 Technical Check List for Coke A133-086-16-44-CL- A
Drum Struture Elevator (Lift) 4140 17/09/2013
(8 sheets)
2 Job Specification for Coke A133-086-16-44-SP- A
Drum Struture Elevator (Lift) 4140 17/09/2013
(9 sheets)
3 PMC's Job specification for 44NC-4600- B
coke drum structure elevator 0086/M.02/0023/A4 30/06/2010
(Lift) (9 sheets)
4 Data Sheet for Coke Drum A133-086-16-44-DS- A
Struture Elevator (Lift) (6 4140 17/09/2013
sheets)
5 Vendor Data Requirement for A133-086-16-44- A
Coke Drum Struture Elevator VDR-4140 18/09/2013
(Lift) (4 sheets)
6 Scope of Work & Job A133-086-16-50-SP- A
Specification (Electrical) for 4140 16/09/2013
Coke Drum Struture Elevator
(Lift) (9+125 sheets)
7 General Specification for Shop 44NC-4600-0000- 1
and Feild Painting (45 sheets) V.02-0111-A4 08/07/2010
In case of any subsequent revision of MR or PR, only revised sheets of the
attachments listed above shall be issued alongwith the revision.
GENERAL NOTES:

ENGINEERS INDIA LIMITED REQUISITION NO. REV.
16 Client: CPCL A133-086-LZ-MR-4140 B
Page 325 of 674

Sheet 4 of 4
Format No.: EIL-1641-1923 Rev.1
Engineers India Limited Status

Vendor Drawing/ Document Submission Schedule Date
Client: CPCL Project: RESID UPGRADATION PROJECT-COKER BLOCK Vendor Name:
Item Description: COKE DRUM STRUCTURE PR No.: Address:

ELEVATOR (LIFT) (HAZARDOUS AREA)
Date of LOI:
PO No.:
Date of PO: City:
Page 326 of 674

EIL Originating Department: PACKAGE EQUIPMENT Contact Person(EIL): Contact Person: Fax:
Phone: Email:
Drg./ Doc. Nomenclature Category Scheduled Form

S.No. Equipment Number as per EIL Vendor Data Vendor Drg. / Doc. Numbe Vendor Drg./ Doc. Title Electronic Remarks
Review (R) / date of 1st
Requirement Records (I) Submission (E)/ Print (P)
TECHNICAL CHECK LIST DOCUMENT No.
FOR
A133-086-16-44-CL-4130 Rev. A
COKE DRUM STRUCTURE
ELEVATOR (LIFT) Page 1 of 8
TECHNICAL CHECK LIST

COKE DRUM STRUCTURE ELEVATOR
(LIFT)
(86-LZ-20)
PROJECT : COKER BLOCK (EPCC-1)

RESID UPGRADATION PROJECT, CPCL, CHENNAI
OWNER : CHENNAI PETROLEUM CORPORATION LIMITED
PMC : JACOBS ENGINEERING INDIA PRIVATE LIMITED
CONTRACTOR : ENGINEERS INDIA LIMITED
JOB NO. : A133
A 17/09/2013 ISSUED WITH MR DK SD SPC
Rev. No. Date Purpose Prepared by Checked by Approved by
Format No. EIL 1641-1924 Rev. 1 Copyright EIL All rights reserved
Page 327 of 674
FOR
A133-086-16-44-CL-4130 Rev. A
COKE DRUM STRUCTURE
Bidder to note that bidders quotation shall be evaluated (technically) based on bidders
reply/confirmation to this technical checklist. Bidder is required to give categorical reply to
each point of this technical checklist, so that bidders offer is properly evaluated. Therefore
bidder must submit this technical checklist dully filled in, signed & stamped with the
quotation.
Bidder's reply "Not Confirmed" to be supported with reasons (attach separate sheet, if
required). Please answer 'Confirmed' or 'Not Confirmed' to the following:
Sl. No. DESCRIPTION BIDDERS ANSWER

Confirmed / Not
Confirmed
1. Confirm that the bidder has quoted for the

complete scope of supply & services as per
Material Requisition (MR) specifications and
attachments.
2. Bidder to confirm categorical compliance to all

clauses of specifications, data sheets, drawings
and other requirements of requisition.
3. If answer to Sl.No.2 above is Not Confirmed,

Bidder to furnish clause wise deviations, if any, with
respect to MR specifications and other attachments
in the enclosed Deviation/Clarification Schedule
Format (Annexure-4 of this technical checklist).
4. Bidder to note that, if any comment arises during

detail engineering from EIL/PMC/Owner (as per
contract), same shall be incorporated by bidder
without any time and price implication and approval
of vendors documents/drawings during detail
engineering are subject to final approval from
PMC/Owner.
Confirm compliance.
5. Bidder to note that data sheets, drawings and other

technical details submitted with bid shall be
retained for information only and shall be reviewed
during post order stage for compliance with bid
specification requirement. Confirm compliance.
Further please note that your offer will be evaluated

technically based on bidders reply to this technical
check list and deviation/clarification schedule
(Annexure-4 of this technical checklist), if any,
furnished along with bid only.
6. Bidder to confirm that duly filled in signed and

stamped (each sheet) Bidders proven track record
proforma attached as Annexure-1 of the Technical
check list has been submitted with the bid.
Format No. EIL 1641-1924 Rev. 1

Page 328 of 674
FOR
A133-086-16-44-CL-4130 Rev. A
COKE DRUM STRUCTURE

Confirmed / Not
Confirmed
7. Confirm that the inspection & Testing requirements

as specified in the Bid Specifications shall be
complied.
8. Bidder to confirm that statutory approval from local

authorities (i.e. lift inspector) for installation and
operation of the elevator is included in bidders
scope.
9. Bidder to confirm that they will supply mandatory

spares as per the mandatory spares philosophy
given in annexure-3 of this document and a
separate lump sum price has been quoted for the
same.
10. Bidder to confirm that the list of recommended

spares for two (2) years of normal operation &
maintenance with itemized price along with quantity
filled in Spare Parts Interchangeability Report
(SPIR) format (Annexure-2 of this technical
checklist) has been included in the bid. Owner (M/s
CPCL) shall order these spares separately.
11. a. Confirm that erection and commissioning

spares, as required, have been included by the
bidder within the quoted price for main
equipment and the list of quoted commissioning
spares has been included with the bid.
b. Confirm any and all spares required during

commissioning, over & above quoted spares
shall be supplied by bidder without any time &
price implication. Also, if any spares are
consumed during commissioning from
mandatory spares, the same shall be
replenished by vendor without any cost
implication within a mutually agreed time.
12. Confirm that Special Tools and Tackles as

required for normal operation and maintenance of
Coke drum structure elevator have been included
by the bidder within the lump sum price quoted
for main equipment.
Also confirm that bidder has included list of quoted
Special Tools and Tackles in the bid.
Else, bidder to confirm that special tool & tackles

are not required.

Page 329 of 674
FOR
A133-086-16-44-CL-4130 Rev. A
COKE DRUM STRUCTURE

Confirmed / Not
Confirmed
13. Bidder to confirm that Bidders free maintenance

services alongwith requisite spares shall be
available for a period of one year after the elevator
is commissioned and handed over to Owner within
lump sum quoted price for main equipment (Refer
clause no. 5.1.8 of job specification no. A133-086-
16-44-SP-4140).
14. Please confirm that bidder shall provide AMC

services after free maintenance period for life time
of the equipment on yearly renewable basis as
mentioned in clause no. 5.1.9 of Job Specification
(Doc. No. A133-086-16-44-SP-4140).
15. Confirm that all Drawings / Data required to be

submitted with bid as per Vendor Data
Requirement (Document no.-A133-086-16-44-VR-
4130) sheet have been included in the Bidders
proposal.
16. Confirm that in the event of order, all drawings,

documents and data shall be furnished in
accordance with Vendor Data Requirement sheet
included in this requisition.
17. Confirm that bidder has submitted following

documents along with bid.
i) Duly filled in, signed & stamped technical
check list
ii) Bidders proven track record proforma
(Annexure-1)
iii) List of commissioning spares
iv) Itemized price list of 2 years spares in
SPIR format (Annexure-2)
v) Signed & stamped mandatory spares list
(Annexure-3)
vi) Deviation / clarification schedule, if
applicable. (Annexure-4)
vii) GA drawing of Lift (for downstream
engineering)
viii) Machine Room layout (for downstream
engineering)
ix) Utility Consumption (Electrical power) (for
downstream engineering)
x) Foundation load data (for downstream
engineering)
Bidders Seal with date Signature of Authorised Representative

Page 330 of 674
DOCUMENT No.
TECHNICAL CHECK LIST
FOR A133-086-16-44-CL-4130 Rev. A
COKE DRUM STRUCTURE ELEVATOR (LIFT) Page 5 of 8
(Annexure-1)
Bidders proven track record proforma
ITEM : Coke Drum structure Elevator (Lift) (Hazardous Area)
ITEM NO : 86-LZ-20
MR No. : A133-086-LZ-MR-4140
Sl. Name of Contact Whether bidder has Year of Duty/ Application Capacity Lift Travel Area classi- Has the elevator
No. Client & Person and engineered, Commi- (Passenger cum (kg) Length fication completed 8000 hrs
Location Address, Ph. manufacture, ssioning goods/ Goods) (meter) (Hazardous/ without any major
No. & Email packaged, tested and Non-Hazardous) overhaul as on date of
Id supplied the elevator? issue of enquiry?
NOTE:
1. Bidder to submit duly signed and stamped this proven track record proforma with the bid.
2. Only those reference which complies with the requirements specified in cl. 4.1 of PMCs job specification for Coke drum structure elevator (Lift) (Doc. No.
44NC-4600-0086-M.02/0023/A4) needs to listed here.
3. Bidder to submit copy of purchase order/ technical specification/ IRN/ approved drawing/ user certificate/ feedback in support of references being submitted.
4. Incorrect information furnished in this proforma shall render the bid liable for rejection.
5. Bidder to submit their standard reference list also.
Bidders Seal with date Signature of Bidders Authorised Representative
Page 331 of 674
SPARE PARTS INTERCHANGEABILITY REPORT (SPIR) (Annexure-3)
REFERENCE NO
TAG NUMBER /
SPIR NUMBER:
SPIR DATE:
MANUFACTURER AND ADDRESS
REVISION NO: EQUIPMENT PO No.
TO BE COMPLETED BY VENDOR
PRICE VALIDITY:
DATE
SUBMITTED:
1
LOCATION:
MODEL NO
PROJECT TITLE:
CONSULTANT AND ADDRESS
PROJECT NO:
2 TO BE COMPLETED BY VENDOR EQUIPMENT DETAILS
SPARES
AVAILABILITY:
CURRENCY:
LEAD TIME WEEKS

INSTALLED PARTS
USER RECOMM'D
MINIMUM STOCK
COMM.SPARES
UNIT OF ISSUE
ITEM NUMBER
INITIAL ORDER
SPARES (2 yrs)
TOTAL NO OF
ITEM STATUS
ORIGINAL
MANDATORY
EST ANNUAL
CRITICALITY
CATEGORY
OPERATING
BIN STOCK
MATER
SERIAL NO
MANUFACTURER
IP CODE
SPARES
USAGE
(V/E/D)
IAL
QTY
QTY
DRAWING AND UNIT Item No.
3 DESCRIPTION OF PARTS SPECIF REMARKS SAVINGS PR NO
NO MANUFACTURER' PRICE (MESC)
ICATIO
S
N
PART NO
NO OF
4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
UNITS
N
U
M
B
E
R
O
F
5 P
A
R
T
S
P
E
R
U
N
FIELD ORIGINATOR FIELD AUTHORITY COMMERCIAL SUPPORT DIVISION CODING SECTION PROCUREMENT (Opns) APPROVAL
NAME
NAME : NAME : NAME : : NAME :
TITLE : TITLE : TITLE : TITLE : TITLE :
SIG : SIG. : SIG. : SIG. : SIG. :

DATE : DATE : DATE : DATE : DATE :
NOTE:- This format is under development. This is the sample format. Approved format shall be given to vendor later on.
Imbi/SPIR-SPF/03 Page 332 of 674
FOR
A133-086-16-44-CL-4130 Rev. A
COKE DRUM STRUCTURE
(Annexure-3)
Mandatory Spares List

ITEM NO : 86-LZ-20
MR No. : A133-086-LZ-MR-4140
Mechanical Mandatory Spares
Sl. No. Part Description Quantity Required
1. GEAR BOX
a. High speed & Low speed gears and 1 Set
shaft assembly
b. Radial Bearings 1 Set
c. Thrust Bearings 1 Set
d. Labyrinths, Oil seals 1 Set
e. Gaskets / O- Rings 1 Set
Electrical Mandatory Spares
Refer cl. No. 5.3.3 of Scope of work & Job specification (Electrical) for coke drum
structural elevator (Lift) (Doc. No. A133-086-16-50-SP-4140)
Instrumentation Mandatory Spares
1. All types of Instruments/ sensors/ 10% of each type or minimum 1 no.
lamps/ Push Buttons
2. All Types of modules/ I/O cards etc. 10% of each module or minimum 1 no.
Note:
1. Bidder to note that detailed list of mandatory spares is not to be submitted at bid
stage. This shall be finalized during detail engineering stage as per the above
mentioned mandatory spares philosophy without any commercial implication.
2. Bidder shall submit duly signed and stamped copy of this Annexure-3 along with bid.
3. The word TYPE means the Make, Model No., Type, Range, Size/length, Rating, and
Material as applicable.
4. Wherever % age is identified, Bidder shall supply next rounded figure.
Bidders Seal with date Signature of Bidders Authorised Representative
Page 333 of 674
FOR
A133-086-16-44-CL-4130 Rev. A
COKE DRUM STRUCTURE
(Annexure-4)
Deviation/Clarification Schedule

ITEM NO : 86-LZ-20
MR No. : A133-086-LZ-MR-4140
Sl. Document No. Sheet Clause Requisition Deviation

No. No. No. Requirement /Clarification
1.
2.
3.
4.
5.
6.
7.
8.
NOTE:
1. Bidder to note that pre-bid meeting shall be held. The date of pre bid meeting will be as
specified elsewhere. Bidder is required to furnish deviation/clarifications, if any, w.r.t.
bid requirement before pre bid meeting, so that the same can be resolved during pre
bid meeting and can be regularized through amended bidding document.
2. However, in exceptional cases, if there is any deviation/clarification (no deviation is
expected in bid); same shall be listed only under this deviation/clarification schedule
format (see above). Deviations/Clarifications brought out by bidder in this
deviations/clarifications schedule format only shall be considered.
Deviations/Clarifications, included elsewhere in the offer shall not be taken cognizance
of and shall be considered as invalid.
3. If there is no deviation to MR requirement, bidder shall write NIL: and submit along-
with the bid.
4. Bidder is requested to submit duly signed and stamped deviation/clarifications schedule
with the bid.
Bidders Seal with date Signature of Authorised Representative
Page 334 of 674
JOB SPECIFICATION DOCUMENT No.
FOR A133-086-16-44-SP-4140
COKE DRUM STRUCTURE Rev A
JOB SPECIFICATION
FOR
(LIFT)
(86-LZ-20)

JOB NO. : A133
Page 335 of 674
FOR A133-086-16-44-SP-4140
1.0 GENERAL
1.1 The intent of this requisition is to outline the Purchasers requirements under which
the bidder shall design, engineer, procure, manufacture, assemble, inspect & test
at works, paint, pack & forward, supply, erect, test and commission One (1) no.
Coke Drum Structure Elevator (LIFT) for transportation of Goods & Passengers,
complete with all auxiliaries and features required for safe, efficient & satisfactory
operation for Delayed Coker unit of CPCL, Chennai, India.
1.2 All equipment and materials supplied under these specifications shall be designed
and manufactured in accordance with sound engineering principles, good
fabrication and construction practices. No omission in these specifications shall
relieve the bidder of his responsibilities for complying with statutory regulations,
codes as applicable. All materials supplied shall be adequate for the intended
service.
1.3 The equipment supplied shall be complete in every respect, ready for installation
and operation. Any item not specifically mentioned in this specification but required
for proper operation, maintenance and safety of the equipment / personnel shall
deem to have been specified and bidder shall include the same in his scope of
supply.
2.0 GENERAL INFORMATION
2.1 SITE LOCATION
The equipment to be supplied under this requisition shall be installed the Refinery
III Complex of the CPCL Refinery at Manali, Chennai, in the State of Tamil Nadu,
India.
State : Tamil Nadu

Nearest important Town : Chennai- 15 km.
Nearest Railway Station : Chennai central - 15 km
Nearest Port : Chennai port- 13 km
Nearest Airport : Chennai - 35 km (Meenambakkam airport)
Source of Water : From Chennai Metropolitan Water Supply &
Sewerage Board and Recycled Water
Rainy season : October to December
2.2 METEOROLOGICAL DESIGN DATA
Sl no. Parameter Minimum Normal/A Maximum/De

verage sign
(A) METEOROLOGICAL DATA
1. Elevation above mean sea 3.5
level, m
2. Ambient temperature, C tmin=18 tnor=35 tmax=45
3. Relative humidity, % 80%@tmax
Page 336 of 674
FOR A133-086-16-44-SP-4140
4. Rainfall data (mm): 100

(a) for 1-hour period
b) for 24-hour period 450
5. Wind data: 180 km/hr (as
a) wind velocity per IS:875
Part-III).
b) wind direction North East &
South West
(B) DATA FOR EQUIPMENT DESIGN
1. Low ambient temperature for MDMT, 0C 15
0
2. Design temperature for equipment, C 65
3.0 UTILITIES AVAILABLE AT BATTERY LIMIT
3.1 Electric power as detailed in Electrical specification attached with MR (Doc. no.
A133-086-16-50-SP-4140).
4.0 SCOPE
4.1 SCOPE OF SUPPLY
Bidder shall supply One (1) no. Coke Drum Structure Elevator (86-LZ-20) of 3000
kg capacity for the transportation of goods and passengers complete with all
Accessories as per the Technical Specification and Data Sheet attached. Lift shall
be suitable for machine room located immediately over the hoist way/ lift well.
Coke Drum Structure Elevator shall mainly comprise of, but not be limited to,
the following:
4.1.1 Complete Car body with door, Fan on top, Operating device(s), Car Guide rails,
Brackets, etc. with all other accessories.
4.1.2 Counter weight and its guide rails with suitable fixtures, Brackets, etc.
4.1.3 Drive mechanism with support arrangement, rope & sheaves - located in machine room
(non-pressurised).
4.1.4 Automatic controller located in machine room (non-pressurised).
4.1.5 Accessories such as limit switches, landing stop switches, door contacts, alarm bell, car
buffers, counterweight buffer, channels for buffer support in the pit and all other
necessary accessories for ensuring safe operation of elevator.
4.1.6 Operating device at landing with necessary indicating devices. Following push buttons
are to be provided as minimum:
Car movement
Fan on/off switch
Page 337 of 674
FOR A133-086-16-44-SP-4140
Buttons for all floors

Emergency stop button
Emergency alarm button
Emergency light
4.1.7 Landing door with necessary contacts.
4.1.8 Landing door with emergency unlocking facility.
4.1.9 Overspeed safety mechanism
4.1.10 Automatic Rescue Device with battery and battery chargers
4.1.11 Pit ladder
4.1.12 Lighting in the car, machine room, pit and hoistway.
4.1.13 All Electrical equipment as per attached Electrical specification (Doc. no. A133-086-16-
50-SP-4140).
4.1.14 Minor civil/structural works such as Chipping/Grouting/Fixing of all bolts, sills, support
members, indicator and button box etc.
4.1.15 Necessary erection material for erection of elevator in the hoist way.
4.1.16 First fill of all lubricants & oils (To be included in lump sum base price of main
equipment).
4.1.17 Quotation of recommended Spares for two years of normal operation and
maintenance. Vendor to submit separate itemized priced list along with recommended
quantity in the Spare Parts Inter-Changeability Report (SPIR) (Annexure-2 of Technical
Checklist A133-086-16-44-CL-4140) format attached with MR and submit the unpriced
copy of the same alongwith unpriced offer.
4.1.18 Erection & Commissioning spares as required. (To be included in lump sum base
price of main equipment).Vendor to furnish the list of quoted commissioning spares with
bid.
4.1.19 Mandatory spares as per the mandatory spares philosophy given in Annexure-3 of
Technical Checklist (Doc No. A133-086-16-44-CL-4140). (Separate lump sum price to
be quoted).
Detailed list of mandatory spares is not to be submitted at bid stage. This shall be
finalized as per mandatory spares philosophy defined in the Annexure-3 during
detail engineering stage without any commercial implication. Bidder is required to
submit signed & stamped Annexure-3 as a confirmation for supplying of mandatory
spares as per philosophy mentioned therein along with the bid
4.1.20 Special tools and tackles for maintenance. (To be included in lump sum base price of
main equipment). Bidder to furnish the list of offered Special tools and tackles with bid.
4.1.21 All drawings and documents as per Vendor Data Requirement (A133-086-16-44-VR-
4140). (To be included in lump sum base price of main equipment)
Page 338 of 674
FOR A133-086-16-44-SP-4140
4.1.22 Any other item not specifically mentioned but required for safe and efficient operation of
the elevator.
5.0 SCOPE OF SERVICES
5.1 The scope of services shall include, but not be limited to, the following.
5.1.1 Design, Engineering, Manufacture, Inspection & Testing at manufacturers work,

Painting and supply of the complete equipment.
5.1.2 Handling and transportation from purchasers store to work site, temporary storage
and assembly of the equipment at work site.
5.1.3 Erection of Elevator equipment including welding supports brackets for car and
counter weight. These shall include drilling holes wherever required and making
good after erection is complete.
5.1.4 Test at site as per code.
5.1.5 Commissioning.
5.1.6 Inspection and certification of elevator installation at site by statutory authorities.
5.1.7 Third party inspection requirement shall be as per commercial part of RFQ.
5.1.8 Bidder's free maintenance service shall be available on the Freight cum passenger
elevator for a period of one year after the Freight cum passenger elevator
equipment is commissioned and handed over to the Purchaser. During free
maintenance period, replacement of damaged parts including supply of
consumables such as lubricants, oils etc. shall be done by Bidder free of cost and
Bidder shall carry out load testing and safety checks once in six month to meet the
statutory requirement.
5.1.9 After free maintenance period, Bidders AMC (Annual Maintenance Contract
Services on Chargeable basis ) services shall also be available for regular
maintenance (i.e. attending breakdown of elevator within short notices, checking of
clearances, necessary adjustment, lubrication etc. including replacement of
damaged parts ) for which Bidder shall quote AMC charges separately on yearly
basis to client, if so required.
5.1.10 Bidder shall be obliged to provide AMC (renewable every year) for lifetime of
equipment.
5.2 INSTRUCTIONS TO BIDDER
5.2.1 Bidder to indicate per meter cost for increase/decrease in shaft length .
5.2.2 Bidder shall also indicate cost for increase/decrease per Landing/Opening.
5.2.3 Bidder shall furnish lubrication schedule with specifications & the equivalent grade,
type of lubricants, grease, oils of Indian brand (such as IOCL, HPCL, CPCL etc.)
Page 339 of 674
FOR A133-086-16-44-SP-4140
5.3 WORKS EXCLUDED FROM BIDDERS SCOPE
5.3.1 Properly framed and enclosed hoist way including overhead machine room, along
with associated civil/strl. & foundation works. The machine room shall not be
pressurized. All electrical components for hazardous area lift shall be suitable for
non-pressurized machine room.
5.3.2 Elevator pit (RCC type) of proper depth below the lowest landing along with curb
wall.
5.3.3 Trolley mounted chain pulley block along with mono rail shall be provided by the
Purchaser in the machine room. However, Bidder shall provide the capacity &
lift of C.P block.
5.3.4 Continuous sill bearing area for each hoistway entrance of proper
construction so as to achieve anchorage and support for each sill, if
& wherever required.
5.3.5 Unloading at site and initial storage at purchasers store.
5.3.6 Power supply shall be made available as per electrical specification (Doc. no. A133-
086-16-50-SP-4140) attached with the MR.
6.0 TECHNICAL REQUIREMENTS
6.1 Coke drum structure elevator shall comply with the requirements given in Document
Job Specification for Coke drum structure elevator (Document No: 44NC-
4600-0086/M.02/0023/A4) and Datasheet for coke drum structure elevator
(Doc. No. 44NC-4600-0086-M.04/0034/A4) attached with this requisition with
following Amendments:
Sl. Clause Addition(A)/ Description

No. no./ Deletion(D)/
Modification(M)
Page no.
Job Specification for Coke drum structure elevator (Document No: 44NC-4600-
0086/M.02/0023/A4)
1. General M The term EPCC Contractor shall be read as Vendor
wherever specified in the document.
2. 3.5/ M The clause shall be read as follows:
4 of 9
Freight-cum-Passenger elevator (Lift) shall be provided for
transportation of goods and passengers from grade to the
cutting deck (platform) of coke drum structure with number of
landings as indicated datasheet for coke drum structure
elevator attached with this requisition. At grade level, entry shall
be from both sides.
3. 3.6/ M The clause shall be read as follows:
4 of 9
Capacity of lift or elevator shall be considered as 3000kg.
4. 4.1.3/ A Vendor shall submit filled in signed & stamped bidders proven
track record proforma attached as annexure-1 to Technical
Page 340 of 674
FOR A133-086-16-44-SP-4140
4 of 9 Checklist along with the bid. Same shall form the basis of
evaluation for compliance with equipment qualification criteria
as specified in cl. 4.1 of Doc. No. 44NC-4600-
0086/M.02/0023/A4.
5. 5.2/ M Chain pulley block of adequate capacity in machine room for
maintenance purpose shall be supplied by purchaser. However,
8 of 9
lift and capacity of the same shall be provided by vendor.
6.2 All electrical equipment shall meet the technical requirement as per enclosed
Electrical specification (Doc. no. A133-086-16-50-SP-4140) and Electrical data
sheets.
6.3 Vendors drawing/ document shall be subject to reviews by PMC. Comments made
by PMC, during detail engineering, shall be taken care by vendor without any
commercial implication.
7.0 SPARE PARTS AND TOOLS & TACKLES
7.1 COMMISSIONING SPARES
Commissioning spares shall cover the erection, pre-commissioning and commissioning

of the equipment and materials and shall be supplied by vendor as part of the Lump
sum price. The commissioning spares shall also include parts and assemblies normally
used or consumed during installation of equipment, cleaning, flushing and inspection.
Commissioning spare parts are to safeguard the operation of the equipment during the
running-in and start-up periods. Commissioning spare parts must arrive on worksite at
the same time as the parent equipment, but in any case prior to erection. The spare
parts shall be packed separate from the main order. Each item shall be duly marked
with the Purchase Order, reference number (if any) and spare parts identification
numbers.
Any and all spares required during commissioning, over & above quoted spares, (except
for unsupervised damage or accidental breakage) shall also be supplied by Vendor
without any time & price implication. Also, if any spares are consumed during
commissioning from mandatory spares, the same shall be replenished by Vendor
without any cost implication within a mutually agreed time.
7.2 MANDATORY SPARES
Mandatory spares as per the mandatory spares philosophy given in clause no. 4.1.19
of this Document. Other requirements as stated above for commissioning spare parts
shall be applicable for Mandatory Spare parts as well. Vendor shall not utilize
mandatory spares during commissioning. If the same are used as emergency
requirement during commissioning, Vendor shall replenish the same within a mutually
agreed time without any commercial implication to owner.
7.3 OPERATION AND MAINTENANCE SPARES
Vendor shall provide a list of recommended spares for two years operation and
maintenance of the equipment. Critical important factors for selection of O&M spare
include key operation and safety functions of equipment, possibility of damage during
installation / commissioning, service intervals etc. by manufacturers. The offer validity
Page 341 of 674
FOR A133-086-16-44-SP-4140
for supply of 2 years operation & maintenance spares shall be as per commercial
documents. These spares shall be ordered separately by client (M/s CPCL). All spare
parts shall be new, of acceptable quality and in unused condition with relevant
warranties and guarantees provided. The spare parts shall be identical in Design,
specification to the original equipment component.
7.4 SPECIAL TOOLS AND TACKLES
Special tools are those tools which are not readily available. Equipment vendor shall
identify and supply all special tools and tackles required for operation and maintenance
of equipment. Vendor shall ensure that all such items are clearly identified as to the part
for which the special tool/ tackle is required and the list of same shall be furnished with
the bid. All special tools shall be in new condition with warranties and guarantees
provided. In the event Vendor may need to use the special tools during installation, pre-
commissioning and commissioning, same shall be promptly replaced by new one, if
damaged.
7.5 SPECIAL INSTRUCTIONS FOR SPARE PARTS
Following minimum details for spare parts to be included in spare parts manual to aid
the procurement of such spare parts by client (end user) at later stage:
Reference No. of spare parts.
Description of spare parts.
Name of manufacturer and the complete address with phone no., e-mail ID, Web
address etc.
Address of local representative of spares vendors, if applicable.
8.0 PROTECTION & PAINTING
Protection and Painting shall be as per attached General specification for shop and
field painting (Document no. 44NC-4600-0000-V.02-0111-A4) suitable for corrosive
environment.
9.0 TESTING AT SITE
After commissioning of the elevator, Bidder shall demonstrate following at site:

- Rated capacity of the elevator.
- Speed of the elevator.
10.0 ORDER OF PRECEDENCE
For all equipment, contractor shall follow the requirements in documents in the following
order of precedence:
a) Mechanical datasheets.
b) Job specification.
c) Process data sheet.
d) EIL/PMC Standard
e) Other Codes and standards.
However all conflicts / discrepancies in the above mentioned documents shall be
submitted to EIL for approval and EIL/PMC decision shall be final without any
commercial impact to EIL.
Page 342 of 674
Page 1 of 9
CHENNAI PETROLEUM CORPORATION LIMITED

MANALI REFINERY, CHENNAI
RESID UPGRADATION PROJECT
LSTK-1 : COKER BLOCK : DELAYED COKER UNIT & LPG CFC TREATING UNIT
PART : III
SECTION : B.4.6
JOB SPECIFICATION FOR

COKE DRUM STRUCTURE ELEVATOR ( LIFT) ( 86-LZ-20)
DOCUMENT NO : 44NC-4600-0086/M.02/0023/A4
Rev no. Issue date Pages Rev description Prepared Checked Approved
By By By
A 22.03.10 9 Issued for FEED HK GHD SNG
B 30.06.10 9 Client comments GAK GHD SNG

incorporated and issued
for FEED
Page 343 of 674

CPCL Chennai JOB SPECIFICATION FOR PART-III Section B.4.6
44NC - 4600 COKE DRUM STRUCTURE ELEVATOR ( LIFT) Sheet 2 of 9
LSTK-1 Coker Block Doc. No. 44NC-4600-0086/M.02/0023/A4 Rev. B
TABLE OF CONTENTS
1.0 SCOPE 3
2.0 CODES & STANDARDS 3
3.0 BASIS OF DESIGN 4
4.0 TECHNICAL REQUIREMENTS 4
5.0 SCOPE OF SUPPLY 7
6.0 INSPECTION AND TESTING 8
7.0 PACKING AND IDENTIFICATION 9
Page 344 of 674

1.0 SCOPE
1.1 This specification along with other documents attached with FEED describes the minimum
requirements for design, engineering, manufacture, testing, supply, supervision of erection
of the coke drum structure elevator ( Lift).
2.0 CODES & STANDARDS
2.1 Apart from the various codes and standards listed below, vendor shall have to comply with
other requirements of codes and standards mentioned in the FEED documents for design,
manufacture & testing. Latest edition of codes and standards shall be followed
The equipment shall comply with all currently applicable statutes, regulations and safety
codes related to the design, construction and operation in the locality where the unit will be
installed. Nothing in this specification shall be construed to relieve the vendor of
responsibility for proper design, workmanship and materials to meet the specified
conditions.
2.2 The codes and standards to be followed by vendor for design, construction, testing of the
equipment shall be as listed below.
BS EN 81-1 Electric lifts

95/16/EC European Lift Directive
98/37/EC European Machinery Directive
BS EN 81-1, 1998 Electric Lifts
BS 6399 Pt 2, 1997 Loadings for Buildings. Code of Practice for Wind Loads
IS: 14665: Part 1 Guidelines for Outline dimensions of Passenger, Goods, Service &
Hospital Lifts.
IS: 14665: Part 2 Code of practice for Installation, operation and maintenance of
Electric Passenger and Goods Lifts.
The installation and testing shall be carried out as required by the local codes and as per
normal practice prevalent in the Lift Industry, Lift Act & Rules.
All electrical equipment / works in connection with electric Passenger cum Freight Elevator
shall be in accordance with the latest provisions of Indian Electricity Act1910 and Indian
Electricity Rules.
3.3 In case of conflict between this specification and other attached specifications, in general
the most stringent requirements shall govern. Order of precedence will be as below
(a) Licensors documents
(b) Job Datasheets
(c) P&I diagram (If applicable)
(d) Job specification
(e) Engineering Design basis
(f) National and Local rules and regulations
(g) Indian national codes and standards
(h) International codes and standards
Page 345 of 674

However, all the conflicts shall be referred to PMC/Owner for clarification and the decision
of PMC/ Owner shall be final and binding on the bidder without any cost and delivery
implications.
3.0 BASIS OF DESIGN
3.1 This specification, data sheets and other FEED documents along with following shall form
the basis of design.
3.2 Area classification : Zone 2 & Zone 22- dust, IIA/IIB, T3
3.3 Installation : Outdoor
3.4 Duty : As specified in data sheet
3.5 Freight-cum-Passenger elevator (Lift) shall be provided for transportation of goods and
passengers from grade to the cutting deck (platform) of coke drum structure with number
of intermediate landings (3 nos minimum). All elevations, number of landings shall be
reviewed post order stage for compliance with operational requirements of the plant. At
grade level entry shall be from both sides.
3.6 Capacity of Lift or Elevator for shall be at least 3000 kg or weight of the largest component
to be handled with a design margin of minimum 20%. The capacity selection calculation
shall be submitted for Owner/PMC review.
3.7 The design, installation and testing of Lift shall comply with local laws and regulations,
as per IS: 14665: Part 1& 2.
3.8 Lift controls shall be micro processor based
3.9 VVVF drive shall be provided for the lift.
3.10 Lift shall be suitable for area classification where it will be installed.
3.11 All motors and electrical items in lift shall be flameproof ( EExd)
4.0 TECHNICAL REQUIREMENTS
4.1 Equipment qualification criteria
4.1.1 The vendor for the complete unit shall be an established manufacturer of elevator( lift) and
he shall also be the manufacturer of the proposed elevator having adequate design,
engineering, manufacturing and testing facilities for the same. Relevant information of the
offered equipment like catalogues, references, users certificates etc. shall be furnished
along with the offer
4.1.2 The vendor shall have engineered, manufactured, packaged, tested and supplied at least
two identical or validly similar elevator in terms of capacity, span, lift, duty, etc. from the
proposed plant in last fifteen years at least one of these shall have successfully operated in
the field for at least 8000 hours without any major overhaul as on the date of issue of
enquiry
4.2 The equipment shall be of proven design. Vendor shall take full responsibility for the
complete design and engineering of the equipment .The Coke drum structure elevator shall
generally be provided with following minimum features. Additional features required as per
elevator vendors standard design shall also be provided. The Coke drum structure
Page 346 of 674

elevator shall be suitable for operation in hazardous area.
4.3 DRIVE UNIT
The Drive Unit shall be of the single wrap traction type, and shall include a motor, electro-
mechanical brake, reduction gear, sheave, shaft, all compactly mounted on a single base
plate. The worm shaft and sheave shaft shall be provided with suitable bearings. The
bearings shall be selected for minimum 40,000 hrs life. The driving sheave shall be
grooved to ensure sufficient traction and minimize rope wear. Adequate means of
lubrication shall be provided for all bearings and gearbox.
4.4 BASE PLATE
A properly machined drive unit base plate of steel construction shall be supplied.
4.5 FOUNDATION
The machine shall be placed directly above the hoist way in machine room on suitable
steel structure and RSJ sections with suitable anti vibration pads in between machine base
plate and its support to reduce vibration.
4.6 BRAKE
The direct current brake shall be spring applied and electrically released and designed to
provide smooth stops under variable loads. Mechanism shall be provided to stop freefall of
car incase of any accident.
4.7 CONTROLLER
An automatic controller shall be provided which shall control all the operations starting/
stopping, application of brake in case of power failure etc. An automatic rescue device
shall be provided, that will move lift to the nearest upward and downward landing (subject
to load) in the event of power failure.
4.8 ROPES
The Passenger cum Freight Elevator shall be provided with traction steel hoist ropes
(galvanized).
4.9 CAR FRAME
The car frame consisting of car enclosure and the floor shall be fabricated out of rolled
sheet sections. Suitable guides shall be provided for smooth up/down movement of the
car. The car safety device shall be located underneath the car frame. Floor plate shall be
chequered type. The car frame shall be robust enough to withstand occasional impact
loading by a forklift or platform truck.
4.10 OPERATING DEVICES
These shall be furnished as flush type finished metal panel containing buttons marked to
correspond with landings served. An emergency stop switch and an alarm button
connected to a bell shall serve as an emergency signal. It shall be possible to operate the
Passenger cum Freight Elevator both from inside the car and from various landing floors.
4.11 DOOR OPEN & EMERGENCY BELL
A bell, furnished and installed in the car, shall ring while a landing button is pressed and
the car gate or hoist way door is open. Emergency call bell shall be provided at ground
floor. Contractor shall also make provision to extend the alarm to nearby control room.
Page 347 of 674

4.12 CAR GATE CONTACT
An electric contact shall be provided for the car door or gate. The contact shall be
designed to prevent movement of the car away from a landing unless the door or gate is in
properly closed position. For starting the lift, the door shall be closed manually and a
button shall be pressed.
4.13 CAR OPERATION
4.13.1 The car shall not start unless the car gate is in the closed position and all hoistway doors
are locked in the closed position.
4.13.2 Momentary pressure of car or hallway button shall send the car to the landing selected
where the car will automatically stop. Car operation shall be of selective/collective type.
4.13.3 Momentary pressure of a landing button shall bring the car to the desired landing. Car
position shall be indicated at all the floors and also inside the car.
4.14 GUIDES
Contractor shall furnish steel Tee guides with necessary brackets for car and
counterweight.
4.15 HOIST WAY DOOR AND CAR DOOR
The hoist way door as well as the car door shall be of sliding shutter type (vertical bi-
parting) of steel construction and shall be suitable for manual operation. Each hoist way
door shall be provided with an interlock, which shall prevent movement of car away from
the landing unless all the doors are closed and locked. The interlocks shall also prevent
opening of the doors except at the landing where the car is stopping or has stopped.
4.16 HOIST WAY LANDING
Suitable Push button shall be provided at each landing. It shall be possible to load the
Passenger cum Freight Elevator at any floor and send unmanned to any floor.
4.17 COUNTER WEIGHT
For economical operation of the Passenger cum Freight Elevator suitable counter weight
arrangement, moving in guided structural steel frame, shall be provided.
4.18 OVER SPEED SAFETY
An over speed safety device to stop the car whenever the car achieves runaway speed
limit resulting from high speed descending of the car, shall be provided. The device shall
be operated by a centrifugal governor, which continuously and automatically senses the
car speed. The actuation of the safety device shall cut off the power supply to the motor
and apply the brake immediately. An alarm shall be activated. Afterwards it shall be
possible to bring the car safely to the nearest landing to rescue men and materials.
4.19 TERMINAL AND FINAL LIMITS
Terminal limit switches shall be provided to slow down and stop the car automatically at
the terminal landing. To arrest movement of car beyond the terminal landings, final limit
switches shall be provided which on operation shall cut off the power and apply the brake
immediately. Inching device shall be provided for accurate positioning of the car with the
landings.
Page 348 of 674

4.20 TERMINAL BUFFERS
Spring buffers shall be installed as a means of stopping the car and counterweight
at the extreme limits of travel. Buffers in the pit shall be mounted on steel channels
provided by purchaser, placed between both the car and counterweight guide rails.
4.21 INDICATIONS
4.21.1 Following signals shall be provided:

(a) Hall buttons with Up/Down arrows at all floors.
(b) Car position indication with arrow in the car.
(c) Car position indication with arrow in hall on all floors.
4.21.2 Following details shall be displayed inside car

(a) Name plate indicating capacity of lift.
(b) Operating instructions in English and Hindi language.
(c) Overloading alarm shall be provided.
(d) Emergency rescue procedure shall be displayed in machine room.
4.22 ELECTRICAL EQUIPMENT
Complete electrical works for the Elevator shall be in Elevator Vendors scope and shall be
as per enclosed Electrical specification.
Access to elevator door shall not be less than the width of the car. Also, Forklift access to
the grade level landing shall be ensured while making the layout.
4.23 PAINTING
Painting shall be as per structural painting specifications enclosed elsewhere in FEED

document.
4.24 Lift shall be provided with telephone facility for emergency.
5.0 SCOPE OF SUPPLY
5.1 The minimum scope of supply of freight cum passenger elevator vendor shall consist of
design, engineering, manufacture, testing , painting, erection and supply of the complete
equipment at site.
5.2 The Freight-cum-passenger elevator shall be complete with, but not be limited to,
the following:
- Complete Car body with door, Fan on top, Operating device(s), Car Guide etc.
with all other accessories
- Counterweight and its guide rails with suitable fixtures.
- Drive mechanism with rope & sheaves - located in machine room.
- Accessories such as limit switches, landing stop switches, door contacts, alarm
bell, car buffers, counterweight buffer and all other necessary accessories for
ensuring safe operation of lift.
- Operating device at landing with necessary indicating devices.
- Landing door with necessary contacts.
- Landing door with emergency unlocking facility.
- Over speed safety mechanism
- Pit ladder.
Page 349 of 674

- Lighting in the car.

- Lighting in hoist way and pit
- CP Block of adequate capacity in machine room for maintenance purpose
- All Electrical equipments
- Commissioning spares
- Special tools and tackles, if any, for maintenance.
-
5.3 Erection of elevator equipment shall be complete including cutting holes, welding supports,
brackets and making good for car and counter weight rail brackets.
5.4 Properly framed and enclosed hoist way including its extension (machine room) above the
roof. All civil & foundation works.
5.5 Passenger cum Freight Elevator pit of proper depth below the lowest landing.
5.6 Continuous sill bearing area for each hoist way entrance of proper construction so as to
achieve anchorage and support for each sill, if & wherever required.
5.7 Monorail beam in the machine room and rolled steel sections with bearing plates for
support of the machine with metal grating, buffer support channels in the pit.
5.8 Vendor shall arrange inspection and initial certification of Elevator installation at site by
statutory authorities..
5.9 Vendor's free maintenance shall be available on the Passenger cum Freight Elevator for a
period of one year after the Passenger cum Freight Elevator equipment is commissioned
and handed over to the purchaser. During free maintenance period, Vendor shall carry out
load testing and safety checks once in six month to meet the statutory requirement.
5.10 After free maintenance period, the Elevator Vendor's AMC services shall also be available
for regular maintenance (i.e. attending breakdown of elevator within short notices,
checking of clearances, necessary adjustment, lubrication etc. including replacement of
damaged parts ) on chargeable basis, for which Elevator Vendor shall quote AMC charges
separately on yearly basis to Client. Elevator Vendor shall be obliged to provide AMC
(renewable every year) for lifetime of equipment.
6.0 INSPECTION AND TESTING
6.1 Vendor shall carry out the tests as required by the local code and as per normal practice of
the lift industry.
6.2 Over-load testing shall be done as per applicable codes for coke drum structure elevator.
6.3 Elevator vendor shall comply with the requirement of local laws and statutory authorities.
Lift inspection etc. and getting the requisite certification for operation of lift at site is
included in contractors scope of services. All inspection / certification expenses shall be
borne by contractor.
6.4 Equipment shall be subjected to stage-wise expediting, inspection and testing at

contractors / sub-contractors works by Owner / PMC / third party.
6.5 All tests shall be witnessed by Owner / PMC / third party. However, such inspection shall
be regarded as check up and in no way absolve the contractor of his responsibility. A
certified record of test figures/results shall be provided.
6.6 Owner/PMC/third partys attendance to such inspection and/or test shall not be interpreted
Page 350 of 674

as in any way to relieve contractor from any liability or responsibility for any defects which
may be found during the guaranteed period.
6.7 Test certificates of all bought out components shall be provided. All electrical equipment
shall be tested as per relevant IS / applicable specifications and test certificates for motors
and brakes shall be provided. All electrical equipment for hazardous areas shall be
certified by CMRI / CEE, BASEEFA or equivalent and necessary certificates shall be
furnished.
6.8 All inspection and testing shall be as specified in FEED document.
7.0 PACKING AND IDENTIFICATION
7.1 All packaging shall be done in such a manner as to reduce the volume. The equipment
shall be dismantled into major components suitable for shipment and shall be properly
packed to provide adequate protection during shipment. All assemblies shall be properly
match marked for site erection.
7.2 Attachments, spare parts of the equipment and small items shall be packed separately in
wooden-cases. Each item shall be appropriately tagged with identification of main
equipment, item denomination and reference number of the respective assembly drawing.
7.3 Detailed packing list in water proof envelope shall be inserted in the package together with
equipment.
7.4 Each equipment shall have an identification plate giving salient equipment data, make,
year of manufacture, equipment number, name of manufacturer, etc.
Page 351 of 674

DATA SHEET Document No.
FOR A133-086-16-44-DS-4140
ELEVATOR (LIFT)
Page 1 of 6
(HAZARDOUS AREA)
DATA SHEET
FOR
(LIFT)
(86-LZ-20)

JOB NO. : A133
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL All rights reserved
Page 352 of 674

FOR A133-086-16-44-DS-4140
ELEVATOR (LIFT)
Page 2 of 6
(HAZARDOUS AREA)
1. GENERAL
a. Tag No. 86-LZ-20
b. Service To carry Goods & Passengers
c. Operation Intermittent, 24 Hours/Day
d. Capacity (kg) 3000
e. Area classification in which LIFT to be Hazardous (Refer electrical specification)
installed (Refer Note-3)
f. No. of landings (Refer Note-2)
Operational GF+5
Intermediate Emergency 3
Landings
g. Elevations (Refer Note-1)
GF 100.000 m
1st Intermediate Emergency 108.800 m
Landing
2nd Intermediate Emergency 114.000m
Landing
1st Landing 122.250 m
2nd Landing 130.634 m
rd
3 Landing 140.400 m
4th Landing 151.000 m
3rd Intermediate Emergency 158.500 m
Landing
5th Landing 167.813 m
h. Mode of operation of Lift Automatic, without operator, push button
control
i. No of starts per hour 240
j. Location Coke Drum Structure
k. Control VVVF drive
l. Mode of operation Push button operation
m. Speed of Travel (Refer NOTE-4) 100 ft/min to 120 ft/min (0.5 meter/sec. to 0.6
meter/sec.)
2. CAR
a. Car inside size (mm X mm) 3000 (clear width)X2000(clear depth)
b. Car inside Height (H) (mm) 2200 (As per IS 14665) (min.)
c. Outside dimensions of Car (Width X *
Depth X Height) (mm X mm X mm)
d. Door opening size (mm X mm) *
e. Type of door Vertical bi-parting door (Sliding Shutter)
Ground floor landing Opening from two
sides (through way type)
All other floors landing Opening from one
side

Page 353 of 674
FOR A133-086-16-44-DS-4140
ELEVATOR (LIFT)
Page 3 of 6
(HAZARDOUS AREA)
f. No. of Doors Two (2)

g. Door operation Manual
h. Floor position indicator Required
i. Lighting Required
j. Total weight of car Un-laden (kg) *
k. Type of Bottom & top buffers *
l. Shape/size of car guide ways *
m. Diameter of guide wheel of car (mm) *
n. Material of Construction
Car *
Guide Wheels *
Rails / Guide Ways *
o. Car construction details Stainless Steel interior of car with floor of
chequered plate.
3. BALANCING SYSTEM
a. Total balance weight (kg) *
b. Balance weight sheave diameter *
(mm)
c. Balance weight rope diameter (mm) *
d. Balance weight rope length (mm) *
e. Shape/size of guide ways for balance *
weight
f. Material of Construction
Counter weight *
Guide wheels *
Rails / Guide Ways *
Sheaves *
Rope *
4. HOIST WAY
a. Size of Hoist way (inside of Hoist * (Refer Note-5)
Way)
b. Entrance door type Vertical bi-parting door (Sliding Shutter)
Ground floor landing Opening from two
sides (through way type)
All other floors landing Opening from one
side
c. Hoist way entrance Door size (mm X *
mm)
d. Lighting inside Hoist way Required
e. Hoist way type Structural
5. PIT
a. Pit Depth *

Page 354 of 674
FOR A133-086-16-44-DS-4140
ELEVATOR (LIFT)
Page 4 of 6
(HAZARDOUS AREA)
b. Pit dimensions of hoist way(mm X *(Refer Note-5)

mm)
c. Ladder in pit Required
d. Lighting in Pit Required
6. MACHINE ROOM
a. Size (LXWXH) (mm X mm X mm) *(Refer Note-5)
b. Overhead required 4800 mm (Refer Note-6)
c. Monorail beam size, recommended *
(shall be supplied by purchaser)
d. Machine room entry door size (mm X *
mm)
e. Total weight of machine (kg) *
f. Machine room chain pulley block, *
recommended capacity (Kg)
(shall be supplied by purchaser)
g. Recommended lift required for Chain *
Pulley Block (mm)
7. TRACTION ROPE
a. Diameter (mm) *
b. Construction *
c. Type *
d. Factor of Safety *
e. Tensile designation for wire rope *
f. Material of Construction *
g. Code which wire rope complies *
8. DRIVE UNIT
8.1 MOTOR
a. Rating, kW *
b. Speed, RPM *
c. Make / Model */*
d. Type *
8.2 GEARBOX
a. Type *
b. Make / Model */*
c. Ratio *
d. Sub vendors catalogue Required
8.3 COUPLING
a. Input (Type/ Make) */*
b. Output (Type/ Make) */*
c. Sub vendors catalogue Required
8.4 BRAKE
a. Type *
b. Make / Model */*

Page 355 of 674
FOR A133-086-16-44-DS-4140
ELEVATOR (LIFT)
Page 5 of 6
(HAZARDOUS AREA)
c. Sub vendors catalogue Required

8.5 Integral base plate *
8.6 Sheaves diameter (mm) *
8.7 Power supply *
8.8 Material of Construction
Gear Box *
Coupling *
Brake *
Sheave *
Base Plate *
9. ACCESSORIES
a. Fan on car ceiling(Flame proof duty) Required
b. Handset with speaker for emergency Required
communication (in car & machine
room)
c. Fire extinguishers Required
d. Car inside lighting Required
e. Emergency light inside car including Required
battery & charger
f. Hall buttons with Up & Down arrows Required
on all floors
g. Car position indicator with arrows Required
Inside car
h. Car position indicator with arrows at Required
each Landing entrance
i. Emergency call bell inside car for Required
audio alarm in unit and unit control
room
j. Door open bell outside car Required
k. Car dispatch button Required
l. Bypass key switch Required
10. SAFETY ACCESSORIES
a. Alarm Bell Required
b. Emergency Alarm Bell Required
c. Emergency Key Required
d. Limit Switches Required
e. Door locks Required
f. Automatic rescue device with battery Required
& charger
g. Keyless emergency stop switch Required
h. Emergency acknowledge signal light Required
i. Firemans service switch Required

Page 356 of 674
FOR A133-086-16-44-DS-4140
ELEVATOR (LIFT)
Page 6 of 6
(HAZARDOUS AREA)
11. MISCELLANEOUS
a. Rails with fixtures Required
b. Counter weight Required
c. Guides for counter weight Required
d. Bearing plates Required
e. Buffer support channels Required
NOTE:-
1. Elevations mentioned in data sheet are tentative and shall be finalised during detail
engineering. Bidder to indicate per meter cost for increase/decrease in shaft length.
2. Bidder shall also indicate cost for increase/decrease per Landing.
3. As the elevator including machine room is located in hazardous area, so all electrical
item, panel etc shall be suitable for hazardous area as per hazardous area
classification mentioned under electrical specification.
4. Bidder to indicate actual selected speed from the range specified.
5. Bidder to furnish dimension with plan view.
6. Bidder to either confirm the given dimension or indicate the requirement of overhead.
7. *:- Bidder to furnish.

Page 357 of 674
VENDOR DATA REQUIREMENTS Document No.
A133-086-16-44-VDR-4140
FOR Rev. A
(LIFT) Page 1 of 3
VENDOR DATA REQUIREMENTS

FOR
COKE DRUM STRUCTURE ELEVATOR (LIFT)
A 18-SEP-2013 ISSUED WITH MR DK SD SPC

Rev. Date Purpose Prepared by Checked by Approved by
No.
Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved
Page 358 of 674

A133-086-16-44-VDR-4140
FOR Rev. A
(LIFT) Page 2 of 3
The following drawings/documents marked " " shall be furnished by the bidder.
LIFT
POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. Filled in Technical Check List - Lift
2. Exception/Deviation List (if any) in the
exception/ deviation Schedule format
3. Fully filled in Mechanical datasheets for
equipment, driver, auxiliaries & instruments.
4. General Arrangement (GA) Drawing including
Machine Room with Drive unit and openings
Hoist way with Car, Guide rail with suitable
fixtures and Counterweight
Pit with buffers and ladder
Drive unit foundation plan with load data
8. Sub Assembly drawing alongwith instruction for
assembly/dis-assembly
9. Cross-sectional drawings with bill of materials
10. Equipment technical catalogue for bought out
items
11. Utility Consumption figures
12. Weight Schedule of equipments/package
13. Write-up for on operational philosophy
14. List of sub-vendors
15. Calculations for Selection and sizing of motor
Ratings
16. List of Special Tools & Tackles, if any
17. List of commissioning spares
18. List of recommended spare parts for 2(two)
years normal operation and maintenance (with
itemized price)
19. List of Mandatory spares.
20. Lubrication schedule along with specifications
of lubrication
21. Quality Assurance Plan
22. Test Certificates - Material Test Certificates @
23. Test Certificates - Non destructive test reports @
24. Test Certificates - Shop Inspection & Test

reports
Page 359 of 674

A133-086-16-44-VDR-4140
FOR Rev. A
(LIFT) Page 3 of 3
POST ORDER
S. WITH WITH
BID
(FINAL)
25. Installation, operation & maintenance manuals
containing all certified drawings & documents
26. Spare parts manuals
27. Storage instructions, preservation of equipment
for prolonged period
28. Painting Specifications
29. Test Procedure for Shop Testing & Test at Site
30. As Built Drawings
31. Other Department documents, if applicable Refer note-8 & 9
Notes :
1. "TICK" denotes applicability.
2. Post order, drawing / document review shall commence only after approval of Document Control Index (DCI).
3. All post order documents shall be submitted / approved through EIL eDMS portal.
4. All drawings & documents shall be submitted in A4 or A3 paper sizes. Documents in higher paper size shall
be submitted in exceptional circumstances or as indicated in the MR/Tender.
5. Post order- The schedule of drawing / data submission shall be mutually agreed between EIL & the bidder /
contractor / supplier during finalization of Document Control Index (DCI).
6. "@" indicates submission of documents to Inspection Agency.
7. Bill of Material shall form part of the respective drawing.
8. Also refer other department's VDR :-
9. Electrical
10. Soft copy of the final documents shall be submitted in a single file, indexed and bookmarked form
11. Final documents along with number of hard prints of final documents shall be submitted as per Annexure-1
to Vendor Data Requirement
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Annexure-1 to Vendor data requirement
APPEN DI X 9 T O SCC
COM PLET I ON DOCU M EN T S
\\Nmumfil01\project\WIP\4401-4600\4401-4600_Procurement\draft_tenders\EPCC_1-Draft\Final_After incorporation of CPCL Comments\26_SCC_Appendix 9_Completion documents.doc
Page 361 of 674

EPCC-1 Completion Documents Part I : Section 2.2
1.0 COMPLETION DOCUMENTS

1.1 GENERAL
1.1.1 The LSTK Contractor shall provide the documentation for the complete facilities under this
LSTK Contract as detailed in Annexure AA attached to this document.
1.1.2 The above documentation shall be prepared by the contractor for each process unit / offsites
facility / utilities systems as applicable. Contractor shall provide full details of the work as
built and shall include for the back drafting of all drawings / documents to ensure, they reflect
the actual as-built configuration of each unit and component.
1.1.3 All pages, drawings, data, etc., shall be of a size, suitable for insertion in an A4 (210 x 297
mm) hard core binder. In general, all drawings shall be reduced to A3 size for convenient in
handling. The documents shall be compiled in book volumes and shall be in A4 format.
1.1.4 All books shall be bound in the 280 mm side and shall not exceed 75 mm in thickness. As
many volumes as necessary for each unit / facility shall be made so as not to exceed this
dimension.
1.1.5 Any legible print of the specified size may be included. Larger legible prints shall be reduced
to the required dimensions. Exceptionally large prints will have to be reduced in sections to
obtain legible prints, in which case each section should be clearly referenced. All reduced
drawings, data, etc. must be readable.
1.1.6 Manufacturers prints, which do not show the equipment and order numbers, shall have these
numbers marked on the print, on the lower right hand corner. If these prints are to be
reproduced, they should be marked before reproduction.
1.1.7 Contractor shall provide 2D CAD drawings in auto CAD Version 2000/2002 (or similar
approved format) and 3D installation on Owner PDS with necessary software to run it.
This requirement also applies to detail drawings such as isometrics, piping arrangements,
pipe supports, cable tray layouts and supports, electrical and instrument drawings, structural
steel drawing, concrete foundations and the like.
11.8 Contractor shall obtain from vendor and subcontractors, documentation appropriate to the
supply of the item or service. Contractor is to ensure that all vendor or subcontractor
documentation is accurate and complete in every respect and in addition reflects the as-built
configuration of each unit or component.
1.1.9 All record book covers are to have the appropriate title printed on the hard front cover and are
to have a reinforced spine to fit the thickness of the book; these spines are also to have the
title printed on them. The title shall include :
The project name and designation
The facilities name and unit number
Owner name along with logo
Volume title, section, volume number (e.g.) 10 of 50 for each set.
1.2 OPERATING MANUALS

1.2.1 General Requirements
Contractor shall provide operating manuals, for each process unit / each facility as applicable.
The operating manuals for process units shall be based on preliminary operating manuals
prepared by Licensor.
Page 362 of 674

Contractor shall ensure that the manuals are provided in the correct format and in accordance
with schedules agreed with Owner.
1.2.2 Language
Operating manuals shall be in English language.
1.2.3 Preparation
Contractor shall produce manuals in accordance with Clause 1.2.4.
Contractor shall submit six draft copies of the manuals to Owner for review and approval in
sufficient time to ensure that bound copies of the final issue are in Owners hands max. four
months after detailed engineering.
Owner shall approve the draft copies of the operating manual within one month.
Such manuals shall be checked against Approved As-built Drawings and necessary
modifications shall be made accordingly.
The standard document shall be produced in twelve sections as listed herein below with a
brief resume of its contents. Typical operating manual index is given in 1.2.4.
1.2.4 Contents of Operating Manual
Section 1 Basis of Design
This section gives the duty conditions of units/facilities, the quantity and
quality of products and feed stocks, material balances, battery limit
conditions and any design features.
Section 2 Description of Process
This section consists of the process flow sheet(s) and a concise
description of the main process stream and side streams, mentioning
the main equipment. This shall include PFDS and PIDs.
Section 3 Description of Units Control
This section gives the method of control anticipated operating
conditions and process variables.
Section 4 Utility and Chemical Requirements
This section gives requirements for fuel, steam, water, power, etc., and
chemicals in the correct system of units.
Section 5 Preparation of initial start-up
This section deals with specific aspects of preparing the relevant unit
for start-up.
Section 6 Normal Start-up
This section covers the final preparations required, and a guide
procedure of the steps to be taken to bring units on to stream at full
throughput.
Section 7 Normal Operation
This section details the normal operating instructions for various
equipments of the unit and trouble-shooting to restore normal operation
in case of deviation.
Page 363 of 674

Section 8 Normal Shut down

This section covers the procedure to be followed to bring the units
down safely to a cold condition.
Section 9 Emergency Shutdowns
This section gives a general emergency shutdown procedure, and the
effects of various failures of utilities etc., with the action to be taken.
Section 10 Safety Equipment
This section lists the safety valves, alarms, and trips together with their
set points.
Section 11 Instrument Data
This section lists the control valves, orifice plates, pressure, level,
temperature indicators and salient information.
Section 12 Summary of Major Equipment
This section contains a brief summary of all equipment in list form for
vessels, columns, reactors, towers, exchangers, pumps, compressors,
etc.
Section 13 Test
This section describes qualitative tests required for good operation.
Details of adopted analytical methods, procedures of sample taking
and required laboratory equipment are included in this section.
Section 14 Drawings
Engineering flow-sheets and plot plan are included in this section.
Notes: General aspects of preparation for initial start-up are described in General
Procedure Manual. Details of starting pumps and other machinery shall be part
of vendors supply included in mechanical catalogues. Section 6, 7, 8 and 9 are
a philosophy of operations for the supervisory personnel, not a valve by valve
instruction. Sections 11 and 12 do not go into details of equipment as this
information is available from requisitions, vendors literature, drawings, etc. This
information is supplied in the mechanical catalogues.
1.2.5 Typical operating manual index shall include, but not be limited to :
Section 1.0 Basis of Design
1. Duty of unit/facility
2. Feed Characteristics
3. Product Specification
4. Material Balances
5. Battery limit conditions
6. Design Features
Section 2.0 Description of Process
Page 364 of 674

1. Process flow diagram(s)

2. Process flow description
3. P&IDS
Section 3.0 Description of Units Control
1. Method of Control
2. Operating Conditions
3. Process Variables
4. Instrument List
5. Control Panel
Section 4.0 Utility and Chemical requirements / Consumables
1. Fuel
2. Steam
3. Electrical Power
4. Water
5. Chemicals and Catalysts
6. Plant Air
7. Instrument Air
8. Cooling Water
9. D.M.Water
10. Plant Water
11. Resins
12. Lube oil
Section 5.0 Preparation for Initial Start-up
1. Units check-out
2. Line Flushing
3. Water circulation
4. Leak Testing
5. Heater dry-out
6. Catalyst Loading
7. Chemical cleaning
8. Steam or Air blow out procedure
9. Safety valves setting
10. Fuel system blow out
11. Major machinery oil system flushing
12. Electric equipment test
Page 365 of 674

13. Resin loading

Section 6.0 Normal Start-up
1. Summary of start-up
2. Final preparation
3. Purging
4. Cold circulation
5. Heating up
6. Streaming products/intermediate streams with relieve and tankage
references
7. Normal operation
8. Instrument calibration
9. Safety system checking
10. Protection relay selling
11. Log sheet preparation
12. Surge system checking
Section 7.0 Normal Operation
1. Normal routine of operation
2. Trouble shooting
Section 8.0 Normal Shut-down
1. Summary of shutdown
2. Reduction of flow rates
3. Shutdown heaters
4. Internal circulation
5. Flushing of unit
6. Steaming out
7. Catalyst regeneration and decoking
8. Steps and precautions for prolonged shut-down periods
9. Lone exchanger regeneration
10. Nitrogen purging and blanking
Section 9.0 Emergency Shut-downs
1. General emergency shutdown
2. Power failure
3. Steam failure
4. Instrument air failure
Page 366 of 674

5. Fuel failure
6. Mechanical failure
7. Cooling water failure
Section 10.0 Safety Equipment
1. Safety valves
2. Alarm settings
3. List of interlocks (process and individual equipment)
4. Trip settings
Section 11.0 Instrument Data
1. Control valves
2. Orifice plates
3. Temperature indicators
4. Description of any unconventional instrument loops
Section 12.0 Equipment Summary
Section 13.0 Tests and Chemical Analysis
1. Sample taking
2. Quality tests
3. Quantity tests
4. Analytical methods
5. Laboratory equipment
Section 14.0 Drawings
1. PFDs
2. Plot plan
3. Material balance tables
4. Piping and instrumentation diagrams
5. Hazardous area classification
6. Control panel layout
7 Simplified logic diagram (process & individual equipment)
8 All PIDs of vendors for package units etc., required for
commissioning
Section 15.0 Hazardous substances
1. Chemical and Catalyst hazards
2. Detailed listing and precautionary measures
Page 367 of 674

Section 16.0 Safety

1. Introduction
2. Maintenance
3. Fire Fighting
4. Taking samples
5. Handling gas cylinders
6. Precautions for entering into reactors
7. Tower, storage tanks etc.
8. Acid, caustic, resins and active material handling
1.3 GENERAL PROCEDURE MANUAL

Contractor shall prepare general procedures manual for each process unit / facility.
General procedures manual shall be in the English language.
Bound copies shall be provided to Owner within 6 months after detailed design of the process
units / facilities (number of copies is specified in Annexure AA).
1.3.1 General procedures manual shall cover most aspects of checking, pre-commissioning and
running of equipment with guidelines of pre-commissioning work and also details of
hazardous substances.
1.3.2 Typical general procedures manual index shall include, but not be limited to :
Section 1.0 Mechanical Completion
1. Introduction
2. Units checkout
3. Piping & pressure test specification
4. Vessels
5. Electrical
6. Instrumentation
7. Machinery
8. Heaters
9. Heat exchangers
Section 2.0 Pre-Commissioning
1. Introduction
2. Utility systems
3. Process unit flushing
4. Leak testing
5. Water circulations
6. Heater dry out
Page 368 of 674

7. Chemical cleaning instruction

8. Requirements for sentinel hole drilling, if any
9. Pressure testing of piping sections
10. Steam or air blow out procedure
11. Safety valve setting
12. Oil flushing procedures for machinery
13. Fuel system blow out
14. Electrical equipment test
15. Catalyst, clay and resin loading and unloading procedure
16. Dry out procedure for stack, heater and all refractory lined
equipment
17. Test running of compressors
18. Hot bolting and hot alignment procedure
19. All such further typical items which contractor judges.
Section 3.0 Equipment Operation
1. Introduction
2. Fired heaters
3. Electric motors
4. Steam turbine, gas turbines, if any
5. Centrifugal pumps
6. Positive displacement pumps
7. Compressors (all types)
8. Air blowers and exhaust fans
9. Heat exchangers
10. Lubrication schedules for rotating equipment
11. Filters, columns, vessels, agitators, ejectors etc.
12. Solid handling equipment
13. Hydraulic reactor cleaning pumps
14. Driers
Section 4.0 Special Procedures
1. Reflux condenser clean-out procedure
2. Chilled water generation
3. Reactor cleaning
4. Steam system boil out
5. Steam / air decoking
Page 369 of 674

6. Catalyst regeneration loading and unloading
1.4 UNIT(S) MAINTENANCE SCHEDULE

Contractor shall produce bound copies of maintenance schedule for each process unit /
facility (number of copies are specified in Annexure AA).
This schedule shall state routine shut-downs and general overhaul. Schedules shall be in a
format agreed with Owner/PMC. The above schedules shall be in English language.
1.4.2 Content of the maintenance schedule shall include, but not be limited to:
The schedule shall give the timing and outline the action for inspection and maintenance as
collected from manufacturers for :
Lubrication of machinery and moving parts
Topping up or refilling of filled systems
Checking of flow in equipment and piping in services liable to fouling
Checking of flows in drainage system
Checking of wear in moving parts and electrical contacts
Checking of relay settings and operations
Checking of wall thickness of equipment and piping in erosive or corrosive services
Electrical insulation tests
Checking of vibration in rotating equipment
Checking of defects on protective lining layers of the lined equipment
Scale formation in boilers
Correct functioning of steam traps
Checking of relief valve settings
1.5 MECHANICAL CATALOGUES
Contractor shall supply bounds of mechanical catalogues for each unit/facility at least one
month before the mechanical completion (number of bounds as per Annexure AA).
1.5.2 Contractor shall obtain from vendors all data books, for maintenance and operation. Also
final certified manufacturers inspection and test certificates and other data required for
completion of the mechanical catalogue.
1.5.3 Mechanical Catalogues shall contain the data listed here
The arrangement of the data in section 11 onwards shall follow the numerical sequence of the
equipment requisition numbers.
The headings listed in section 11 onwards represent the most common categories. Other
headings shall be included as required following order of requisition numbers.
1.5.4 Contractor shall refer to Part III Sub-section B.14 and include in mechanical catalogue, all the
review / approval / record vendor data listed therein.
Page 370 of 674

1.5.5 Content of mechanical catalogues shall include, but not limited to:
a) Index of content
b) Contractors drawing index
c) Vendor drawing index
d) Equipment lists
e) Photographs, maps, survey sketches
f) Requisition index
g) Plot plans
h) Flow-sheets : Process and Engineering
i) Line classification lists
j) Job specifications (including civil, piping, equipment (static and rotating), instrumentation,
electrical, painting, insulation, chemical cleaning, cathodic protection and refractories etc.,
including PMS/VMS.
k) Vessels (towers, reactors, drums, tanks)
i) Contractors requisitions, design data sheets
ii) Contractors drawings which includes vendor drawings, layout drawings,
fabrication drawings etc.
iii) Design calculations
iv) Inspection documents
l) Tubular Heat Exchangers
i) Contractors requisitions
ii) Design calculations, data sheet with design data and boiling / condensation
curves, as applicable
iii) Equipment P&IDs Control Scheme for Air Coolers
iv) GA drawings
v) Code Certificates
vi) Cross Sectional Drawings and Bill of Materials (final as built fabrication
drawings)
vii) Gasket Drawings
viii) List of Testing Accessories as applicable with write up on testing
ix) Fan Performance Curves and Catalogues
x) Material test certificate, inspection reports of third party, release notes etc., for
all equipments
m) Pumps, Turbines and motors, compressors, blowers, etc.
ii) Summary Sheet Pumps and Drivers & compressors
Page 371 of 674

- Data Sheet Horizontal Centrifugal Pumps
- Data Sheet Vertical Centrifugal Pumps
- Data Sheet Rotary Pumps
- Data Sheet Squirrel Cage Induction Motors
- Data Sheet Direct Acting Steam Pumps
- Data Sheet Steam Turbines
- Data Sheet Power Pumps
- Data Sheet Positive Displacement Pumps
- Centrifugal, Rotary and Steam Pump Packing Schedule
- Pump and Driver Outline Drawings including Base Plates
- Certified Performance Curves
- Pump Cross Sectional Drawings and Parts List
iii) Drawings of pump and driver arrangement, driver, mechanical seal, coupling,
cooling water and seal flushing piping.
iv) Manufacturers Pamphlets
v) Manufacturers Installation and Operating Instruction
vi) Specifications and Data sheets : Compressors, Blowers, Fans and Machinery
- Characteristic Curves
- Manufacturers Outline Drawings and Sections
vii) Packing Specifications
viii) Parts Lists with code numbers, along with drawings
ix) Material test certificates, inspection reports of approved third party, release
notes, etc., for all equipment
n) Compressors, Blowers and Motor Drivers
i) Contractors requisitions and P&IDs
ii) General assembly drawings (compressor and driver)
iii) Drawings of foundation, seal and lube oil system, control panel auxiliary
equipment, mechanical details.
iv) Compressor and driver performance curves and data.
v) Test certificates
vi) Descriptive literature on accessories and controls.
vii) Complete parts list, showing for each part the real or factory part number,
including section drawings with parts identified.
Page 372 of 674

viii) Installation, operating and maintenance instructions including information on

starting compressor units.
ix) Where pumps and coolers are furnished as an integral part of the compressor
unit, data sheets, outline drawings, complete parts lists, installation, operating
and maintenance instructions are required.
o) Fired Heaters
i) Design Data Sheet for Furnace, including Temperature, Pressure and
Vaporisation Curves
ii) Equipment Data sheet for Furnace, Air Preheaters, Fans, Burners and other
auxiliaries to furnace system.
iii) Furnace Heaters, Stacks, Flue Assembly Drawings and Sections and drawings
of other auxiliaries like Air Preheaters, Burner, Fans, etc.
iv) Tube numbering Diagrams giving Tube Thickness and Material
v) Detailed Drawings Return Bend and Terminal Headers, Screws, Plugs, etc.
vi) Parts List.
vii) Material test certificates, inspection reports of approved third party, release
p) Tankages
i) Data sheets, design calculations
ii) Code Certificates / material certificates
iii) Specifications
iv) Tank Appurtenance Layout including mixers / heating coils, etc.
v) Subcontractor / Vendor drawings
vi) Blanketing
vii) Tank Calibration Charts
viii) Material test certificates, inspection reports of approved third party, release
q) Piping
i) Piping Specifications including tracers
ii) Piping Nomenclatures including Test Pressure
iii) Plans and Elevations of Piping
iv) Details of Alloy Piping
v) Isometric Details
vi) Hanger / Spring Supports
vii) Piping Stress Analysis Report
viii) Outline Prints of Special Valves, Flanges, Fittings
ix) List of Material and Schedule for Steam Traps
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x) List of Material for Piping

xi) List of Material (re-capitulation for Entire Facilities)
xii) Vent, Drain and Coolant Piping for Pump and Turbines
xiii) Auxiliary Piping Turbines and Reciprocating Pumps
xiv) Heat Exchanger Vent and Drain Schedule
xv) Soft copies of 3D modelling.
xvi) Material test certificates, inspection reports of approved third party, release
r) Miscellaneous Equipment (e.g. Package units)
ii) Data sheets, design calculations
iii) Outline drawings
iv) Complete parts list, showing for each part the real or factory part number,
including sectional drawings (if standard practice) with parts identified.
v) Performance curves or data (as required)
vi) Installation, operating and maintenance instructions
vii) Test certificates and inspection documents
s) Electrical
i) Contractors requisitions and final data sheets
ii) Single line diagrams with equipment ratings, available setting of relays etc.,
schematic and wiring diagrams
iii) Area classification drawings
iv) Installation, operating and maintenance instructions for all equipment
v) Composite operating instructions of the unit / facility electrics
vi) System design reports including voltage profiles, reacceleration and fault
studies
vii) Cable selection calculation sheets
viii) Cable termination instructions and drawings
ix) Power layout and cable schedules
x) Earthing drawings
xi) Relay co-ordination sheets
xii) Power and Lighting Distribution Including Conduit Layout and Grounding
xiii) UPS
xiv) HT / LT Switchgear
xv) Transformer
xvi) Communication / Telephone Exchange Layout
Page 374 of 674

xvii) Phone and Signal Systems Layouts, Power and Lighting Layouts, Wiring
Diagrams of Annunciator Panels
xviii) Manufacturers Wiring Diagrams of Elements
xix) Schedule of Motors and Starters
xx) Manufacturers Pamphlets
xxi) Parts Lists
xxii) Fire Alarm
xxiii) List of Electrical Material
xxiv) Approved test reports, inspection documents, material test certificates
t) Instruments
ii) Instrument flow diagrams
iii) Panel board panel drawings / DCS documents
iv) Control room layout drawings
v) Instrument electrical single line diagram
vi) Special circuit diagrams and description or operation (if not part of requisition)
vii) Schedule of Reference Data for Recording, Indicating and Controlling
Instruments
viii) Schedules of Reference Data for Pressure Gauges, Temp. Points and Gauge
Glasses
ix) Schedule of Reference Data for Relief Valves
x) Schedule of Reference Data for Bursting Discs
xi) Schedule of Orifice Plates
xii) Orifice Meter Data and Calculation Sheets
xiii) Piping Material for Instruments
xiv) List of Material for Thermocouple and Thermowell Installations
xv) Layout of Main Instrument Board and Alarms
xvi) List of Name Plates for Instruments Annunciator Panel etc.
xvii) Plot Plan and Layout Drawings of Instrument Lines
xviii) Conduit Runs for Instrument Board
xix) Diagrammatic Sketches and Instructions for Special Instrument Installations
xx) Drawing of Special Instrument Installations
xxi) Parts List
xxii) Installation, operating and maintenance instructions including parts lists and
sectionalised drawings
xxiii) Approved test reports, inspection documents, material test certificates
Page 375 of 674

u) Buildings / Civil / Structural

i) Contractors technical specifications (major buildings only)
ii) Contractors arrangement drawings, showing plan, sections and elevations
iii) Design calculations for foundation and structures, pipe rack, CRWS and storm
water drains
iv) Foundations, Plans and Sections
v) Details of Foundations for Vertical and Horizontal Vessels, reactors, pipe
sleepers and other equipment
vi) Piping Layout and Loading
vii) Pile Layout and Loading
viii) Pile Driving Data sheet
ix) Specifications
x) Reinforcing steel layouts (exclude bar bending details)
xi) Details of Structure
v) Project Description Basic Design Criteria
w) Project Drawing Index
x) Piping and Instrumentation Diagrams / Process Flow Diagrams
y) Summary of Utility Consumption including Electrical
z) Summary of Chemical Consumption including material data sheets
aa) Equipment Summary Sheets
bb) Material Selection Analysis
cc) Original approved drawings & documents obtained from statutory authorities including
the correspondence
1.6 AS BUILT DOCUMENTS

Any modifications made subsequently upto issue of the Final Acceptance Certificate will be
recorded by the contractor on a master set of prints and these will be transferred to original
by Contractor.
Contractor shall update all process P&IDs based on approved vendor data/drawings with
respect to all static and rotating equipment. All auxiliary system P&IDs of equipment from
vendor shall be integrated with Process P&IDs to reflect As built status of P&ID.
1.6.1 As-Built Process Package
1.6.2 As-Built 3D Model (Soft)
1.6.3 As-Built Drawings
Contractor shall provide as-built revisions of drawings / documents which include but not
limited to the following for each unit / facility :
a) Civil
Page 376 of 674

- Foundations, building, structures, general civil, layouts of CRWS, OWS, paving,

sanitary disposal including design calculations
b) Piping
- GADs, Isometrics, pipe supports, layouts, PMS / VMS, Design Calculations.
c) Electrical
- SLDs, layouts substations details, equipment details, design calculations, cable
details etc
d) Instrument
- Layouts, Loop diagrams, DCS / PLC
e) Equipment
- Fabricated equipment, mechanical equipment, etc.
f) General
- Plot plans, PIDs, etc.
g) Drawings of items buried or otherwise hidden from view, e.g. foundations, underground
system cable runs, vessel internals to this purpose contractor shall report on the original
transparency the modifications to the original design marked-up by the competent
erection contractor or civil work contractor on the copy of the final revisions of the
pertaining drawing.
1.6.4 The following documents shall also be submitted in hard binder (4 sets) for records :
However 2 sets of the following drawings shall be submitted before mechanical completion :
a) Welding Procedure Qualification Report
b) Welder Qualification Report
c) Radiographic Procedure Qualification
d) Radiographic Report along with radiographs (Radiographs only with the original)
e) Batch Test Certificate from manufacturers for electrodes
f) Hydrostatic and other test results & reports
g) Pre-commissioning and commissioning checklists
h) Documents indicating satisfaction of all other requirements as specified in the respective
specifications
i) As built drawings
j) Field test reports for all Mechanical, Electrical, Instrumentation and Communication
systems and fire alarm system
k) Material Inspection/Test Report for supply of all materials
l) Any other drawing/document/report specified elsewhere in the bidding documents
Page 377 of 674

1.7 TRANSPARENCIES AND CD / DVD etc.

1.7.1 Contractor shall provide original sized transparencies of all vendor and subcontractor
drawings and contractor drawings, specifications and data sheets unless such drawings are
CAD generated.
1.7.2 Generally, all drawings shall be provided on AutoCAD in CD / DVDs.
CD / DVDs will all have same information as that provided on the hard copy volumes.
1.7.3 All As-built vendor drawings and documents shall be either in AutoCAD or in scanned
images stored in Electronic media.
1.7.4 Contractors As-built drawings supplied in original / CD / DVDs shall include but not be
limited to the following:
Contractors drawing index
Vendor s drawing index
Foundations
Buildings
Structures
All equipment including reactors, heat exchangers, vessels, pumps, columns, compressor
etc.
Electrical
Engineering flow-sheets
Instrument layouts
Control panels
Plot plans
Piping arrangement drawings (Piping plans)
Piping Isometrics
Plan drawings of rack piping
1.8 SPARE PART LIST

Separate list shall be given for each disciplines along with the index & contents.
1.9 PURCHASE ORDER COPIES AND ADDRESSES
(Signature & Seal of Bidder)
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44NC-4600 - CPCL, MANALI REFINERY, CHENNAI
Resid Upgradation Project
DOCUMENTATION MATRIX - PMC

Annexure AA to Appendix 9
HARD COPIES SOFT COPIES (CDs)
Sr. No. DESCRIPTION REMARKS
CPCL JACOBS TOTAL CPCL JACOBS TOTAL
E As Built Documents
1 P & IDs 8 1 9 8 1 9
Sepia of Complete set pertaining to civil, mechanical,
2 2 - 2 1 - 1
electrical and instrumentation
3 Set of Equipment Folder containing: 8 - 8 8 1 9
- As built Tracing
- Design drawings, Calculations and documents
- Specifications
- Detailed fabrication / installation drawings
- Stage wise inspection reports
- Third party inspection release notes
- Guarantees / Warrantees Certificates
4 Final Operating Manuals of Process Units 8 1 9 8 1 9
5 Purchase Requisition & PO of each equipment 4 - 4 - - -
Operating and Maintenance manual/Mechanical
6 8 1 9 6 1 7
Catalogue for all bought out items
Hard Binder consisting of: Original +
7 1 4 - - -
3 sets
- Welding Procedure Qualification Report
- Welder Qualification Report
- Radiography/NDT Procedure Qualification/Records
- Weld / NDT Maps
- Radiographic Reports along with Radiographs
(radiographs only with originals)
- Heat Treatment Charts
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44NC-4600 - CPCL, MANALI REFINERY, CHENNAI
DOCUMENTATION MATRIX - PMC

Annexure AA to Appendix 9
HARD COPIES SOFT COPIES (CDs)
Sr. No. DESCRIPTION REMARKS
CPCL JACOBS TOTAL CPCL JACOBS TOTAL
- CR / NCN copies
- Material Test Certificates
- Hydrostatic and other test results and reports
- Pre-commissioning and Commissioning check list
- All other requirement as specified in the respective
specifications
Notes:
1. All soft files shall be in native (editable) format.
2. All text data shall be on MS Word in Windows XP.
3. All spread sheet work shall be on MS Excel in Windows XP.
4. All other documents like presentation etc. and other data shall be in MS Office in Windows XP.
5. All drawings shall be furnished in PDS format.
6. All drawings / documents shall be furnished on separate Compact Discs (CDs)
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MANALI REFINERY, CHENNAI
LSTK-1 COKER BLOCK
STANDARD SPECIFICATON FOR FIELD HSE ACTIVITIES
DOCUMENT NO : 44NC-4600-003/X.02/0004/A4
Rev No. Issue Date Pages Rev Description Prepared Checked Approved
By By By
A1 12.04.2010 101 Issued for Tender IA SGR RPG
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CPCL, Chennai Annexure C Part I Section 6.0
44 NC 4600 Construction Supervison & Management
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LSTK-1 COKER BLOCK Standard Specification For Field Hse Activities Rev. A1
TABLE OF CONTENTS

0.0 Definitions
1.0 Purpose
2.0 Compliance
3.0 Objectives
4.0 Contractor Safety Policy and Assurance Plan
6.0 Roles and Responsibilities
7.0 Safety Meeting
8.0 Proactive Safety Monitoring
11.0 Documents and information to be submitted by Contractor
14.0 Site Access and Security Procedure


20.0 Housekeeping
21.0 Safety Signs
23.0 Form Work
24.0 Excavations
25.0 Hot Work
28.0 Working at height
30.0 Sling and Lifting Gears (Rigging)
32.0 Lifting Activities
33.0 Construction Vehicles
34.0 Construction Machineries
35.0 Noise
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TABLE OF CONTENTS
36.0 Confined Space

37.0 Radiography
38.0 Hand Tools
39.0 Demolitions

Penalties for Violation/Non-Adherence of Safety Procedures and
41.0
Practices
Attachments
Attachment 1. Legal Obligations / Requirements for Construction
Attachment 2. Safety Assurance Plan
Attachment 3. Site Safety Organisation Chart
Attachment 4. Minutes of Meeting
Attachment 5. Field Safety Observation Report (SOR)
Attachment 6. SOR Summary Sheet
Attachment 7. Safe Plan of Action (SPA)
Attachment 8. General Inspection Report
Attachment 9. Routine Inspection Plan
Attachment 10. Safety Audit Checklist
Attachment 11. Safety Induction Checklist
Attachment 12. Tool Box Format
Attachment 13. Training Matrix
Attachment 14. Training Register
Attachment 15. Safety Update Board
Attachment 16. Weekly Safety Report
Attachment 17. Monthly Safety Report
Attachment 18. Incident and Investigation Report
Attachment 19. Incident Report Chain
Attachment 20. Contents of First-aid box
Attachment 21. IS Code for PPE
Attachment 22. PPE Issue Register
Attachment 23. PPE Stock Register
Attachment 24. DG Checklist
Attachment 25. Excavation Checklist
Attachment 26. Hot Work Activity Checklist
Attachment 27. Welding Set Checklist
Attachment 28. Gas Cutting Set Checklist
Attachment 29. Grinding Machine Checklist
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Attachments
Attachment 30. Fire Extinguisher Monthly Inspection
Attachment 31. Scaffolding Checklist
Attachment 32. Slings and Lifting Gear Register
Attachment 33. Wire Rope Sling Checklist
Attachment 34. Synthetic Web Sling Checklist
Attachment 35. Crane Register
Attachment 36. Mobile Crane Daily Inspection
Attachment 37. Monthly Mobile Crane Inspection
Attachment 38. Pre-Lift Checklist
Attachment 39. Construction Vehicle Checklist
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0.0 Definitions
Owner : Chennai Petroleum Corporation Limited, Manali Refinery, Chennai
Consultant : Jacobs Engineering India Private Limited
Contractor : Person, Firm or Corporation to whom the work will be awarded by the Owner.
Shall : Mandatory requirement.
Should : Guideline that is strongly recommended.
May : Guideline that is to be considered.
Supervisor : Contractors engineer responsible for specific tasks.
1.0 Purpose
The field HSE specification set forth is the minimum requirements that shall be implemented
during the project execution. The contractors are required to implement these standards and any
additional requirements as per local laws and statutory requirements and best practices in industry
whichever are higher. Owner and consultant may issue further changing requirements from time to
time as the work progresses to fit changing site conditions, which will be binding on the contractor.
The owner is fully committed for providing safe and healthy working conditions for all employees
working on the project and our goal is zero incidents in our operation. Safety is an overriding value
that the operation shall be conducted in such a manner that reasonably practicable measures are
taken to protect people not only in our employment but also others who may be affected by our
activities.
We believe that incidents are caused and eliminating the causes of incident can prevent them.
Safety is the responsibility of every employee but line management is ultimately responsible for the
implementation of safety requirements.
Everyone involved must be committed to achieving high standard of HSE Performance with proactive
approach at all levels in the organization with excellent teamwork.
All personnel should share a sense of empowerment on safety matters with an effective
communication system to facilitate the flow of safety information both up and down through the
organization
2.0 Compliances
All activities shall be in compliance with relevant local laws, statutory requirements, codes and
practices pertaining to health & safety of employees
2.1. Contractors or other third parties in the refinery shall abide by

Fire & Safety rules and regulations of the Refinery (Latest revision)
Security instruction issued by refinery management time to time
All requirements under the Factory Act 1948
The Contract Labour Act 1970
All requirements of Worker Compensation Act 1923 & ESIS Act including all amendments thereto.
Other statutory requirements shall also be applicable as mentioned.
Attachment 1: Legal Obligations / Requirements for Construction
2.2. The Contractors shall not employ minors (persons below the age of 18 years) in any part of the
refinery.
2.3. Contractor shall display notice at the conspicuous place showing the rates of wages of the workers,
hours of work, wage periods, date of payment of wages, names and addresses of the Inspectors
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having jurisdiction and date of payment of unpaid wages, in English, Hindi and in the local language
understood by the majority of workers.
2.4. Contractors personnel shall abide by the applicable instructions as may be issued from time to time
to handle any emergency situations, such as explosion, fire, terrorist attacks, major accident, etc. In
the event of such emergencies, the Contractors personnel shall stop their work and proceed to a
safe designated place assembly point in the area of their work and inform the Engineer-in-Charge
immediately. If needed, they shall be safely evacuated.
2.5. Contractors vehicles, trucks, tractor, cranes and other portable equipments e.g. Air Compressor, DG
Set, Dewatering pumps etc. used inside Refinery premises (where Hydrocarbon is used as fuel) for
execution of the job must be mechanically sound and have an approved spark arrester and have
exhaust complying pollution norms. Idle running of those vehicles and equipments shall be avoided.
2.6. The Owner or the Engineer-in-charge may at any time require the Contractor to subject any contract
workman, to a medical examination, generally or in relation to specific jobs such as in canteen, tank
cleaning, work at height, etc.
2.7. Contractor shall not carry any work without having supervisor at site. If it is required to work
simultaneously in more than one location under the same contract, one supervisor must be put in
each of the locations. If a supervisor has to leave his site for any reason, he must stop his activities
for that period of time.
2.8. Female employee shall not be allowed to bring their child to workplace inside Refinery premises.
Contractor shall make suitable arrangement in case need, outside Refinery premises at his own cost.
2.9. The Contractor shall not be entitled to any extra or additional payment or other compensation for the
compliance with all applicable safety rules.
2.10. The requirement to comply with all applicable safety rules shall not entitle or justify the Contractor to
demand or claim any time or cost overrun.
2.11. The Contractor shall be solely responsible for any and all liability under the Workmens
Compensation Act, and other applicable laws with respect to all those engaged by the Contractor or
any sub-contractor.
2.12. In addition to this specification, contractor shall adhere to Health Safety Environment Procedure
(HSEP) of owner and consultant.
3.0 Objectives
3.1 General
The contractor shall practice safety leadership, demonstrate visible commitment to the project's
safety policy and strategic objectives, and provide resources to promote a culture that embraces and
accepts absolute safety behavior
Developing, signing, distributing, and emphasizing the safety policy at the outset of the project.
Leading and driving the project safety program in order to achieve a world class performance,
together with active participation at all levels with owner and consultant to ensure safe completion
of the project.
Implementing proactive monitoring system that provides feedback to ensure continuous
improvement in HSE performance.
Ensure compliance with all applicable laws, statutory requirements, codes of practices and
standards set forth.
In essence NO SAFETY NO WORK.
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3.2 Targets
The following Safety targets apply to the Project:
Injuries and Illness - Zero

Environmental Incidents - Zero
Property Damage - Zero
Vehicle Incidents - Zero
4.0 Contractors Safety Policy and Safety Assurance Plan

4.1 The contractor shall formulate a Safety & Health policy and shall be signed by authorised person.
The copy of the Safety & Health Policy shall be displayed at conspicuous places at work sites in
English, Hindi and a local language understood by the majority of construction workers.
4.2 The contractor shall submit copy of safety policy, HSE plan and safety assurance plan to
owner/consultant in the standard form for implementation and monitoring of HSE requirements.
Attachment 2: Safety Assurance Plan

5.1 Contractor shall post a qualified and experienced Safety Manager and deploy Safety Engineers /
Officers, Supervisors and observers in every shift, to exclusively oversee and ensure compliance with
all applicable safety rules. Contractor shall notify the name of the safety manager, safety officer/
engineer and other safety personnel along with their bio-data to the owner and consultant for the
approval. Only on approval by the owner/ consultant these personnel are authorised to work.
5.2 Qualifications of Safety Managers and Safety Engineer/officer shall not be less than as prescribed in
local regulations.
5.3 Contractor shall submit site safety organisation chart along with HSE plan.
Attachment 3: Site Safety Organisation Chart
5.4 Working hours per shift shall not exceed 12 hours per day.
5.5 Contractor shall appoint safety personnel as given below for every work shift:
Safety Observer : At all times minimum one observer for workers not exceeding 100 in numbers.
That means contractors are expected to deploy additional safety observers when
number of workers crosses beyond 100 and thereon.
Safety Supervisor: In addition to above, contractor shall depute one Safety Supervisor for every 250
workers.
Safety Engineer : In addition to above, one safety engineer/ officer for every 1000 workers.
Safety Manager : Minimum of one Safety Manager at all times required to be at site.
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Requirement of Safety Personnel for every shift

No. of Workers
deployed Safety Engineer/
Safety Observer Safety Supervisor Safety Manager
Officer
1- 50
One
51-100
101-150 One
Two
151-200
201-250
Three
251-300 One
One
301-350
Four
351-400 Two
401-450
Five
451-500
Up to 1000 Ten Four
Up to 2000 Twenty Eight Two
5.6 In case any of the safety personnel leave the contractor the same shall be intimated to the owner/
Consultant. The contractor shall recruit new personnel and fill up the vacancy.
6.0 Roles & Responsibilities

The contractor shall ensure that an employee of suitable seniority and authority with responsibility
for health and safety is always present on site during the course of the work, to supervise and
direct the work and to receive and implement instructions from the owner/consultants senior
representative.
Contractor skilled workmen like riggers, scaffold erectors, welders, fitters, crane operators etc
should have sufficient past experience and skill on the relevant jobs. The electrician deployed
must have valid wireman License.
All supervisory staff and workmen shall be capable of following instructions and shall be made
aware of their responsibilities.
6.1 All Employees involved in project

Take reasonable care for the health and safety of him and other persons who may be affected by
his acts or omissions at work.
Co-operate with his management or others to enable compliance with statutory requirements.
Report to their immediate supervisor about hazardous situations and defects found in premises,
plant and equipment.
Avoid improvisation, which might entail risk.
Consider and suggest means of eliminating hazards.
Co-operate in maintaining a safe and healthy working environment.
Attend safety-training classes as and when organized.
Attend safety meetings if invited.
Participate in safety campaigns when organized.
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Never intentionally or recklessly interfere with, or misuse, anything provided in the interests of
health, safety or welfare.
Draw to the attention of management /supervision improvements to health and safety which
appear to be necessary or advisable.
Immediately report any incident/ near misses to his/her supervisor.
Demonstrate leadership and commitment to HSE, setting a personal example at all times.
6.2 Contractors Construction Manager

He shall understand the Owners/consultants HSE requirements and the responsibility allocated to
each grade of supervision.
Understand and implement the contractual HSE requirements along with relevant Central / Local
legal and statutory regulations.
Assign clear responsibilities to achieve safety objectives and verify that sub-ordinates are
executing these responsibilities properly.
Ensure compliance of all the HSE policy and procedures.
Provide written method statements to establish safe work methods. (Explaining the sequence of
operations, provide outline potential hazards at each stage and identify safety measures to be
adopted).
Provide the resources necessary to maintain a safe and healthy work environment.
Locate storage areas, access and site office locations in line with owners/ consultants
requirements.
Ensure availability of all welfare, First -aid and sanitation facilities.
Enforce identified work permit procedures and requirements.
Check over work methods and precautions with supervision before work commences.
Shall lead the safety meetings and safety inspections/ audits and ensure safety deficiencies
identified are correct promptly.
Enhance safety awareness by promoting safety meetings, motivation programs, Trainings etc.
Ensure all incidents and near miss incidents are reported immediately and submit investigation
reports, participate in any other investigations as may require.
Set a personal example on site by adopting a safe working attitude.
6.3 Contractors Safety Personnel

He shall understand the owners/consultants HSE requirements and advice management to ensure
Legal and contractual requirements affecting Health, Safety and Environmental issues.
Assist site management in identifying resources required to work safely.
Monitor the site activities to ensure only safe work methods are practiced at site, Health and
safety requirements are being observed, all welfare and first aid facilities are adequate and
properly maintained.
Inspect the work site and daily, report and correct unsafe conditions/ acts.
Check the provision and status of PPE requirements of the site.
Assist supervisor in preparing Safe Plan of Action (SPA).
Conducting investigation of all accidents and incidents at site, measures to prevent recurrence of
such incidents.
Facilitate, conduct and participate safety meetings, trainings, promotional activities at the site.
Initiate safety awareness and safety promotional activities
Review overall safety performance, record and analyse accident/ incidents and
Document and maintain all HSE statistics, reports and records.
Submit all documents related to HSE to owner and consultant regularly.
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6.4 Contractors Supervisory Personnel

Understand the company/owners/consultants HSE policy requirements and implement:
Organise work to the required safety standards to prevent injuries, damage to property and
environment.
Prepare and implement only safe and approved work methods, instruct and ensure compliance by
work force.
Enforce and comply with all work permit procedures.
Prior to assigning the days task inspect the work site, correct unsafe conditions if any and report
to site management to prevent recurrence.
Prepare Safe Plan of Action (SPA) and communicate the same to his workforce.
Communicate and ensure all identified hazards and preventive measures related to the task are
understood by the workforce.
Ensure all required safety resources are available and in good condition.
Inspect all scaffold, elevated platforms, fall and fire preventive/protective equipments involved in
the task,
Inspect all tools and equipments, safety guards, instruments are in good operating conditions.
Ensure required Personal Protective Equipments are available.
Plan and ensure a good housekeeping.
Monitor and control the task for unsafe acts and conditions.
Co ordinate task with other activities in the job site.
Ensure awareness of Emergency procedures, First aid, Fire fighting etc among the workforce.
Cooperate and implement instructions from Safety and Fire departments.
7.0 Safety Meetings

Effective communications raises safety awareness, and is vital to the successful implementation of
the Site Safety Plan. Objective of safety meeting is to improve the understanding of safety matters, to
obtain the support, co-operation and commitment of all interested parties.
7.1 Safety Kick-Off Meeting

On award of contract, a safety kick off meeting will be arranged and shall be attended by Contractor.
The agenda shall include
Type and nature of work.
Scope of work.
Contractor Safety Policy
Contractors HSE plan.
Site Safety Organisation
Allowable working hours.
Legal requirements and documents to submit
Entry of Personnel and vehicle in to premises
Personnel Protective Equipment
Safety Management Programs
- Safety Induction
- Toolbox Talks
- Job Specific Training
- Safety Observation Report (SOR)
- Safe Plan of Action (SPA)
- Safety Inspections and Colour Coding Program
- Monthly Safety Audit
Reporting of incidents.
Permit System - administration and requirements.
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Plant and equipment and test certificates

Safety Promotional Activities.
Interfaces with other contractors.
Any other specific anticipated hazards related to the work scope.
Emergency Response Action Plan
Welfare facilities for workers
Work Stoppages and Disciplinary Actions
7.2 Weekly Safety Meetings

Contractors Site Manager, Contractors Safety Managers/officers, Contractors Discipline Heads shall
attend weekly safety meeting with consultants site management team. At these meetings previous
week safety performance would be analyzed and the activities planned for the forthcoming week
would be reviewed.
Coordinator Consultants Safety manager
Contractors RCM
Contractors Safety Manager
Contractors discipline heads
Members Consultants RCM
Owners representative
7.2.1 Weekly meeting in weekdays shall be predetermined with mutual agreement between contractor and
owner/consultant.
7.3 Monthly Safety Committee Meeting

7.3.1 In order to ensure better communication and coordination for realising safety targets, the project shall
establish an independent safety committee comprising of Owner Representative, Consultants
Construction Manager, Consultants Safety Manager, and Consultants Discipline Heads, Contractors
Site Manager, Contractors Safety Managers/officers, Contractors Discipline Heads and workers
representatives.
Chairman Owners Representative
Secretary Owners Safety Manager
Consultants RCM
Members Contractor RCM
Contractor Safety Representatives
Contractors discipline head
Workers Representative
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7.3.2 Site safety committee meeting shall be conducted at least once in a month. The agenda shall include
Review of previous minutes
Review of site safety performance
Monthly safety statistics
Contractors safety performance
Challenges ahead
SOR trend
Safety inspection & Audit reports
Issues by Owner/ Consultant
7.3.3 Contractor shall send circular to all safety committee members about the date and venue of monthly
safety committee meeting at least seven days prior to the day of meeting.
7.4 The Minutes of the meeting shall be prepared and sent to all members within 1 working day
preferably by mail/fax followed by hardcopy. Safety Committee meeting minutes shall also be
displayed in the notice board for wider publicity to all concerned.
Attachment 4: Minutes of Meeting
8.0 Pro-Active Safety Monitoring

Contractor shall implement proactive safety monitoring programs that provides feedback to ensure
continuous improvement in safety performance and compliances.
8.1 Safety Observation Report (SOR)

8.11 The SOR is used as a tool for supervisors to record good safety practices unsafe acts/conditions and
the steps taken (immediately and as follow-up) to correct the unsafe practices and recommendation
to prevent its recurrence.
8.12 It is everyones responsibility to take immediate corrective action if any unsafe act/ conditions are
observed.
8.13 Contractors job supervisor is responsible to close-out the SOR by taking corrective action during
follow-up action.
8.14 SOR shall be submitted to consultant and it shall be summarized periodically for effective tracking, to
analyse the trend and identify frequently occurring unsafe act/ conditions for improved safety
implementation.
Attachment 5: Safety Observation Report (SOR)
Attachment 6: Safety Observation Report Summary Sheet
8.2 Method Statement

Contractors shall submit method statements for each work to owner/consultant at least seven days
prior to the commencement of the work. The method statement shall detail:
The job to be undertaken
The steps of activities required completing the job.
The individual trades/disciplines involved in the activity.
Plant, equipment, tools to be used in the activity.
Any hazardous substances/chemicals to be used along with their MSDS.
A detailed description of how the work will be done including control measures and procedures to
complete each activity and the overall job safely.
Compliance with the procedure on the work method statement and relevancy to current operations
shall be monitored on a daily basis and also shall be discussed on safety meetings.
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8.31 The SPA is the primary tool used at site to identify and plan to mitigate safety hazards. This form
shall be completed by the contractors supervisor along with crew before starting a new activity and
kept at the work place for ready reference.
8.32 The SPA has sections for the employees to:

State the task to be performed
Location of the task to be performed
Safety hazards anticipated
Steps to be taken to prevent the risks identified
Equipment, tools, or materials needed for protection against the hazard and to perform the work
safely.
Authorisation by reviewing and approving personnel
The name(s) of the Supervisor(s) for each activity.
The name of the person in overall charge of the job.
Duration of the job.
8.33 It is the responsibility of the supervisor to ensure that all resources (equipment, tools, materials etc)
identified through SPA are implemented and all the steps identified to prevent the hazards are
implemented while executing the job.
8.34 It is the responsibility of the job supervisor to communicate the SPA to all workmen involved in that
specific task
8.35 A copy of SPA shall be displayed proximity to the actual works location in Hindi /vernacular language
& English.
Attachment 7: Safe Plan of Action (SPA)
8.4 Safety Inspections

The purpose of safety inspection is to identify any variation in construction activities and operations,
machineries, plant and equipments for ensuring an activity whether it is executed in accordance to a
general set of safety rules.
All equipments, machineries, tools, slings, lifting gears, lifting appliances involved in site shall be
inspected periodically.
Monthly colour coding program shall be implemented by the contractor and after the periodical
inspection, stickers for the corresponding month shall be pasted. Documents related to the inspection
shall be maintained and submitted to owner/consultant regularly.
Month Colour code

January & July Yellow
February & August Orange
March & September Pink
April & October Green
May & November Red
June & December Blue
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8.41 General Inspection (Safety Walk Around)

General inspections shall be performed at predetermined intervals and the inspection shall involve
contractors RCM and contractors safety manager, Owner/Consultants representatives.
Attachment 8: General Inspection Format
8.42 Routine Inspections

Routine inspections referred to the inspection of work site, equipment, temporary structures, work
activities etc.
Job specific inspections are performed on activities without a predetermined date. Competent
supervisors usually perform inspections for ensuring an activity whether it is executed in accordance
to a general set of rules.
Contractor shall inspect all equipments, tools etc initially before putting those into the service.
Contractor shall formulate the required checklist for all activities and equipments. As a minimum,
contractor shall conduct inspection as per the attachment.
Attachment 9: Routine Inspection Plan
8.5 Safety Audit

Safety audits are mandatory. The purpose of safety audit is to monitor and assess the effectiveness
of the site safety plan at workplace. It helps to develop the safety procedures further if the existing
procedures are found un-satisfactory. It assesses potential risk, liabilities and the degree of
compliance of construction safety plan and its supplementary procedures and programs against
applicable and current safety legislation regulations and requirements of the owner/consultant.
Contractors construction manager holds the ultimate responsibility in ensuring implementation of

safety audit program during the construction work.
8.5.1 Monthly Safety Audit

Monthly Safety Audit shall be performed once in a month with prior notice. It shall be oragnised by
consultants safety manager with representatives from owner and contractor with a pre-determined
format.
These audits will play a vital role in assessing the Contractors Safety performance rating.
Based on the audit team observation, the evaluator shall allot the score based on the compliance
observed of the requirement and summarise the overall scoring of the audit.
The audit findings along with the recommended corrective actions with target date shall be circulated
to the respective contractors. The contractor should complete the recommended corrective actions
and submit the corrective action report.
The date for the audit shall be agreed by the owner/consultant and contractor.
Attachment 10: Safety Audit Checklist

Contractor must ensure that his employees are adequately trained and experienced to carry out
their work safely. Training should continue throughout the project and should include regular
toolbox discussions.
Contractor must also ensure that specific hazards likely to be experienced on the site are notified
to their workforce together with any precautions to be taken and local rules to be observed.
Where particularly severe or unusual hazards arise, consultant reserves the right at no additional
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cost to request contractors employees to attend safety training and instruction sessions, whether
carried out on site or externally.
Contractor shall provide a dedicated training room for conducting training for their workers.
9.1 Initial site orientation / safety induction and ID cards

9.11 All personnel working on the site shall be required to attend a safety induction briefing before
commencing work. Safety induction shall cover all topics included in the attached checklist.
Attachment 11: Safety Induction
9.12 The contractor shall conduct a site visit for his new employees in groups of less than 25 to familiarize
the new employees with essential services, their work place, and general site layout.
9.13 It is the responsibility of the contractor to familiarize all new personnel to the project on the actual
location of assembly points, fire alarm points, first-aid center, welfare facilities and other important
locations.
9.14 Contractors are responsible for arranging site safety induction for their workmen and they shall
inform consultants safety representative at least one day in advance.
9.15 Induction card duly stamped as Safety Inducted and the date of induction by contractor shall be
issued after the completion of Induction.
9.2 Toolbox Talks

Contractor shall conduct job specific and weekly tool box talks to encourage two way
communications with the employees.
Contractor shall maintain records of Toolbox Talks and shall be submitted to Consultant on regular
basis.
Attachment 12: Tool Box Talk
9.21 Job specific tool box talk

Contractors task supervisor shall conduct job specific toolbox talks (SPA) for all workers before
commencement of their job.
Topics shall include hazards and safety precautions as identified in the SPA.
9.22 Weekly tool box talk

Contractors safety manager shall conduct weekly tool box talk preferably on Monday at the start of
the shift.
Duration of talk shall not be less than 15 minutes.
Topics may be the current site safety issues that shall be agreed between the contractor,
consultant/owner.
9.3 Training from Owner

Contractors and their supervisory staff shall undergo a one-day training programme annually from
owner on Safe Working Practices in the Refinery Premises so as to familiarize themselves with the
safety rules, regulations and practices. Contractor shall be in possession of valid safety training
badge while working in the Refinery premises.
The Contractors shall ensure that their supervisors must undergo Fire & Safety Training &
subsequent Test at Fire Station before starting the job. All contractors must disclose to CLM Cell the
name of supervisors and arrange safety training at Refinery Fire Station, before obtaining a gate
pass. CISF will issue the gate pass meant for supervisor, only after getting the confirmation from Fire
& Safety. It is the duty of supervisor to train his work force in Fire & Safety on regular basis. The
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9.4 Site safety training

Contractor is responsible for site safety awareness training for all personnel working in his areas.
Training includes
Personal Protective Equipment Scaffold

Housekeeping Fall prevention and protection
Work permit Hot work
First-aid Heavy lifting and Rigging
H2S Fire prevention and protection
Mock drill including fire rescue, evacuation etc Electrical Safety
Excavation Hand and power tools
Manual handling Confined Space Entry
Driving Safety Pre-commissioning Safety
Working at Height Lock-out and Tag-out
Completion of specific hazard training is mandatory before working on such tasks. A list of all trained
persons shall be maintained at site.
The contractor shall prepare the training calendar for safety activities and submit to owner/consultant
on monthly basis.
Attachment 13: Safety Training Matrix
Contractor shall maintain records of training register and copy shall be submitted to owner/consultant
after completion of training program
Attachment 14: Training Register
9.5 Safety Hand Book

The contractor shall ensure that the workmen working with him comply with safety rules mentioned in
the Safety booklet for Contractor and their employee. Booklet can be had free of cost from owners
Fire & Safety Dept.

In order to develop safety consciousness and awareness amongst the employees, the contractor site
management shall organize suitable Safety campaigns, Safety competitions and Safety rewards.
10.1 Safety Posters

The contractor shall take every effort to communicate the safety measures through displaying
posters, banners and sign boards around the work site.
Posters should be in Hindi, English and other suitable language deemed appropriate.
Posters should be replaced at least once in a month to maintain its effectiveness.
10.2 Safety Update Board

Contractor shall display safety statistics board at conspicuous locations such as site, contractor site
office; workers rest shed etc and shall be updated on regular basis.
Attachment 15: Safety Update Board

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10.3 Safety Notice Board

Contractor shall provide a dedicated notice board for display of safety alerts, safety shares or any
other safety related notices for awareness among work force.
10.4 Safety Campaigns

Contractor may organize monthly/weekly safety campaigns by on different safety themes to maintain
the focus on the hazards involved in the activities.
10.5 Safety Competitions

Contractors may plan for various safety competitions to motivate employees to take active part in
safety program.
10.6 Awards and Recognitions

Construction site safety awards programs may be instituted with focus on remarkable achievements
and contributions towards safety.
Contractor shall formulate safety reward program for individuals safety performance excellence as
Supervisor of the Month
Worker of the Month
10.7 Important days to observe

Contractor should observe the following important days related to Health, Safety and Environment by
displaying banners, badges, distributing pamphlets, competitions etc
4th March - National Safety Day
14th April - Fire Safety Day
5th June - World Environment Day
9th July - Occupational Health day
11.0 Documents and Information to be submitted by Contractor

11.1 Apart from safety policy, safety plan, safety organisation chart, safety assurance plan contractor shall
also submit the documents as required.
11.2 Contractor shall submit Man Power Report on daily basis at least by 10.00 am every day.
11.3 Contractor shall submit Weekly Safety Report every Monday as per the approved format. The data
shall be from Monday to Sunday.
11.4 Contractor shall submit the listed supporting documents along with the weekly safety report.
Safety Induction
Tool box Talks
Safety Observation Report (SOR)
Safety Observation Summary Sheet
Safety inspection reports
Safety Audit Report (if any)
Safe Plan of Action (SPA) of each activity.
Method statements
Safety training and mock drill records
Incident and Investigation Report (if any)
Attachment 16: Weekly Safety Report
11.5 Contractor shall submit Monthly Safety Report as per the approved format
Attachment 17: Monthly Safety Report

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Test Certificates for lifting tools and tackles, lifting gear, lifting equipment and appliances.
Test certificates of air receivers.
Information relating to hazardous materials used and their MSDS.
Employers liability insurance certificate.
Copies of all Statutory Registers maintained by the contractor when asked for.

The Contractor shall display a Safety Policy at a prominent place at his site office and each work
spot.
At all work sites, contractor has to display a board containing following information:-
OWNER site in-charge name;

12.1 Any incident at site how slight they are or which entails a person reporting to hospital or leaving site
for treatment shall be verbally reported immediately to consultant / owners representative. This will
enable the owner/ consultant to reach to the scene of incident / dangerous occurrences to
monitor/assist any rescue work and/or start conducting the investigation process so that the
evidences are not lost.
12.2 The return date of injured workmen back to the work shall be reported to Owner/ consultant promptly.
12.3 Written reports of all incidents and dangerous occurrences shall be submitted within 6 hours as per
format attached
Attachment 18: Incident and Investigation Report
12.4 Contractor shall ensure that any incident that occurs is fully investigated to find root cause and
preventive measures are adopted to prevent its reoccurrence. Owner/ Consultant shall have a right to
conduct independent inquiry of the incident.
12.5 Near misses and minor incidents should also be investigated by the Contractor as soon as possible
as they are signals that there are inadequacies in the safety management system.
12.6 Incident reporting chain and emergency contact numbers shall be displayed at conspicuous locations
at site and contractor offices.
Attachment 19: Incident Reporting Chain and Emergency Contact Numbers

13.1 A detailed site emergency procedure shall be worked out and communicated to all employees at site.
Necessary arrangements shall be made to deal with such emergency situations. An emergency
response team will be formed to tackle such situations.
13.2 The contractor shall ensure that an Emergency Response Plan is prepared to deal with emergencies
such as
Fire and explosion
Collapse of lifting appliances and transport equipment
Collapse of building, sheds or structure etc.
Gas leakage or spillage of dangerous goods or chemicals
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Excavation collapse
Fall of person from height
13.3 The following shall be considered to establish emergency procedures.

Make a list of available emergency services and confirm their communication channels.
Set up emergency response teams.
Ensure that supervisors clearly understand their responsibility and role in the site emergency
procedures.
Designate first aid and provide medical supplies and other material and equipment that may be
required for emergency use.
Determine emergency evacuation routes for work areas and construction site.
Make sure that all personnel clearly understand emergency warning siren signals or other warning
signals used by owner.
Designate a supervisor to conduct a head count and give instructions to evacuees as necessary.
Post-emergency information for each work area on the site.
13.4 Contractor shall conduct an onsite emergency mock drill once in every month for all his workers.
13.5 Bombs, Unattended Baggages/Objects

The following actions shall be taken by the contractor and his employees/workmen about Bombs,
Unattended baggage / Objects lying in secluded places in the Plant.
On noticing any bomb/ unattended baggage or object lying in the plant area, they should
immediately inform the CISF control room on Telephone No.3685 & 3660 and OWNER Fire
Control Room No. 3630 & 3663.
They should not touch the object or try to open the baggage or fiddle with the wires or battery if
found attached to the object.
They should move away to a safety distance of approximate 300 m. without creating any panic.
In case of unattended baggage, they should help CISF personnel in identifying the claimant.
They should not move to the area unless clearance is given by security personnel.
Dos & Donts in case of Bomb/Unattended baggage lying secluded places in the Plant.
Sl. Sl.
Dos Donts
No. No.
1. On noticing any bomb or unattended 1. Do not touch the bomb / unattended
baggage, in form CISF Control Room baggage.
by quickest possible means or on 2. Do not lift any attended baggage
Intercom Telephone No. 3685 / 3660
and OWNER Fire Control Room on 3. Do not go very close to the object
101 / 3630 / 3663.
2. Move away from the bomb/unattended 4. Do not create panic.
baggage.
3. Help security personnel in identifying 5. Do not fiddle with wires or battery if
unattended baggage. found attached with any object.
4. Help ladies and injured person during 6. Do not open any unattended
evacuation process from the affected baggage.
area.
5. Move back to your place of work after 7. Do not try to defuse any bomb or
clearance has been given by CISF. explosive material
14.0 Site Access and Security Procedures

14.1 Site Entry Permit Personnel and Machinery
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Refinery is an operational area, therefore, contractor and his employee shall observe all fire &
safety regulations of the refinery and shall so organise his work as not to interfere with the running
of the Refinery in any manner whatsoever. The contractor shall ensure that their staff/workmen
carry with them valid passes/work permits etc for proper identification inside the battery area.
Contractor shall arrange to apply for and secure valid gate passes for the entry and exit of his
men, materials and equipment, including those of the sub-contractors, from the concerned
authorities of the Owner.
The contractor shall ensure that their workmen/ supervisors shall not move to other places other
than their work premises without proper permission / authorisation.
The contractor shall ensure verification of antecedents of the labourers/ supervisors from Polices/
other officials before they are engaged by him. No person having adverse antecedent shall be
employed by the contractor. The contractor shall be held responsible for all the acts carried out by
his workmen.
Access to the site must be at all times via recognized roadways and footpaths. Personnel must
not access to construction areas through unauthorized areas. Anyone found disregarding this rule
would be subject to disciplinary action.
Contractor shall prepare and display the workers and vehicle site movement chart. The same
shall be communicated to all workmen in the site.
Persons without proper PPE shall be restricted at gate by security personnel. Entry to the site will
be permitted with PPE only.
Contractor must obtain this permit prior to the start up of the job, column, vessels, tanks or any
enclosed area where the chemicals or hazardous materials is either used or stored into it. It is the
contractors duty to see that daily, the above permits are obtained from the area-in-charge till the
completion of the job. All points stipulated in the permit must be strictly complied with.
14.2 Gate Pass/ ID Card

The Contractor shall make his own arrangements of Gate Pass with photo for his employees as
prescribed and instructed by the Security dept. i.e. CISF, and Contract Labour Management Cell
(CLM) at his own cost, each gate pass has to be endorsed by the Security Officer of the Refinery
before the pass be used by any employee. In case of termination of the service of any of his
employee during the contractual period, the contractor shall have to surrender the Gate Pass
issued to the employees to the Security Dept. At the end of the project all the gate passes
endorsed by the Security Dept. for use of the contractors employees shall have to be returned.
Gate pass shall be issued only after completing the site orientation / induction and local
statutory regulation formalities.
Separate entry passes shall be issued for visitors. Visitor passes will be valid only for a day
(Normal working hours) and at entry gate visitor shall undergo site safety instructions to be
followed during the visit and shall be provided with required PPE.
14.4 Working in Night

Contractor shall arrange necessary arrangement for working at night. The authorisation for
working at night shall be obtained from owner/consultant.
Responsible person shall be assigned as in-charge and it shall be informed to consultant/ owner.
Contractor shall arrange Necessary lighting, emergency vehicle and emergency DG.
14.5 Prohibited Items and Activities

Gambling, fooling on the work, horseplay, mock fighting or fighting is strictly forbidden in the
Refinery premises Project area.
Fooling on the job, mock fighting or fighting within the Refinery premises will not be tolerated.
Gambling within the Refinery premises is strictly forbidden.
Entering the Refinery premises while in possession of weapons such as knives & gun etc. is
prohibited.
Contractor personnel shall not pick up quarrel or get into arguments with Refinery personnel or
act in any misunderstanding, such problems should be referred to appropriate Refinery personnel.
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Working under influence of alcohol/ narcotics and entering Refinery premises while in the
influence of alcohol/ narcotics is strictly forbidden. The contractor should ensure compliance of
above by him and all his workmen.
Contractors are prohibited from using Cellular phones within the Refinery premises, except to the
extent permitted by the Owner by special or general order / instruction.
Carrying Match Boxes / Lighters and No Smoking

Carrying / Striking of matches, lighters inside the Owners premises or smoking within the refinery,
tank farm or dyke limits are strictly prohibited. Owners regulatory officials shall be entitled to
forthwith remove, using force if necessary, anyone violating the No Smoking and other fire safety
rules.
Any contractors employee who is found smoking or in the possession of matchbox or lighter or
any other means of ignition in a prohibited area will be turned out from the premises of the
Refinery. Suitable action as decided by the Management will also be taken against the
contractor/contractors employees.
Unsafe Practices: Any unsafe practices or disregard of normal safe working practices by contractor
personnel when pointed out by company personnel shall be immediately corrected.
14.6 Disciplinary Actions

Contractor shall implement a disciplinary action policy whereby contractor and sub-contractors
employees, found violating safety rules.

15.1 A permit to work system is a safety strategy designed to protect personnel and plant and which
consists of an organized and predefined safety procedure. It forms a clear record of all foreseeable
hazards, which have been considered in advance of the construction operations.
15.2 The contractor shall not commence the job without the valid permit for the area and for the job.
Clearance shall be obtained from the area-in-charge and shift engineer
15.3 The following is the list of some of the activities, which would require permit, and list may change
depending upon work situation.
Working at Height
Excavations
Lifting Operations
Hot Work
Electrical Works (Isolation & Energisation)
Confined Spaces
Radiography
High Pressure test
Commissioning of equipment
15.4 Before starting any work, contractor shall apply at least one day ahead for fire & safety permit for
excavation, electrical, gas welding and cutting work to Engineer-in-Charge of work/ works who in turn
will arrange for such permits. The contractor shall take all the precautions given in the permit before
starting of the work to the full satisfaction of the Engineer-in-Charge of the sections. On account of
operational problem it is possible that the clearance and permit may get delayed for which the
contractor shall not ask for the idle charges. Fire equipment such as fire extinguishers, fire hoses,
control type nozzles, personal protective equipment, Blow man air apparatus etc required for safety
precautions are to be arranged by contractor himself. However in case of emergency on
authorization from Engineer-in-Charge those items will be issued from the Refinerys Fire Station on
chargeable basis and shall be returned after completion of the work / works in working conditions, to
the full satisfaction of the Fire & Safety Officer. In case of any damage to the fire & safety equipments
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issued or used by the contractor, the contractor shall bear the cost of such damage in full and the
same will be recovered from his bills.
15.5 Safety measures stipulated in the respective Work Permits shall be strictly complied at all times when
within the premises of the Owner.
15.6 Owner reserves the right to cancel a work permit without assigning reasons. When called upon to
stop the work by the Engineer-in-charge, the Contractor shall immediately cease to continue the
work. Before re-commencement, fresh work permit must be obtained.
15.7 The Engineer-in-Charge reserves the right to terminate the contract and forfeit any or all amounts
due to him in case he finds that the precautions written on the permit are not strictly adhered to by
the Contractor.
15.8 Permit to work shall be valid for a shift (8 Hours) only. However, Engineer may extend the permit to a
maximum of another 4 hours if necessary.
15.9 A copy Permit to Work shall be displayed, during its validity, in a conspicuous location in close
proximity to the actual works location to which it applies.
15.10 Hot work Permit

The entire job is to be carried out within the running unit of Refinery. The Contractor shall take all
necessary safety precautions and obtain required certificates/ fire permits / safety/ work permits etc.
from the competent authority before carrying out any hot works during the execution of the entire
works covered by this tender.
A hot work permit issued by the concerned department or area-in-charge must cover any work
carried out within Refinery. In addition a clearance must be obtained from the concerned
departments officer or supervisor prior to commencement of any job. A hot permit is required for:
Any work involving open flames, spark such as welding, gas cutting, soldering, grinding, concrete
breaking, use of hurricane lamps and internal combustion driving vehicles / Radiography / Crane
lifting / Vessel entry.
Sand blasting, Trucks, Jeeps, Cranes, Lifts, Cars or any kind of vehicle driven by an internal
combustion engine or by batteries
Entry of vehicles inside battery limits of process area within tank dykes and adjacent to pump
houses and loading gantries etc.
While carrying out the hot job, the contractor and his workmen must ensure the following safety
measures and job should be carried with
Provision of running fire water hose at work place.
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The owner may provide certain facilities. However the contractors shall provide drinking water,
required number of toilet for male and female, washing facilities and rest shelters in suitable locations
as per statutory regulations.
16.1 Drinking water

16.11 The contractor shall make in every worksite, effective arrangements to provide sufficient supply of
wholesome drinking water. Quality of the drinking water shall conform to the requirements of national
standards on Public Health.
16.12 While locating these drinking water facilities due care shall be taken so that these are easily
accessible within a distance of 200m from the place of work for all workers at all location of work
sites.
16.13 All such points shall be legible marked Drinking Water in a language understood by a majority of the
workmen employed and shall be situated within six meters of any washing places, urinals or latrines.
16.2 Latrine and urinals

16.21 The contractor shall provide sufficient latrine seat and urinal facility in the worksite.
16.22 When women are employed, separate latrine and urinals accommodation shall be provided.
16.23 Notice shall be displayed outside each block of latrines or urinals a containing therein "For Men
Only" or "For Women Only", where both male and female workers are employed, written in the
language understood by the majority of such workers.
16.3 Canteen
16.31 In every workplace wherein not less than 250 workers are ordinarily employed the contractor shall
provide an adequate canteen.
16.32 The charges for food stuff shall be based on no profit no loss basis. The price list of all items shall
be conspicuously displayed in such canteen.
16.33 Building of the canteen shall be situated at the distance not less than fifteen point two meters from
any latrine or urinal or any source of dust, smoke or obnoxious fumes.
16.34 Waste water from canteen shall be carried away in suitable covered drains and shall not be allowed
to accumulate in the surroundings of canteen

The owner at project site may provide a first-aid center for the treatment of minor injuries and illness.
However all major injuries and illness cases shall be referred to the Hospitals and contractor shall
make his own arrangement for such treatment as required.
The contractor shall provide sufficient number of stretchers and shall be readily available in an
emergency.
The contractor shall maintain injury record. A separate first-aid register shall be maintained and it
shall be submitted to owner/ consultant on regular basis.
17.1 First Aid Box

The contractor shall provide sufficient number of First-aid box for providing First-aid to the injured
workers. Every First-aid box is distinctly marked First-aid and is equipped with the articles specified
in Attachment
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Attachment 20: Contents of First-Aid box
17.2 Hospital Tie-up and Emergency vehicle

17.2.1 Contractors shall require to tie-up with the hospitals located in the neighbourhood for attending
medical emergencies.
17.2.2 Emergency vehicle shall be kept on standby duty during all working hours for the purpose.
17.2.3 The emergency vehicle shall not be used for any other purposes other than its indent purpose.

18.1 Prevention of mosquito breeding
Empty cans, oil drums, packing and other receptacles, which may retain water shall be deposited
at a central collection point and shall be removed from the site regularly.
Still waters shall be treated at least once every week with oil in order to prevent mosquito
breeding.
Drainages shall be cleaned regularly.
The contractor at periodic interval shall arrange to prevent mosquito breeding by fumigation /
spraying of insecticides.
18.2 Prevention of snake bite

Contractor shall remove weeds from site regularly to keep away the snakes.
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19.1 The contractor shall provide all required PPE to his employees & workers, which are duly inspected
and approved by the owner/consultant. NO PPE ZONE would be identified separately.
All PPE provided by the contractor shall confirm to Bureau of Indian Standards (BIS).
Attachment 21: Bureau of Indian Standards for PPE
Copy of Manufacturers test certificates of PPE used shall be submitted to owner/ consultant.
19.2 The contractor shall:

Maintain records of issue and replacement of PPE.
Maintain 10% PPE stock of total requirement available at their store and stock record.
Issue PPE to worker free of cost.
Maintain all personal protective equipment in good working condition.
Periodically check and replace all defective / broken personal protective equipment.
Contractor shall submit PPE issue register and PPE stock record to owner/consultant on regular
intervals.
Attachment 22: PPE Issue Register
Attachment 23: PPE Stock Register
19.3 As a minimum, every worker shall wear safety shoes, safety helmet and safety goggles at project
site.
Depending upon the job requirement other PPE shall used.
Head Protection Safety Helmet
Foot Protection - steel toe cap shoes, steel toe cap gumboot
Eye Protection - Goggles, Helmet mounted face shield
Hand Protection - Gloves
Respiratory Protection - Nose mask, Self Contained Breathing Apparatus
Hearing Protection - Ear plugs, Ear muffs
Personal Fall Protection - Full body harness with double lanyard, Rope-grab fall arrester, etc
Body Protection - Full body apron
19.3.1 Head Protection

Safety helmet shall be worn by all persons at all times on project site. It shall consist of
suspension cradle and chin strap.
All persons on the project site shall wear chin strap at all time.
Logo of corresponding main contractor shall be affixed on the safety helmet.
Damaged helmet shall not be used and should be discarded from the site immediately.
19.3.2 Foot Protection

All personnel shall wear suitable safety footwear with steel toe cap at all times while on the project
site.
19.3.3 Eye/Face Protection

Contractor shall provide suitable eye/face protectors where there is a potential of injury to the
eyes and face from dust, flying particles, molten metal, chemicals, fumes or vapors, light radiation
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or combination of these.
Operation Hazards Eye Protectors
General site use Dust, flying particles Safety goggles (Plain)

Sparks, harmful rays,
Welding goggles (Black Shade) -
Gas Cutting molten metal, flying
eyecup type
particles.
Sparks, intense rays, molten
Electric (Arc) welding Welders hood mounted on helmet
metal
Grinding Flying particles Face shield mounted on helmet
Chipping goggles (Plain) eyecup
Chipping Flying particles
type
Chemical resistant goggles and face
Chemical handling Splash, acid burns, fumes
shield.
Contractor shall inspect the goggles used by workmen and shall replace the defective goggles
immediately.
Eye protection for Helpers exposed to light radiation from welding, gas cutting activity shall be
provided with black shaded welding goggles.
19.3.4 Hand Protection

Contractor shall choose and use suitable gloves for the task.
Protection Level
Hand protector Sharp Activity
Heat Chemical Electricity
objects
Cotton dot type Inspection work, Climbing
Medium Poor Poor Poor
glove Ladders.
Leather & cloth
Good Medium Poor Poor Scaffolding
type glove
Leather riggers Hot work, Rigging, Manual
Good Good Poor Poor
Gloves Handling.
Rubber moulded For use with Chemicals &
Poor Medium Good Good
gloves Acids
Rubber Gloves Poor Poor Poor Good Electrical works
In addition to above, gloves shall be used by personnel involved in works with possibility of the
risk from abrasion, cutting, tearing, chemical, or other burn, infection.
19.3.5 Respiratory Protection

19.3.5.1 Respiratory protective equipment to be used in confined space and activity involving any
chemicals shall be as advised by owners Engineer-in-Charge / Fire & Safety Dept.
19.3.5.2 Supplied Air Respirators and Self Contained Breathing Apparatus (SCBA) used for working in
hazardous atmosphere shall be advised by owners Engineer-in-Charge / Fire & Safety
Department. The same shall confirm to BIS and shall be approved by owner/ consultant.
19.3.5.3 Contractor shall organise practical demonstration training on the methodology to use SCBA or
Supplied Air Respirators in consultation with owner/consultant.
19.3.5.4 Air Purifying Respirators

Contractor shall use appropriate particulate filter respirators like dust mask depending upon the
fineness of particulates to filter.
Personnel involved in housekeeping, handling cement, insulation material etc shall use suitable
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dust mask.
Contractor shall use chemical cartridge respirators while performing outdoor spray painting.
19.3.6 Hearing Protection

Hearing protection shall be worn by personnel involved in works in areas of high noise levels, or
when working with equipment that generate high noise levels.
Hearing protection can be of an external cup-type protector normally ear muff which fits over
the outside of the ear, or plug-type, usually disposable type ear plugs made of compressible
foam, which fits inside the ear.
Disposable ear plugs shall be of one time use and shall be disposed properly.
19.3.7 Personal Fall Protection

Full body safety harness shall be required when working two meters or above. It shall be fitted
with double lanyard and the maximum length of the lanyard shall be not greater than 1.8 m.
The lanyard shall be fitted with shock absorber and anchoring hook shall be of scaffold type snap
hook.
Full body safety harness fitted with shock absorber shall be used while working 3 m or above.
19.3.8 Body Protection

Full body apron suitable for the task such as hot work, chemical handling shall be used.
Contractor personnel shall not wear loose clothing while working around moving or rotating
equipment.
20.0 Housekeeping
20.1 Contractor shall maintain very high standard of housekeeping at all times.
Keep the site neat and tidy. Keep adequate number of skips / waste bins.
Keep the access clear of all obstructions.
Remove the nails or bend them down from the wooden scrap and remove them from job site.
Store the material in an orderly manner.
20.2 The contractor shall on daily basis keep the premises and surrounding area free from accumulation
of waste materials or rubbish caused by activities.
20.3 At the completion of days work contractor shall remove these materials to avoid Slip/ Trip hazards
and provide safe areas for movement of all workers and supervisors.
20.4 Empty gas cylinders shall be removed from the site and shall send back to the contractors store.
22.5 Contractor should establish regular maintenance program of sweeping and hosing to minimise
accumulation of dirt and dust in such areas.
20.6 If the Contractor does not clear the area after the completion of work, the same shall be got done by
owner and recoveries shall be made from the bills of the Contractor at double the rate at which the
owner has got it done.
20.7 On completion of the job the contractor shall remove all his construction material, tools etc. and
remove all temporary constructions and leave the job site thoroughly cleaned up and ready for use. A
job will not be considered completed until all surplus material, scrape and debris / rubbish are
removed from the job site.
20.8 When required contractors should suspend other operations and do housekeeping.
20.9 Waste Disposal
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Waste generated at site shall be segregated at source and disposed off in accordance with
environmental control regulations and municipality rules. Consultant shall be informed of procedure
followed by the contractor before disposal.
20.9.1 Scrap yard shall be identified and waste shall be disposed temporarily at designated scarp yard.
Scrap yard shall be barricaded and shall be clearly marked as Scrap Yard in English and other local
languages.
22.9.2 All receptacles shall be constructed of metal or other suitable types of containers of non-flammable
materials. Cardboard, wooden boxes or crates and similar types of containers shall not be used for
the collection of combustible waste.
22.9.3 Skips containing combustible waste should be strategically placed to ensure fire does not spread in
the case of combustion within a skip.
22.9.4 Contractor shall maintain routine housekeeping inspection record and shall be submitted to
owner/consultant.
21.0 Safety Signs

Contractor shall post safety signs which give a general safety message in workplaces to draw
attention rapidly to the objects and situation affecting health and safety.
21.1 Colours of safety signs, dimension and layout shall confirm to IS 9457:2005
Red : Prohibition signs
Yellow : Warning signs
Green : Mandatory action signs
Blue : Safe condition signs
21.2 Bands
The band colour for indicating hazard location shall be the combination of Yellow and Black.
The band colour for indicating prohibition shall be the combination of Red and White.
The band colour for indicating mandatory action shall be the combination of Blue and White.
The band colour for indicating safe condition shall be the combination of Green and White.
21.3 Tags
Contractor shall implement tag system for scaffold, LOTO and unsafe equipment.

22.1 Competency
The contractor shall appoint a competent person on site who will be responsible for the control of
all electrical systems.
All maintenance and repairs of electrical system shall carried-out qualified and authorised
electricians only.
22.2 Power Supply

If the owners supply electricity, it will be provided at one point, which would be determined by the
owner. The supply would be of 230V, 50Hz, and single phase or of 415/ 433V, 50Hz, three phase.
Power distribution beyond this point shall be through armoured cable only. No deviation on this
would be permitted. The provision of all connections and equipment required beyond this point shall
be responsibility of the contractor.
If the electricity supply is in contractor scope, the contractor shall assess required electrical loads and
shall install required capacity diesel generators for power supply.
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The contractor shall submit electrical Single Line Diagram (SLD), schematic diagram and the details
of the equipment for all temporary electrical installation to the owner/consultant.
22.3 Diesel Generator (DG)

The contractor shall install only acoustic DG. It shall confirm to national standards.
The DG shall be placed on firm base and shall be protected from water logging.
The noise level from DG shall not exceed 85dbA.
The DG shall be barricaded to restrict any unauthorised entry.
The body of the DG and main electrical panel shall be properly grounded.
DGs Exhaust shall be fitted with spark arrestor.
Barrel shall be kept on spill tray while transferring diesel to DG. Any diesel spillage around DG
shall be cleaned immediately.
Diesel barrels irrespective of empty or full shall not be stored near DG.
Adequate fire extinguishers and sand buckets shall be provided.
Rubber mat shall be provided for main electrical panel.
22.3.1 Contractor shall display the following details near the DG.
Name with photograph and contact number of authorised person to operate the DG
Single Line Diagram (SLD)
Safety signs
Cardio Pulmonary Resuscitation (CRP) and electric shock first-aid treatment chart.
Location of nearest first-aid box availability.
List of emergency services contact numbers.
22.3.2 Contractor shall inspect DG periodically and the record shall be submitted to owner/ consultant.
Attachment 24: Diesel Generator checklist
22.4 Distribution System

Contractor shall ensure that all distribution board (DB) used in the site shall be of IP type which
specification confirms to national standards.
The contractor shall provide sufficient ELCB (maintain sensitivity 30 mA) / RCCB for all the
equipments (including Portable equipments), electrical switchboards, distribution panels etc. to
prevent electrical shocks to the workers
Earth Leakage Circuit Breaker (ELCB) should be provided on all distribution boards and main
switchboards. Single switch multiple socket system would not be permitted.
Rating of fuses and circuit breakers used for the protection of circuits should be coordinate with
equipment power ratings. Use of makeshift wires or conductors as fuse wire is strictly prohibited.
Protection against lightning shall be ensured to all equipment kept in open at sites.
22.5 Cables
Periodic check shall be carried out for defective cables, cracked or perished insulation, loose
joints in conduits, damaged fuse boxes and switchboards, loose pins, faulty sockets and defective
earth wire.
Kinking, twisting, binding or crushing of cables shall be avoided all the time. No electrical
equipments shall be left open or unsecured at the end of the days work.
All power distribution cables should be taken overhead with sufficient headroom.
Cabling passing under the walk way and across way for transport and mobile equipment shall be
laid in ducts at a minimum depth of 0.6 meters.
All switch boards, extension boards, etc. should be protected from rain and water. No water
logging should be allowed around switchboards.
22.6 Plugs, Sockets and Couplers
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The contractor shall ensure plugs; sockets and couplers used shall be splash proof type. The
minimum degree of Ingress Protection should be of IP44 in accordance with national standards.
Plugs and fittings used shall be of the weatherproof type and they should be colour coded in
accordance with the internationally recognised standards
110 volts: Yellow.

240 volts: Blue.
415 volts: Red.
No loose connections or tapped joints shall be allowed any where in the work site, office area, stores
and other areas. Proper cable connectors as per national standards shall only be used to connect
cables
Plugs shall be used to connect with sockets. Inserting the leads into the sockets shall be strictly
prohibited.
22.7 Lighting
The contractor shall provide sufficient lighting at site, of the right type and at the right place.
A far as possible contractor shall provide flood lighting to cover maximum work area.
The access and storage yard shall be well illuminated.
Luminaries should be robust and water proof especially at the point of the cable entry.
Hand held lamps used shall be of 115V and suitably guarded to protect from any mechanical
damage.
Light fitting for hazardous environment shall be of flame proof type which specifications shall
confirm to national standards.
Contractor shall use only 24V lamp in to confined space It shall be guarded and of flame proof
type.
22.8 Power Tools

Power tools include grinder, Drilling machine, Jack Hammer and Concrete breaker etc
The contractor shall ensure all portable power tools do not exceed 125 volts rating and free from
defects and properly grounded.
Rotating tools shall be switched off and held until rotation has completely stopped.
Tools must be disconnected before changing bits, blades, cutters or wheels.
Electrical power hand tools shall be of double insulated type.
All tools shall be used with extension cords which are as short as possible.
Drilling of large holes shall be done stage by stage by using small bore drills and gradually
increasing the drill bit size.
Contractors shall provide suitable storage with suitable racks and bins for storing tools and
equipment.
The contractors qualified electrician shall inspect and tag electrical power hand tools regularly.
The tag shall display name, signature of the individual inspecting the tool, date of inspection.
The contractor shall keep, on site, a register of all electrical power hand tools in use giving all
relevant details about the tool and its inspection.
No electrical powered hand tool shall be used other than it is tagged with a current
INSPECTION tag.
All electrical leads must be connected to the power source through standard industrial
waterproofed plugs and sockets, which shall be in good condition.
While working at higher elevation, adequate precaution to be taken to ensure that they do not fall
down.
22.9 Lock-Out and Tag-Out (LOTO)

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Contractor shall form a LOTO procedure and shall be implemented during any maintenance,
repair, pre-commissioning and commissioning activities.
The equipment shall be isolated from energy sources before carrying any maintenance work.
LOTO register shall be maintained and shall be controlled by a designated person.
Contractor shall be responsible for arranging locks for locking the feeders or panel boards.
All locks shall be neatly labelled for easy identification and the keys of the locks shall be
maintained by the designated person.
22.10 Earthing
Contractor shall ensure all earthing shall confirm to IS 3043:1987
Body of electrically operated tools, equipments, distribution board, electrical panel etc shall be
grounded properly.
Earth pit shall be clearly marked and earth resistance shall be measured on monthly basis and
register shall be maintained by contractor.
23.0 Form Work

Contractor shall ensure no workers shall be allowed to work above vertically protruded reinforcing
steel unless it has been bent over or capped.
Reinforcing steel for wall, pier, column and similar vertical form work structures shall be guyed
and supported to prevent collapse and to guard against possible wind pressure.
Pump concrete or similar system using discharge pipe shall be provided with pipe supports.
Compressed air hose in discharge pipe systems shall be provided with positive fail-safe joint
connectors to prevent separation of section when pressurised.
Banks man shall be deployed for backing the transit mixer and wheel stopper shall be paced.
Form work an shoring shall be designed, erected, supported, braced and maintained so that it will
safety support all vertical and lateral loads that may be imposed during concrete pouring.
No persons shall be allowed closed to the shoring during pour operation.
Scaffolds used for supporting Form Work should be constructed on a firm ground with a base
plate. The staging should as per IS 3696. Staging should be inspected frequently even after
completion of concrete work, or after completion of intended use.
24.0 Excavations
24.1 The contractor shall obtain work permit from owner/ consultant before starting excavation
24.2 Contractor shall prepare a method statement by considering the following factors
Nature & type of the soil
Weather and moisture conditions
Underground utilities
Methodology adopted to avoid cave-in
Depth and width of excavation
Duration of the excavation job
Proximity of other structures, services
Dewatering systems
24.3 Contractor shall stabilise the sides of an excavation by designing the shoring, if the depth is 4 metre
or more and which shall be approved by owner/ consultant.
24.4 All excavations and trenches depth of 0.60 m or more shall be hard barricaded.
The hard barricade shall be made of steel pipes of minimum 40 NB.
The hard barricade shall have hand rail at 1100mm and mid rail at 550 mm and the spacing
between two vertical members should not be more than 1000 mm.
The hard barricade shall withstand a lateral load of 100 kg.
The hard barricade shall be provided at least 1.0 meter away from the edge of the excavation.
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24.5 Excavations and trenches depth less than 600 mm shall be cordoned off and suitable sign boards
warning tapes posted.
24.6 Access shall be provided by mean of portable ladder or ramp if the depth is more than 1.5m.
24.7 Portable ladders shall be provided at intervals of not more than 15 m, depending on the number of
workmen present.
24.8 All excavated materials shall be deposited minimum 1.5 m away from the edge of the excavation.
24.9 Excavating equipments and vehicle shall be operated 2.0 m away from excavated area.
Attachment 25: Excavation Checklist
25.0 Hot Work

Any work involving open flame/ spark shall be considered as hot work.
All hot work involved equipments and fitting shall confirm to relevant IS Standards and the
manufacturers test certificate shall be submitted to owner/ consultant.
Contractor shall obtain hot work permit from owner/ consultant prior to the commencement of the
job.
Fire watcher shall be engaged for each hot work activity and shall be competent in using fire
extinguishers
Work area beneath or adjacent to hot works shall be made free from combustible materials, and
cordoned-off to prevent personnel being injured by welding spatters.
Barriers or screens shall be erected whenever necessary to protect the workmen working near by.
Suitable safety signs & notices shall be displayed near the hot work area.
Contractor shall use non asbestos fire blankets to avoid falling of spatters. Manufacturers test
certificate shall be submitted to owner/consultant.
Fire extinguisher shall always be carried with each welding set, preferably a dry chemical powder
type.
After hot work, contractor shall ensure a good housekeeping by sweeping the work area, stacking
the materials, winding the cables/ hoses and placing the equipments properly.
Appropriate PPE mentioned in clause 19.0 shall be used depending up on the hot work activity.
Attachment 26: Hot Work Activity Checklist
25.1 Welding Activity
25.1.1 As far as possible D.C. Generator / Rectifiers should be used in preference to A.C. Transformer sets.
25.1.2 The contractor shall get welding transformer certified by the owner/consultant Electrical Engineer
before start of work and shall obtain a certificate valid for a period of three months renewable after
every three months.
25.1.3 A copy of the certificate shall be displayed on respective welding sets.
25.1.4 The contractor shall ensure

The welding transformer is kept away from any wet area and shall be located close to work site.
The body of the welding transformer shall be properly earthed.
The length of supply cable to welding transformer shall not exceed 5 m.
The size of the cable used shall be proportional to the voltage supply.
Damaged supply and lead cables are not used.
Lugs shall be used for connecting the lead and return cables with welding transformer.
The welding transformer shall have separate on/ off switch.
The electrode holder handle shall be of non metallic body.
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Grounding from welding return connection shall be done only on work piece. Return connection
shall not be grounded with scaffold member, pipe racks or pipes containing flammable liquid or
gases.
Used electrode shall be collected and shall be disposed properly.
25.1.5 Periodic Inspection shall be carried on the welding transformer and the record shall be submitted to
owner/ consultant.
Attachment 27: Welding Set Checklist
25.2 Gas Cutting Activity

All gas cutting set shall be inspected prior to entry into the site
All gas cutting sets shall be kept at upright position and fastened in the trolley.
Cylinder valve key shall be made available all the time along with the cylinder when on use.
Domestic type LPG (14KG) shall not be used at the site.
Hose clamp shall be used to connect hoses firmly in both sides of cylinders and torch.
Approved type Non-return valve shall be fixed at torch end and Flashback arrester shall be fixed
at cylinder end.
All gas cylinders shall be fixed with pressure regulator and double head dial gauges.
Hoses used shall be free from any damage. Soap solution test shall be carried-out on the entire
length of hoses to check any leak.
Hoses quality shall confirm BIS. Also Red hose shall be for fuel gas and blue hose for oxygen.
Cutting torch nozzles shall be cleaned before commencing the job to avoid any backfire.
Cutting torch showing any physical damage shall be immediately replaced.
The torch shall be ignited by friction lighter. Igniting by match-box and welding arc is strictly
prohibited.
Gas cylinders shall not be placed beneath the hot work area.
Material Safety Data Sheet (MSDS) of gas cylinders shall be displayed at store yard.
Empty/ full cylinders shall be handled by the means of trolley.
Valve protection cap shall be fitted on the cylinder while shifting and storing.
When handling oxygen cylinders, ensure hands, clothes, gloves are free from oil, dirt, grit and
grease. Under no circumstances oil shall be allowed to contaminate a cylinder containing oxygen.
Periodic Inspection shall be carried on the gas cutting set and the record shall be submitted to
owner/ consultant.
Attachment 28: Gas Cutting Set Checklist
25.3 Grinding/ Cutting Activity

Grinding/ cutting activity shall be always carried out by trained and experienced person.
Only reinforced resin-bonded or resin-bonded abrasive wheels must be used in portable grinding
machines.
Grinding wheels should be stored in dry place and shall avoid direct contact of heat. Wet or
soaked grinding wheels shall not be used.
Wheels shall not be used at any time beyond their expiry date.
The RPM of grinding/ cutting wheel should be equal or greater than the machine spindle RPM.
Grinding Wheels should be segregated size wise to avoid wrong selection of the wheel. Grinding
wheel fitted shall be of suitable size for the grinding machine.
Power supply cable used shall be of rated current carrying capacity with plug-top and shall be free
from damages.
Supply shall be routed through ELCB.
Machine selected shall be of non-metallic body. Body earthing shall be ensured the in case of
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metallic body.
All grinding machine shall be fitted with Dead-Man switch and this shall not be bypassed any time.
All grinding/ cutting machines shall be guarded.
Check shall be done for any abnormal sound and/or vibration.
Grinding wheel without manufacturers specification showing size, speed and expiry date shall not
in used.
Portable grinding machine shall not be used as bench grinder. Small work piece shall be fixed on
bench vice.
Proper spanner shall be used for fixing grinding wheel with the machine.
Machine shall be put OFF from the main switch when not in use.
Grinding activity shall not be carried out in confined space without a valid work permit.
Periodic Inspection shall be carried on the grinding/cutting machine and the record shall be
submitted to owner/ consultant.
Attachment 29: Grinding Machine Checklist

26.1 The contractor shall take every precaution and use all reasonable means to prevent an outbreak of
fire and shall tender immediate assistance in case of fire. Any outbreak of fire in or near the
workplace shall immediately be reported to the Owner / Consultants.
26.2 The contractors shall provide adequate number of well-maintained fire extinguishers at each work
area.
26.3 Extinguishers should be sited in such a way that it is not necessary to travel more than 15 meters
from the site of the fire to reach the extinguishers. The location of fire extinguishers shall be clearly
marked by sign boards.
26.4 Contractor shall provide fire extinguishers as per IS 2190:1992
Type of occupancy Recommended scale of equipment to be installed

One 4.5 kg capacity carbon dioxide extinguisher for every 100
Office, Computer installations,
m2 of floor area or part thereof with minimum of two
record rooms,
extinguishers so located as to be available within 10 m radius.
5 kg capacity dry powder extinguisher for every 600 m2 area
Workshops, painting shops,
generator rooms
Flammable liquid stores,
5 kg capacity dry powder extinguisher for every 600 m2 area
storage in drums and cans in
open, paints and varnishes
godown.
One 10 kg dry powder extinguisher or 6.8 kg carbon dioxide
extinguisher for 100 m2 of floor area or part thereof, with
Storage area of LPG and other
minimum of one extinguishers of the same type for every
industrial gases.
compartment; extinguisher should be available within a radius of
15 m.
26.5 The contractor shall ensure that workmen are trained in the use of fire extinguishers, understands the
basics of fire fighting and train the workmen to become familiar with such Fire Fighting Procedures
26.6 Fire drills should be held at regular intervals to ensure personnel are familiar with the location, of
Assembly Point and response expected of them in case of emergency.
26.7 Smoking on site is strictly prohibited. No Smoking signboards shall be displayed at prominent
location including stores/ storage places.
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26.8 Care of flammable materials, oily rags, waste etc. shall not be left lying around or allowed to
accumulate. Covered metal skips should be used for disposal of flammable waste.
26.9 If hot work operations are to be carried out, non-flammable screens and blankets shall be used to
confine sparks hot metal or slag. A fire extinguisher should also be readily available.
26.10 Chemicals and other such goods should be stored in stable racks properly labelled. Mutually
reactive chemicals should be kept away from each other. Storage place should have proper
ventilation.
26.11 Fire extinguishers shall be Periodically Inspected and the record shall be submitted to owner/
consultant.
Attachment 30 Fire Extinguisher Checklist

27.1 Compressed Gases
Handling and Storage of gas cylinder shall comply Gas cylinder rules 2003.
Oxygen cylinders and fuel gas cylinders shall be stored separately, at least 6.6 meters apart or
separated by a fire proof, 1.6 meters high partition.
Flammable substances shall not be stored within 15 m of cylinder storage areas.
Valve protection caps over the cylinder shall be provided in storage yard as well as while not in
use.
All compressed gas cylinders shall be used, stored and transported in an upright position.
Compressed gas storage facilities shall be positioned at a sufficient distance from work area,
offices and roads in such a manner as not to cause a hazard to employees, facilities and/or other
contractors.
Cylinders should be stored in suitably designed racks, which must have chains so that any
number of cylinders can be securely and safely stored.
Signs indicating the contents with separate storage for full or empty shall be displayed.
Warning signs must be posted - DANGER - HIGHLY FLAMMABLE - NO SMOKING and NO
NAKED FLAME.
Oxygen cylinder shall be separated from other combustible gas, oil or grease.
27.2 Combustible Liquids

The handling and storage of combustible liquids shall comply The Petroleum Act, 1934 and
Rules 1976
Flammable and combustible liquids must be stored in a metal storage cabinet with a prominent
sign boards FLAMMABLE - NO SMOKING and NO NAKED FLAME.
The area should be well ventilated and free from flammable material
28.0 Work at Height

Work involving above 1.8m from ground level that include all work activities where there is a need
to control the risk of falling which is able to cause personal injury.
It includes working on scaffolds, access and egress through ladder and working near unprotected
excavation.
The contractor shall ensure that work at height is carried out only when the weather conditions do
not endanger the safety of persons involved in the work.
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Life line shall be installed and full body safety harness with double lanyard of 1.8m with shock
absorber and scaffold type snap hook shall be used to ensure 100% protection.
Fall protection devices shall be secured to an anchorage point or a structural member which can
support a minimum dead weight 2450kg.
Ladders shall be only used as access for ascending and descending. Using scaffold member as
access is strictly prohibited.
No loose materials shall be kept on working platform and shall be kept on baskets.
28.1 Scaffolds
Scaffolding shall be properly designed and erected, with its intended use, where additional,
anticipated loads are to be applied; the structure shall be redesigned and modified accordingly. All
scaffolding material shall be as per relevant IS specification.
Light Duty Scaffold

Medium duty scaffold
Heavy duty scaffold
Bamboo and wooden scaffolding is prohibited. Only steel pipe scaffold shall be permitted.
Return cable of welding machine shall not be connected with scaffolds member.
Scaffold shall be inspected every week or after any adverse weather condition like rain, cyclone
etc.
Scaffold inspection record shall be submitted to owner/consultant immediately after inspection.
28.1.1 Scaffold Erection

Scaffold shall be erected by competent scaffold erectors under the supervision of competent
supervisor.
Scaffold shall be erected with a factor of safety not less than 4.
Survey for all underground utility systems such pipe line shall be identified and possible worst
scenario shall be assessed before erecting the scaffold.
Scaffold should be vertical and plumb.
The footing shall be placed on levelled and firm ground capable of carrying indented load without
settling or displacement.
Base plate shall be provided at a size of 150 mm X 150mm and thickness of not less than 6mm.
Uses of concrete blocks, barrels, boxes, loose bricks as supports are strictly prohibited.
The height of the scaffold shall not be more than four times of its minimum base dimension unless
guy ropes, ties or braces are used.
Scaffold having more than 10 m height shall be secured with fixed structure for stability at every 8
m.
Vertical member shall be connected with horizontal members using right angle type clamp.
Only bracing may be connected with vertical member using swivel clamp.
Landing platform shall be provided at every 9m. Platform shall not be extended beyond 150 mm
from the end.
Platform shall be made of minimum 2 gratings (at least 46 cm) and fastened properly
Hand rail shall be provided at a height of 1100mm, mid rail at 600mm and toe board width shall be
150mm.
Scaffold shall be braced at all four sides.
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Access shall be provided by means of portable ladder and it is the duty of supervisor to provide
safe access. It shall be immediately installed after the completion of second level horizontal or 6
m.
Ladders shall be extended at least 3 rungs from platform.
Full body harness with double lanyards fitted with shock absorbers with scaffold type snap hooks
shall be worn by scaffold erectors.
The completed scaffolding shall be inspected and certified by scaffolding supervisor and engineer
using scaffold.
After completion of scaffold inspection if safe, green tag shall be displayed near the access
ladder. If scaffold found unsafe, red tag shall be displayed near access ladder.
Attachment 31: Scaffolding Checklist
28.1.2 Scaffold Dismantling

Scaffold shall be dismantled by scaffolders under the supervision of competent supervisor.
Area shall be cordoned-off before commencement of scaffold dismantling.
Warning/ notice board shall be displayed as Scaffold Dismantling under progress Shall be
displayed in Hindi, English or vernacular languages.
Dismantling shall be from top to bottom plan wise.
Bracing shall be removed first and then all horizontal members in one plane.
After reaching to second last horizontal plane, first bracing of 3 m from ground level plane shall be
installed. Then the horizontal members from second level shall be removed.
Loose members shall be segregated and shall be collected in boxes and shall be lowered
properly.
Loose scaffold member shall be lowered down by rope and not by using men chain or throwing.
While dismantling or erecting scaffold spanner shall be used with proper string in hand to avoid
any fall.
28.1.3 Mobile Scaffolds

Mobile scaffold shall be used on a level and smooth surface only.
The minimum base dimensions for mobile scaffolds used internally and externally shall be 3.5 and
3.0 times respectively.
If the tower is exposed to movement or exposed to more than light winds, physical ties shall be
used.
Mobile tower scaffolds shall have wheels fitted at base with a locking device.
Mobile scaffold shall not be moved by carrying any workmen or loose materials.
28.1.4 Ladders and Staircases

Ladders shall be of good construction, sound material and made as per standard specifications.
Wooden ladders shall not be permitted at site.
Portable single ladder length shall not exceed 9m.
The space between two rungs shall not be more than 300mm.
The width between side rails in portable ladder shall not be less than 0.45m.
Ladder shall use only after inspection and approval from consultant/owner.
Ladders shall be checked for defects such as worn and missing rungs, loose tie rods, and split or
frayed feet. Defective ladder shall be removed from service immediately.
Ladder shall be installed on level surface and shall be tied properly at the top.
Solid footing shall be provided if the ladders are placed on loose soil.
Ladder shall be placed at angle of 750.
Ladder shall be extended at least 1m from the landing platform.
Three point contacts shall be made while ascending and descending the ladder.
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No load shall be carried while ascending and descending the ladder. Load shall be pulled or
lowered by ropes by means of pulley.
Ladders are a means of access, and they should not be used as working platforms.
Ladders shall not be placed in front of the door or in the path of moving object unless it guarded.
While ascending and descending should be facing towards the ladder
Portable ladder used shall be of anti slip base.

The contractor shall ensure that no worker lifts by hand or carries overhead or over his back or
shoulders any material, article, tool or appliances exceeding in weight as said below.
Adult man : 55 Kg
Adult woman : 30 Kg
Capability of worker for manual material handling should be considered in before assigning the task.
Contractor shall train the workmen on safe lifting posture.
Whenever load-handling operations are essential, consideration should be given to the use of
mechanical handling, like use of lifting appliances or fork lifts. The contractors should consider the
use of such mechanical aids at the planning stage of their activities.
30.0 Slings and Lifting Gears (Rigging)

30.1 General
Slings include wire rope slings, synthetic web slings, chain slings and metal mesh sling. Lifting gears
include block, hook and shackles.
The contractor shall offer his slings and lifting gears for inspection and approval of owner/consultant
before putting it in to the job.
Contractor shall submit manufacturers test certificate and test certificates from Govt. approved
certifying authorities for all of his lifting gear and slings.
Lifting gear in use shall be thoroughly examined once at least in every twelve months by a competent
person.
The Safe Working Load (SWL) and manufacturers serial numbers shall be clearly marked on the
slings and the lifting gears, either by tagging, stamping, engraving or embossing. These markings on
lifting gears and slings shall be inspected and a register shall be maintained.
If SWL and manufacturers serial numbers is not clearly marked, those slings and lifting gears shall
be prohibited to use.
Attachment 32: Slings and Lifting Gear Register
30.2 Wire Rope Sling

Contractor shall use wire rope sling made with suitable thimble to eye splices and loops of ropes for
the attachment of hooks, rings and other such parts.
Contractor shall not use homemade (hand spliced) wire rope slings made of at site.
Wire rope slings made of wire rope clips (bull dog clips) shall not be used at site.
All wire ropes shall be properly handled and stored to avoid any damage.
Contractor shall discard all damaged sling if there are
Ten random broken wire ropes in one lay
Four broken wires in one strand of a rope lay.
Severe localised abrasion or scraping
Kinking, crushing, bird-caging or other damage causing distortion.
Deformed or excessively worn
Severe corrosion and evidence of heat damage.
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Attachment 33: Monthly Wire Rope Inspection Checklist
30.3 Chain Sling

SWL of all attached fittings (hooks, rings, shackles, etc) to chain slings shall be equal to the SWL of
chain sling.
Using of onsite welding repaired chain slings is strictly prohibited and shall be discarded immediately.
Chain slings of bent links, cracked welds and excessive wear shall be discarded immediately from
site.
30.4 Synthetic Webbing Slings

Synthetic webbing slings are manufactured from woven manmade fibre. These slings shall not be
subjected to point loading, sharp edged objects and non vertical lifting.
Attachment 33: Monthly Web Sling Inspection Checklist
30.5 Hooks
Loads shall be applied only in the part designed to take them, Point load shall be avoided as point
load results in overstressing the hook causing it to break.
The hook shall be removed from the service if there is a visible crack and if it is twisted 100 out of
place.
30.6 Shackles
Contractor shall use the correct pin for each shackle. Rebar, mild steel bolts are not acceptable
replacement for shackle pin.
30.7 Spreader Beam

SWL and serial number of all spreader beams shall be clearly marked. Test certificates from Govt.
approved certifying authorities shall be submitted to owner/consultant.
Register of spreader beam shall be maintained by contractor and same shall be submitted to
owner/consultant.

31.1 General
Lifting appliances means mobile cranes, derricks, tower cranes, overhead cranes, chain pulley
blocks, forklift, strand jacks, hydraulic jacks etc.
All lifting appliances including all parts and gears thereof, whether fixed or movable shall be
thoroughly tested and examined by a competent person at least once in a year or after it has
undergone any alterations or repairs liable to affect its strength or stability. Within the validity, if the
lifting appliances are shifted to a new site, re-examination by the same competent person for
ensuring its safety shall also be done.
Contractor shall maintain list of lifting appliances, lifting appliances maintenance register and shall be
submitted to owner/consultant on regular basis.
The contractor shall not employ any person to drive or operate lifting appliances unless he is above
twenty-one years of age and possesses a valid heavy transport vehicle driving licence as per Motor
Vehicle Act and Rules.
The operator shall possess the knowledge of the inherent risks involved in the operation of lifting
appliances.
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The operator shall be is medically examined and the report shall be submitted to owner/consultant.
The laminated photocopies of test certificates issued by competent person, the operators photo,
manufacturers load chart shall be displayed in the operator cabin.
Safe Working Load (SWL) shall be clearly displayed on lifting appliances.
Lifting appliances shall be periodically inspected and reports shall be submitted to owner/consultant.
Attachment 35: Crane Register
31.2 Hydraulic Mobile Crane

All alarms and signals like safe load indicators (SLI), boom angle indicators, boom extension
indicators, over lift boom alarm, swing alarm, hydraulic safety valves, mechanical radius
indicators, etc. shall be periodically examined and maintained always in working condition.
Boom shall be free from bents, cracks, rust, flaking or cracked paint, bulges, greases etc.
Hydraulic pipes any fittings shall be free from any leak.
The operator cabin shall have wind shield, wipers etc. The wind shield shall be clean ad free from
cracks.
Fire extinguisher shall be provided at operator cabin.
Attachment 36: Daily Crane Inspection by Operator
Attachment 37: Monthly Crane Inspection
31.3 Chain Pulley Blocks

The contractor shall ensure the strength of the structure to withstand the load before hanging
chain pulley block.
Chain pulley block shall have safety latch.
Loads in excess of SWL shall not be lifted or lowered.
The hand and load chains shall hand freely without any twist or knots.
Chain pulley blocks are designed for lifting the loads vertically and shall not be used to pull the
loads horizontally.
31.4 Tower Cranes

The instructions of the manufacturer of a tower crane and standard safe practices regarding such
crane are followed while operating or using such crane.
No person other than the operator trained and capable to work at heights are employed to operate
tower cranes
The ground on which a tower crane stands has adequate bearing capacity;
Bases for tower cranes and trucks for rail-mounted tower cranes are firm and levelled and such
cranes are erected at a reasonably safe distance from excavations and are operated within
gradient limits as specified by the manufacturer of such cranes;
Tower cranes are sited where there is a clear space available for erection, operation and
dismantling.
Tower cranes are sited in such a way that the loads on such cranes are not handled over any
occupied premises, public thoroughfares, railways or near power cables, other than construction
works for which such cranes are used;
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Where two or more tower cranes are sited and operated, every care is taken to ensure positive
and proper communication between operators of tower cranes to avoid any dangerous
occurrences.
32.0 Lifting Activity

32.1 Lifting of Material
Contractor shall designate a rigging co-ordinator who shall have adequate knowledge, skill,
experience, qualification and training who shall successfully demonstrate to solve problems related to
safe crane operation. This rigging co-ordinator shall prepare a rigging plan, supervise and control all
lifting activities.
Contractor shall submit a detailed method statement/ rigging plan for critical and heavy lift by
considering following
Rigging sketch
Details of the crane
Rated capacity of crane
List of rigging hardware
Rated capacity of rigging components
Weight of the rigging gear
Weight of the load
Total weight of the lift (Weight of the rigging gear + Weight of the load)
Dimension of the load
Crane Radius
Boom Length
Safe working limits of the crane as per load chart
Ground and site condition
Placement of crane
Swing radius
Sling angles
Hand signal and necessary communication to be used.
Contractor shall submit all manufactures operator manual, third party test certificate to
owner/consultant.
Before beginning any crane operation the supervisor and operator shall complete the pre-lifting
checklist. The same shall be submitted to owner/consultant.
Attachment 38: Per-Lift Checklist
The outrigger of the crane shall be fully extended prior to the lift and shall be padded on firm base.
The operator shall have valid operator license.
adverse condition.
Sufficient clearance shall be maintained while working near over head power lines
Up to 250,000 volts at least six meter clearance shall be maintained.
Above 250,000 volts at least 7.5 meter clearance shall be maintained.
Contractor shall deploy only the riggers having sufficient knowledge, experience and skill.
A trial lift shall be carried out, raising the load a short distance above its pick-up point, to check the
stability of the crane, and the efficiency of the brakes.
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Tagline shall be used to control the load swing.
Crane boom swing radius shall be barricaded and safety sign boards shall be displayed.
Signal man shall be provided with retro-reflective jacket and he is the only authorised person to give
signal to the operator.
No person shall move beneath the load and travel on the load.
32.2 Lifting of Personnel

Contractor shall avoid lifting of personnel by crane. The preference shall be scaffold. If the nature
of job demands, then such lift shall be authorised by owner.
The suspended personnel basket shall be limited to a capacity of six persons.
Suspended personnel basket and attaching device shall be designed with factor of safety greater
than five.
Suspended personnel basket shall have name plate specifying the weight of the empty basket,
maximum number of allowed persons and rated capacity of personnel basket.
Personnel lifting basket shall be tested by third party competent person and the test certificate
shall be submitted to owner/ consultant.
Personnel lifting basket shall have hand rail at 1100mm, mid rail at 550mm and toe guard width
shall be of 150mm.
A trail lift without personnel shall be carried with maximum anticipated load. The taril lift shall be
from ground level to the location to which the basket to be lifted.
adverse condition.
Suitable anchor points shall be provided in the basket and personnel being lifted shall anchor their
full body safety harness to the anchor points.
The crane operator shall not leave the cabin after personnel are lifted. In case of emergency, all
personnel shall be lowered to ground and leave the cabin.
33.0 Construction Vehicle

33.1 Dumpers, trailers, trucks, excavators, transit mixers, road rollers, tractors piling rigs, cranes, tipper,
lorry loaders, skip wagons, crawler tractors, scrapers, graders, tankers etc are considered as
construction vehicles.
33.2 The contractors shall provide a list of vehicles needed to be used at site and formulate a procedure
relating to construction vehicle inspection, operation and maintenance. It must be consistent with the
manufacturer's recommendations and consultants requirements.
Contractor's construction vehicles are to be periodically inspected and maintained according to pre-
determined schedule. Records of all inspection and maintenance shall be maintained and submitted
to owner/consultant on regular basis.
Vehicle maintenance or repairing work shall not be carried out inside the construction site.
33.3 Operators entering site shall be instructed to follow the safe system of work adopted on site. These
shall be preferably, written instructions showing the relevant site rules, the site layout, delivery areas,
speed limits, etc.
33.4 All vehicle operators shall undergo medical fitness test, audiometric test and vision check test. The
medical certificates of those operators shall be submitted to owner/consultant.
33.5 Vehicle operator shall possess valid driving license.
33.6 All construction vehicles shall have

RC and Pollution under Control (PUC) certificate
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Exhaust shall be fitted with flame arrestor.

Horn, mirrors, head and tail lights, indicators, reflectors etc.
Parking brake and brake light
First Aid kit
Fire extinguishers
All Vehicles shall be fitted with audible reverse alarms and maintained in good working condition.
Reversing shall be done only when there is adequate rear view visibility and under the directions of a
banksman.
All vehicles shall be equipped with wind shields and wipers. Cracked or broken wind shields shall be
replaced.
33.7 At start of each shift operator shall check oil, fuel, water and hydraulic levels, that all gauges are
working and the vehicle is functioning smoothly.
33.8 The maximum speed limit on the construction site is 20-km/ hr. The maximum speed limit in work
areas is 15-km/ hr.
Personnel must not be transported while standing on the bed of trucks or trailers or on material
handling / earth mounting equipment or they shall not be allowed to sit on doors.
Material extending from vehicle bed shall be indicated with red flag.
The latch on the dumper skips shall be in working order and release mechanism shall function
smoothly.
The operators shall turn-off the engine and remove the ignition key before leaving the vehicle.
Before moving the vehicle operator shall walk around it to see the area is clear. No one shall be
allowed to sit or lie around or beneath the vehicle.
Wheel stopper shall be provided to while parked at slopes, place near any excavations etc.
33.9 Parking and Vehicle movement in Refinery Premises

Vehicles shall be parked only in designated areas. No vehicle shall be parked opposite fire
hydrants or at the intersection of roads or within 10 meters of any road corner or in front of the
Fire Station.
Vehicle shall not be parked, in any manner that will block emergency services, bends, building
exits and walkways etc.
No vehicles should enter into any operating area without valid fire permit followed by a safety
clearance from the area-in-charge (this includes process areas, tank farms and loading racks).
The contractors shall prominently display the name of their company on all the vehicles including
tractor trolleys, trucks, open jeeps, cranes which are allowed by the owner to enter inside the
Refinery for carrying out the job. The display board shall be put on front and rear side of each of
the vehicle.
Photocopy of the vehicle gate pass along with the drivers photo shall be pasted on the
Attachment 39: Construction Vehicle
34.0 Construction Machinery

The contractor shall ensure at the construction site all motors, cogwheels, chains and friction
gearing, flywheels, shafting, dangerous and moving parts of machinery are guarded. The guard of
dangerous part of machinery is not removed while such machinery is in motion or in use.
34.1 Air receivers / compressors
Contractor shall ensure that air receivers/ compressors shall be
In good condition and properly maintained.
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Individually identified and marked with their safe working pressure.

Be accompanied by a valid test certificate.
Fitted with a properly set pressure relief valve.
Examined and the pressure relief valve tested by an independent examiner at yearly intervals.
A register containing relevant details about the air receivers, compressors shall be maintained at
site such as identification numbers, dates of inspections, pressure ratings etc.
All compressed air fittings shall be wired and/or restrained to prevent them from whipping should
the coupling separate.
Only hose clamps designed for compressed air service shall be used. Worm drive (jubilee) clips
are not acceptable.
35.0 Noise
Noise must be kept to a minimum at all times and must not exceed acceptable and/or any work
activity which is likely to expose any employee on site to a noise level of 85 db(A) or above,
assessments should be carried out. In such circumstances, the contractor must keep stocks of
ear defenders or other suitable hearing protection and issue to the workmen who are exposed to
the higher levels of noise.
The Contractor shall ensure that noise generated from all powered mechanical equipment shall
be effectively reduced using the most modern techniques available including but not limited to
silencers and mufflers.
The Contractor shall construct acoustic screens or enclosures around any parts of the works from
which excessive noise may be generated.
Grinders, Cutters, Jack Hammer (pneumatic drills), Engine driven plant and the like, all give off
levels of noise that is harmful.
Earplugs and earmuffs are the commonest form of hearing protection to be used.
36.0 Confined Space

36.1 General
A confined space is large enough and so configured that an employee can bodily enter and perform
assigned work, has limited or restricted means for entry or exit and is not designed for continuous
employee occupancy.
A person passes through an opening into a confined space and is considered to have occurred as
soon as any part of the entrant's body breaks the plane of an opening into the space is confined
space entry.
The danger may be as a direct result of a process being undertaken by persons in confined space
and the activities such as spray painting, use of cleaning fluids (solvents), hot work, abrasive
blasting, arc air gouging were considered as dangerous activities.
The hazards involved are asphyxiation, fire and explosion, oxygen enrichment or deficiency, dust and
fumes, electrocution, heat exhaustion.
36.2 Preparation
Contractor shall prepare method statement and submit to owner/consultant for review at least seven
days prior to the commencement of the activity. Method statement for work in confined space shall
address the following as minimum.
Work scope and methodology
Nominated supervisors for obtaining permit to work and overall controller of the work activity.
Nominated stand by persons
Tools and equipments to be used
Explosion proof fittings
Flame proof lighting arrangement including emergency lighting
Ventilation arrangement
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Access
Fire safety and fire extinguisher requirements
First-aid facilities
Rescue procedure and availability of equipment/ resource for rescue
36.3 Authorization
Nominated supervisor is a competent construction engineer who has adequate knowledge, skill,
experience and familiarity about working in confined space.
Contractors nominated supervisor shall ensure that workmen and other supervisors employed for
work in confined space are trained and competent in performing such task before signing the work
permit.
All entry into confined spaces shall be controlled by means of a permit to work and this shall be
obtained from owner/consultant.
No new activity shall be introduced in to a confined space without permission and signed approval of
permit to work from owner/ consultant.
36.4 Access
Clear and safe access shall be maintained continuously while workers are in confined space.
Ladder shall be of suitable size and length.
Adequate lighting shall be provided at all access and egress points.
36.5 Communication
Effective communication shall be maintained between personnel in confined space and outside by
combination of visual/ voice or portable radio.
36.6 Ventilation
Contractor shall check the oxygen level and confined space entry shall only be permitted if level of
oxygen by volume is in between 19.5 percent to 23.5 percent.
The oxygen level shall be surveyed at regular interval while any task is performed in confined space.
The oxygen level survey details shall be maintained in log register.
Exhaust fan or other mechanical means shall be used to bring Lower Explosive Limit (LEL) 0% or
toxic gas below Threshold Limit Value (TLV). Also Self Contained Breathing Apparatus (SCBA) shall
be used if necessary.
Whenever spray painting is carried out in confined space, forced ventilation shall be provided to
avoid any accumulation of flammable vapours.
36.7 Electrical Safety

Electrical hand tools to be used in confined space shall be inspected for good working condition, free
from defects, double insulated cables, connections through ELCB and valid test and inspection
stickers.
Contractor shall use only 24V lamp. Lamp shall be suitably guarded
All electrical fittings shall be of Flame proof and confirm to national standards
36.8 Fire Safety

All combustible materials shall be removed wherever possible before performing any hot work.
Fire protection equipments such as fire extinguishers or fire hoses shall be kept at the work area.
A fire watcher shall be deputed whenever hot work is carried out in confined space.
Compressed gas cylinders shall not be taken into confined space under any circumstance.
Gas cutting torch/ electric arc welding torch shall be removed from confined space during any
interval/break and as soon as the job is completed.
36.9 Emergency Rescue

Stand by person shall be deployed at the entrance of confined space to assist in rescue if any.
Stand by person shall be trained in rescue and his duties include evacuation of all entrants in
confined space. Also communicate for any emergency services and assist in rescue.
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Stand by person shall be familiar with all possible hazards in confined space and remain outside
confined space entry until relived by another stand by person.
Rescue equipments such as full body safety harness, tripod, lifelines, Self Contained Breathing
Apparatus (SCBA), stretchers, Man basket, crane shall be kept readily available.
37.0 Radiography
Radiography camera must be operated only by licensed radiographers certified by BARC under
the direct supervision of site-in-charge.
Contractor shall submit list of competent persons involved in radiography at least seven days prior
to the commencement of the job.
Contractor shall submit a list of authorised person involved in radiography associated works such
as isolation of sources, radiation survey meter surveyor, area cordon-off crew.
Field radiography shall be carried out during night time where there is no occupancy around.
All radioactive sources must be clearly identified with its strength of the source, activity at different
levels. A warning label should be displayed indicating Danger Radioactive Material.
The area shall be cordoned-off whenever radiography is carried out and the distance to be
cordoned-off is determined by the type and strength of radiation source to be used, the type of
exposure given, nature of occupancy and the total exposure time per week.
The radiation levels along the cordon should be monitored by suitable and calibrated radiation
survey meter to confirm the cordon-off distance is adequate.
Everyone involved in field radiography activity shall wear personnel monitoring badges.
Radiation warning symbols shall be conspicuously posted along the cordon in English, Hindi and
vernacular languages. It shall be readable from a distance of 7 m under normal illumination.
All safeguards should be implemented to ensure that workmen are not crossing the barricades.
The boundary of cordon on all sides shall be adequately illuminated throughout the duration of
radiography.
Red warning lights must be posted at night along boundary of cordon and especially at the point
of entry.
38.0 Hand tools

Contractor shall ensure that all hand tools used shall be of correct type, size and weight for the job.
Hand tools used for electrical operations shall be properly insulated and shall be non-conductive
type.
Screwdrivers used shall correct size of tip to fit the slot of the screw.
Screw drivers shall not be carried in pockets of clothing.
Hammers handles shall be made of smooth timber. Hammer head should be secured to wooden
handles with proper wedges.
Chisels edges shall be kept sharp all the time. The original shape and angle shall be maintained.
The chisel should be handled by tongs. Holding chisel by hand while chipping shall be avoided.
Shovel blade shall not be allowed to become blunt, turned, split or jagged.
Only spanners and adjustable wrenches shall be used. Improvised extension of spanners may
cause shearing of bolt and slip of tool.
The ordinary wrenches shall not struck by hammer.
Pipe wrenches should be large enough for the job. It should not be struck with hammer nor, shall
be used as hammer.
Pliers used for electrical works shall be fitted with insulated handle.
The hacksaw blade to cut shall be set in hacksaw frame. The teeth shall point forward direction
and sufficient tension should be applied to ensure the blade is maintained rigid.
39.0 Demolition
Prior to the commencement of any demolition work and also during the process of demolition
contractor shall follow the following additional precautionary steps shall be observed.
All roads and open areas adjacent to the particular site shall either be closed or suitably
controlled.
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All underground / overground power / telephone cables or water / sewerage lines in the vicinity of
the particular site shall be either suitably diverted or made non-functional for the duration of the
demolition activity.
All practical steps shall be taken to prevent danger to persons employed from risk of fire or
explosion or flooding. No floor, roof or other part of the building shall be overloaded with debris or
materials as to render it unsafe.

Before erecting temporary shelters like sheds anywhere within the Refinery premises, written
permission of the Engineer-in-charge be obtained.
Temporary fixtures like sheds, tents, etc. shall be erected in conforming with normal safety
standards. Thatched roof to such fixtures will not be permitted.
Temporary piping, hose connections and electrical wiring must be laid in such manner that they
do not cause tripping or hitting hazard
Temporary sheds can be constructed only for the storing of the material / site office. It should not
be used for any other purpose.
However, for all jobs having value more than Rs. One crore, no temporary sheds shall be allowed
for office / stores of the contractor and instead the contractor shall arrange for portal cabin for site
office / stores.
Following information shall be clearly written on the shed:- Name of the contractor; Work Order
No.; Working under the Department; Name of the Engineer-in-charge; Permit No. & it's validity
period.
The shed shall be made of safe construction material and good aesthetic view. The shed shall be
made strictly at the authorised location and size.
All windows shall be either of wire mesh or glass.
Company has the right to open or break the door at any time to inspect the shed.
After completion of the job shed must be demolished within 10 days and area must be cleaned.
All precautions should be taken to ensure that any temporary electrics wiring used within the
Refinery will not cause sparks or shock

41.1 The contractor has to follow all Safety, Health and Environment rules & regulations of the Refinery. In
case of non-compliance of any of these rules and regulations by contractor or his employees, the
contractor shall be held responsible. If any violation or non-fulfilment of these Safety, Health and
Environment rules and regulation is observed by Refinery authorities during checking at any time, a
penalty of Rs. 5000.00 (Rs. Five Thousand Only) shall be imposed on the contractor for each
occasion of non-compliance to these rules and regulations by him or his employees. The decision of
Refinery authorities shall be final and binding on to the contractor in this regard. The amount of
penalties so imposed shall be recovered from the next R.A. Bill of the work or any other dues payable
to the contractor by Refinery
Event Penalty
Absence of Resident / safety Engineer of Contractor in

Rs 1000 per meeting
OWNERs safety meeting
Failure to have regular site safety Inspection (by contractors
Rs 1000 / week
themselves) every week
Failure to conduct Health / Safety / Environment (HSE)
meetings by Contractor at site (in-house) and maintain Rs 1000/month
records
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Failure to submit HSE reports/check Lists, etc., by 5th of Rs 1000 /month and Rs 100 / day
every month to OWNER for further delay
For not providing shoring / strutting / proper slope and not
keeping the excavated earth at least 1.5M away from the Rs 5000 / occasion
excavated area
41.2 In case the violation / non-compliance of above Safety, Health & Environment rules results in results
in any Physical Injury or Fatal Accident, an additional penalty as given below shall also be imposed
on to the Contractor:
41.3 For any reportable physical injury as per Indian Factories Act - 1948: Additional penalty of 0.5 % of
the contract value subject to a maximum of Rs.2,00,000 (Rs. Two Lakhs Only) per injury in addition
to the penalty of Rs.5000 as per 41.2 above
41.4 For Fatal accident: Additional penalty of 1 % of the contract value subject to a maximum of
Rs.10,00,000 (Rs. Ten Lakhs Only) per fatality in addition to the penalty of Rs.5000 as per 41.2
above.

In case of any accidents/injury of a contractor's workmen, the contractor shall pay a suitable
compensation (subjected to the minimum compensation as mentioned below) to the affected person /
his family members in the presence of Engineer-in-charge and in consultation with Chief Medical
Officer of the Refinery. The said compensation shall depend on the seriousness of injury, etc, and
shall be in addition to the hospitalization / treatment charges and Group Insurance Amount payable
to the effected person. The following are the minimum compensation shall be paid to the affected
person / his family as stated above:
42.1 In case of fatal accidents: Rs.1.0 lacs (Rs. One Lakhs) within 5 days of accident.
42.2 In case of loss of both the limbs (hand / legs/eyes/ ears) : Rs.50,000/- (Rs. Fifty Thousand ) within 1
week.
42.3 In case of loss of one limb (hand / legs/eyes/ ears) : Rs.25,000/- (Rs. Twenty Five Thousand ) within
1 week.
42.4 In case of any injury not specified above, Rs.1000/- (Rs. One Thousand) to Rs.5000/- (Rs. Five
Thousand) as directed by Engineer-in-charge within 1 week.
1.7.7.1
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1.7.7.1
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LEGAL OBLIGATIONS / REQUIREMENTS FOR CONSTRUCTION
Factories Act, 1948,

Minimum Wages Act, 1948 and Rules 1950
Employees Provident Fund & Miscellaneous Provisions Act, 1952.
Contract Labour Act, 1970 and Rules 1971
Weekly Holidays Act, 1942.
Fatal Incidents Act, 1855.
Personal Injuries (Compensation Insurance) Act, 1963.
Workman Compensation Act, 1923 along with allied Rules
The Public Liability Insurance Act 1991 and Rules 1991
Child Labour (Prohibitions & Regulations) Act, 1986 and Rules 1950
Indian Electricity Act 2003 and Rules 1956
Motor Vehicles Act as amended in 1994 and The Central Motor Vehicles Rules, 1989.
The Petroleum Act, 1934 and Rules 1976
Gas Cylinder Rules, 2003
Environment Protection Act, 1986 and Rules 1986
Air (Prevention and control of Pollution) Act, 1981
Water (Prevention and Control of Pollution) Act, 1974
The Noise Pollution (Regulation & Control) Rules, 2000
Manufacture, Storage & Import of Hazardous Chemicals Rules, 1989
The Hazardous Waste (Management & Handling) Rules, 1989
Hazardous Waste Management Rules 1989 (as amended in 1999)
Building and other Construction Workers Act, 1996.
1.7.7.1
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HSE ASSURANCE PLAN
Page 431 of 674
Frequency Extent of Checking
Sr. Operating Checking Contractors Consultan Owner

Activity Remarks
t
No Area Safety Safety
Engineer Supervisor Officer
1 HSE Policy Communicate Once in the As applicable Review Contractor

to all working at beginning. imple- to submit.
Project site. mentation
system
2 Safety committee Through To be formed consisting Owner, consultant, Contractor and
meetings at Representatives of workers.
predefined
interval.
3 Training (Induction and For everyone As per Training Matrix Entry passes
Periodic) to be issued
only after
induction.
4 Reporting
4.1 Safety Statistics Monthly Monthly NA NA Monthly Monthly
4.2 Weekly First Aid and Weekly Weekly DC Weekly Once a RAN
Illness Reports Week
4.3 Labour Report with Daily Daily Daily Daily Daily RAN
Workhours
4.4 Incident Reports NB As applicable
4.5 Investigation Report NB As applicable
1.7.7.1
HSE ASSURANCE PLAN
Page 432 of 674
Sr. Activity Operating Checking Contractors Consultant Owner Remarks

5 Statutory requirements Regular Once in 3 NA NA Monthly Once in

(Registration, Records of months Quarter
Payment, Licenses)
6 Facilities
i First Aid Regular RAN N.A Daily RAN Once in a Month
ii Emergency care services Advance RAN N.A Daily Periodic N.B. Once in a Month
(Doctor, Ambulance) arrangement.
iii Medical examination (Pre Regular Periodic N.A N.A Periodic N.B. Once in a Month
& Periodic)
iv Temporary In the RAN N.A RAN RAN RAN

accommodation beginning.
v Drinking Water tank Filling everyday, Through RAN N.A RAN N.B
cleaning once a Records
week.
vi Urinals & Latrines Daily sweeping RAN N.A RAN RAN RAN If applicable
arrangement.
vii Septic tank / Disposal In the NB N.A RAN RAN RAN If applicable
system beginning.
1.7.7.1
HSE ASSURANCE PLAN
Page 433 of 674

viii Mosquito control Once a week, Through N.A RAN RAN RAN If applicable
disinfecting records
arrangement
ix Crches for Children below Required if 50 RAN N.A Daily Monthly RAN
6 yrs. or more females
employed at site
x Canteen Required if RAN N.A Daily Monthly RAN If applicable

more than 250
workers are
employed.
xi Waste disposal Daily RAN N.A Daily Monthly RAN
7 Fire fighting system NB Once in a N.A RAN RAN RAN

month
8 Traffic rules Daily Daily N.A DC RAN RAN
9 Use of PPE Daily Daily By all, regular basis.
10 Work permit system NB DC DC RAN RAN As applicable
11 Safety publicity Continuous Periodic N.A N.A DC RAN
12 Excavation NB NB DC DC RAN RAN NB
13 Cutouts / openings NB NB DC DC RAN RAN NB
1.7.7.1
HSE ASSURANCE PLAN
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14 Barricading NB Daily DC DC RAN RAN
15 Scaffolds NB Regularly DC DC DTC RAN
16 Ladders NB Regularly RAN RAN RAN RAN
17 Welding / Cutting M/C. NB Once in 3 DC DC DC RAN NB

months
18 Elect. Hand tools & NB ---- DC DC RAN RAN NB

Distribution Boards.
19 Mechanical Equipment NB Once in 6 DC DC DTC RAN NB

months
20 Load tests For Heavy lifts. DC N.A DTC DTC Formal procedure
Required for heavy
Lifts
Note: 1. Contractors would be required to maintain records of inspection.

2. Contractor will comply with any additional checks asked by consultant during execution of work from time to time.
3. Consultant / Owner will have right to increase extent of checks.
Legends: - DC : Detail checking (100%),

DTC : Check in detail for critical items,
RAN : Random verification,
NB : Need based (involving co-ordination with Owner).
NA : Not applicable
I : Issue
1.7.7.1
Site Safety Organisation Chart
Page 435 of 674
Owner Owners Project Representative Owners Safety Representative
Consultant Project Manager
Safety Engineer Safety Manager
Contractor Resident Construction Manager
Safety Manager
Safety Engineer
Safety Supervisor Safety Supervisor Safety Supervisor
Safety Observer Safety Observer Safety Observer Safety Observer Safety Observer
1.7.7.1
Minutes of Meeting
Client: Weekly Safety Meeting

Safety Committee
Project:
Meeting
Project Number Meeting Number:
Confirmation of Meeting Telephone Talk

Date Held : Location :
Date Issued : Recorded by:
Issued By : Distribution:
Subject:
Participants:
Client Consultant Contractor
Agreed date
Sl. Target
Remarks in Previous Action by
No Date
meeting
Page 1 of
1.7.7.1
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1.7.7.1
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SAFETY OBSERVATION REPORT (SOR) SUMMARY SHEET
Project Contractor Date From: To:

Page 438 of 674
P - Positive; AR - At Risk: UA - Unsafe Act; UC - Unsafe Condition; LB - Lack of Belief; LT - Lack of Training; LI - Lack of Interest; LR - Lack of Resource; C - Closed; O-Open
SOR
Direct
Observation Indirect Cause SOR SOR Status Closed
Date Time Observer Location Description Cause Corrective Action
category on
P AR UA UC LB LT LI LR C O
Contractors RCM Name Contractors Safety Manager Name

Signature Signature
Date Date
1.7.7.1
Safe Plan of Action
Contractor Date: From: To: Doc no:
Activity/ Task Work area/ location Rev 0

Page 439 of 674
Job description:
PPE Required
Full body double lanyard
Helmet Safety shoes/ Gumboot Safety goggles Hand gloves
safety harness
Nose mask Ear plug Hard hat with welding Shield Grinding visors/ face shield Others________________
Safety Devices
Caution tape/ Barricading Sign/Display boards Fluorescent jackets Lifeline/Fall Arrestor Safety net
pipes
Flash back Arrestor Fire extinguisher Fire blanket Warning lights
Others________________
Steps of Activity/Task Hazard/Reaction to Change Safe Plan Resources
Description Performer (Team members) Approved by Reviewed by

Name
Signature
Company
Date
The signature of the supervisor confirms the completion of the hazard assessment and Safe Plan of Action by the crew.
Supervisors Signature: Date

Instructions: 1. Write name of job or task in space provided. 2. Conduct walk-through survey of work area. 3. Write the steps of the task in a safe sequence. 4. List all possible hazards involved in each step and
reaction to change. 5. In the Safe Plan column, state actions that will be taken to prevent the hazards or injury from reaction to change. 6. In Resources column, list equipment, tools, etc. needed to do the job. 8. Ask
each team member, who helped develop and will use this SPA, to sign in spaces provided. 9. Review the SPA at the end of the task for improvements.
Work shall stop when conditions change, the job changes, or a deficiency in the plan is discovered, and the current SPA will be modified or a new SPA created.
General Inspection Report (Safety Walk Around)
Project Contractor
Location Date Time
Name of team members involved in inspection
Sl.No Observation Hazard Identified Corrective Action Remarks
Signature of team members
Contractor shall complete the corrective action and submit the compliance report to owner/consultant
1.7.7.1 Page 440 of 674

1.7.7.1
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1.7.7.1
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Page 1 of 6
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No Points Score
A Training 20
1 Induction training given to all new joining workers 5
2 Toolbox talks conducted frequently 5
3 Fire drill & site specific training conducted frequently 5
4 Records maintained for all training given at site? 5
B Personal Protective Equipment 25
5 PPE issue and inspection register maintained? 5
6 Compliance of safety shoes, safety goggles and helmets 5
7 Full body safety harness (lanyard length - 1.8 m) anchored 5
8 Welding shield & grinding visor mounted helmet used 5
9 Other necessary PPEs 5
C House Keeping 35
11 All materials are stacked properly? 5
12 Waste materials/ scraps dumped properly at identified areas? 5
13 Electrical cables are properly routed to prevent trip hazards or 5

damages due to vehicle movement
14 Nails or other sharp objects being removed or bent? 5
16 Scrap yard identified at site and waste disposed from site 5

regularly
Page 2 of 6
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No Score Score
D Work at height 20
17 Edge protection & floor opening protection provided? 5
18 Fully planked working platform with handrails, mid rails & toe- 5
guards with secured access ladder extending 1 m from the
19 Fall arrestors, lifelines & safety nets in use wherever 5
necessary?
20 Ensuring everyone anchoring the safety harness when 5
exposed to a fall of 2m and above
E Scaffolds & ladders 40
21 Scaffold designed & erected by trained personnel 5
22 Scaffolding checklist prepared and displayed? Scaffold tags 5

displayed?
23 Scaffold erected on a level surface with base plate / sole plate? 5
23 Appropriate scaffold materials are used & installed properly 5

with necessary supports and back ties wherever necessary.
Staging for shuttering is designed for loads like worker movement,
25 5
impact loads and other incidental loads during various construction
26 Dismantling of scaffolds done under proper supervision? Are 5
all materials properly lowered?
27 Ladders in use are without defects? Positioned in a safe angle 5
and secured properly?
28 Mobile scaffolds are used with proper lock system and 5
appropriate access to the working platform?
F Excavation 20
29 Sloping/ benching or shoring maintained 5
30 Adequate barricading provided for the pit/trench 5
31 Access ladder in place where work is carried out 5
32 Excavated earth removed or deposited 1.5 m away 5

Page 3 of 6
Page 445 of 674

No Score Score
G Electrical 50
33 Electrical Inspection register maintained? 5

34 All power tools are inspected and tagged? 5
35 Does cabling provide sufficient headroom? 5
36 Electrical connections are free of insulation damages, joints 5
and provided with plug tops
36 All electrical connections are taken through ELCB (30 mA) 5
37 Proper earthing for main panel & body earhting for DBs? 5
38 All DBs are provided with a rain protection canopy? 5
39 Adequate safety provisions at panel room? 5
40 Is there enough number of first-aiders having knowledge of 5
CPR for electrocution?
41 DG inspected and maintained 5
H Vehicle movement 30
42 All vehicles installed with reverse horns 5
43 Authorised driver/ operator with a valid driving license is 5
engaged?
44 Vehicle operators given adequate training on speed limit, 5
overloading & site rules
45 Spark arrestors available? 5
46 Banksman available for controlling the vehicle movement? 5
47 Maintenance record and inspection record maintained 5
1.7.7.1
Page 4 of 6
Page 446 of 674

No Score Score
I Welding, gas cutting and grinding 50
48 Adequate PPEs are provided and used? 5

Earth connectors are securely connected to the job and not to
49 5
the adjoining structure or scaffold?
Welding cable used is maintained in good condition without any cut or
50 open/ tapped joints? Gas cutting hose is without any crack/ damage?
5
Flash Back Arrestors installed in the cutting set (both at
51 5
cylinder end and torch end)
Cylinder storage area clearly identified for fuel gas and
52 5
oxygen? Not exposed to sunlight kept in upright position
Cylinder keys are always available on acetylene cylinders?
53 5
Double pressure gauges are in working condition?
54 Grinding machine are with proper guards? 5
Grinding wheel used of proper RPM rating as marked on the
55 5
grinding machine?
Grinding wheel is without any crack or deformation on
56 5
circumference?
Adequate precaution taken to prevent the hazards from hot
57 5
spatters and sparks
J Rigging 30
Inspection and test certificate records maintained for all lifting
58 5
tools and tackles, hydras and cranes?
SWL & date of testing are visibly marked/ painted on all lifting
59 5
tools/ tackles and equipments?
60 Crane operators are trained, qualified, and have valid license. 5
All rigging tools and lifting equipment are in good condition,
61 5
properly inspected and have current certification.
62 Tag lines are used appropriately. 5
63 Cranes are set up properly including extended outrigger pads. 5

Page 5 of 6
Page 447 of 674

No Score Score
11 Other 55
64 SPAs are prepared and displayed at site? 5
65 Emergency response plan established at site and 5

communicated to all. Assembly point identified?
66 Adequate First aid facilities maintained. First Aid register 5
maintained at site?
Confined space works are carried out with a valid authorized permit
67 and is the permit displayed? All requirements specified in the permit 5
are fulfilled before confined space entry?
68 Fire Extinguishers in place for all hot works 5
Are illumination levels at workplace and passage ways
69 adequate? Sufficient lighting arrangements are made for night 5
works?
70 Sign boards and caution boards are kept wherever necessary? 5
71 All rotary parts of machinery are properly guarded? 5
73 Restrooms are made & well maintained. Designated place for 5

drinking water & clearly labeled
74 Participation of execution engineers in implementation of safety 5
program
75 Safety awareness and promotional activity 5
Safety Performance Rating Indicator (Score %) Contractor's Safety Performance

GOOD 90 100 % No of points attended
SATISFACTORY 76 89 % Possible Score
UNACCEPTABLE < 75 % Scores Obtained
Score %
Monthly Safety Audit Checklist Corrective Action Sheet
Page 6 of 6
Page 448 of 674
Sl. Responsible Completion

Observation Corrective Action Target date
No Person date
Contractors RCM Endorsement

Date
Note: Contractor shall complete the corrective action and submit the sheet to consultant/owner.
Safety Induction Induction Number
Project Name Project Number
Contractor Date of Induction
Inductee Name Designation
Age Blood Group Experience in Role:
1.0 Introduction about site
2.0 Safety Policy of Owner, Consultant & Contractor
3.0 Alcohol policy, Drugs, No smoking
4.0 Gate pass procedure
5.0 First aid facilities
6.0 Emergency procedure
8.0 Welfare facilities
9.0 Personal Hygiene
10.0 Good housekeeping
11.0 Fire preventions and protections
14.0 Working at height (Ladders, Scaffolding, Safety harness)
15.0 Fall prevention and protection (Open edges, floor cut outs)
16.0 Safe use of hand and power tools
17.0 Material handling
18.0 Electrical safety
19.0 Gas cutting, welding and Gas Cylinders
20.0 Traffic rules
21.0 Movement on site
22.0 Permit to work
23.0 Dont put yourself and other at risk. If you have any doubts ask your supervisor for help.
24.0 Return home safety
25.0 Any other topic

Your Health - should the Company and your work colleagues know about your health? Are you taking specially
prescribed medication? Are you epileptic or diabetic, or do you have a heart problem/ disease? If we all know - we
can help if you become ill, if we don't know, any help may be too late.
...................................................................
Name of Inductor Name of Inductee
Signature Signature/ Thumb Impression
Date Emergency Contact Number
1.7.7.1 Page 449 of 674

Safety Induction Attendance Register (Required only for two or more attendees)
Date of Induction: Total Number of Attendees: Induction Number:
Emergency Signature/
Gate Pass Blood Experience
Sl.No Full Name Designation Age Contractor Permanent Address Contact Thumb
Number Group in Role
Number impression
Page 450 of 674
1.7.7.1
1.7.7.1 Page 451 of 674
1.7.7.1 Page 452 of 674
Safety Training Matrix
Project Number Project Name
Page 453 of 674
Contractor Training Matrix for the Month of
Earth mover
Supervisor
Electrician
Strength
Bar binder
Operators
Carpenter
Planned
Unskilled
operator
operator
Scaffold
Sl.No Training Topic
Grinder
Vehicle
Painter
erector
Welder
worker
Mason
Rigger
Date
Crane
Fitter
1. Safety Induction
2. Personal Protective Equipment
3. Housekeeping
4. Work permit
5. First-aid
6. H2S
7. Mock drill
8. Excavation
9. Manual handling
10. Driving Safety
11. Working at Height
12. Scaffold
13. Hot work
14. Heavy lifting and Rigging
15. Fire prevention and protection
16. Electrical Safety
17. Hand and power tools
18. Confined Space Entry
19. Pre-commissioning Safety
20. Lock-out and Tag-out
Contractors Endorsement Date
1.7.7.1
Attendance Register for Safety Training
Project Project No
Contractor Topic
Date Location
Time Conducted by
Signature/ Thumb
Sl.No Name Designation Organisation
Impression
1
10
11
12
13
14
15
16
17
Facultys Signature
Date
1.7.7.1 Page 454 of 674

1.7.7.1
Page 455 of 674
Weekly Safety Report
Project Name Name of the Contractor

Project Started on Report Number
Report for the period From to
Description For the Week Cumulative
Work Hours
Average Strength (Staff + Workmen)
Total Recordable Incident Rate (TRIR)
Performance Indicators
Fatal
Injuries & Illness
Recordable
Medical Aid
Incidents
Days away from work

Restricted Workday case
First-aid case
Near miss
Property Damage
Environmental Damage
Motor Vehicle Incident
Brief description of the incident during the week (if any):
Safety Metrics
Safety Induction
Tool Box Talks
Safety Training
Positive SOR
Other SOR
Safety Inspection
Safety Audit
Safe Plan of Action (SPA)
Safety Meeting
Contractors RCM endorsement Contractors Safety Manager Endorsement

Date of Submission
Remarks: Contractor shall submit supporting documents along with weekly safety report.
1.7.7.1 Page 456 of 674

MONTHLY HEALTH, SAFETY & ENVIRONMENT (HSE) REPORT
(To be submitted by Contractor)
Actual work start Date:_____________ For the Month of: :_______________
Name of Work:_________________ Report No._______________________
Name of the Contractor:________________ Status as on:________________
Name of safety officer:_______________
ITEM THIS MONTH CUMULATIVE

Total Strength (Staff + Workmen)
Number of HSE meetings organised at site
Number of HSE awareness programmes
conducted at site
Whether workmen compensation policy Y/N
taken
Whether workmen compensation policy is Y/N
valid
Whether workmen registered under ESI Act Y/N
Number of Fatal Accidents
Number of Loss Time Accidents (Other than
Fatal)
Other accidents (Non Loss Time)
Total No. of Accidents
Total man-hours worked
Man-hour loss due to fire and accidents
Compensation cases raised with Insurance
Compensation cases resolved and paid to
workmen
Remarks
Safety Officer/Resident Engineer

(Signature and Name)
TO: CPCL ENGINEER-IN-CHARGE
CM (F&S)
Page 457 of 674

Page 458 of 674
1.7.7.1 Page 459 of 674
Page 460 of 674
Incident Reporting Chain and Emergency Contact Numbers
Project: Contractor:
Incident (First Witness)
Immediate Supervisor
Contractors RCM Emergency Services

(Name and Contact Number to be updated) (First-aid centre, Fire Services)
Consultants RCM
Head Office Client

Emergency Contact Numbers

Services Name Contact Number Remarks
Medical Centre (To be updated) (To be updated)
Ambulance (To be updated) (To be updated)
Hospital (To be updated) (To be updated) Tie-up Nearest
hospitals
Fire Station (To be updated) (To be updated)
Project Security (To be updated) (To be updated)
Police Station (To be updated) (To be updated)
Consultants Safety Department (To be updated) (To be updated)
Contractors RCM (To be updated) (To be updated)
Contractors Safety Manager (To be updated) (To be updated)
Contractors First-aid centre (To be updated) (To be updated)
Consultant RCM (To be updated) (To be updated)
Client (To be updated) (To be updated)
Note:
First witness shall attend the injured person.
Supervisor shall inform emergency services and also the contractors RCM.
All incidents and near miss incidents shall be reported immediately.
Detail report shall be submitted within 24 hours irrespective of Sundays and holidays if any.
Page 461 of 674

CONTENTS OF A FIRST-AID BOX
A sufficient number of eye wash bottles filled with distilled water or suitable liquid clearly indicated by a
distinctive sign which shall be visible at all times.
4 per cent xylocaine eye drops, and boric acid eye drops and soda by carbonate eye drops.
Twenty-four small sterilised dressings.
Twelve medium size sterilised dressings.
Twelve large size sterilised dressing.
Twelve large size sterilised burn dressings.
Twelve (fifteen cm) packets of sterilised cotton wool.
(Two hundred ml) bottle of certimide solution (1 per cent) or suitable antiseptic solution.
One (two hundred ml) bottle of mercurochrome (2 per cent) solution in water.
One (one hundred twenty ml) bottle of salvolatile having the doses and mode of administration indicated
on the label.
One pair of scissors.
One roll of adhesive plaster (six cm X one metre).
Two rolls of adhesive plaster (two cms X one metre).
Twelve pieces of sterilised eye pads in separate sealed packets.
A bottle containing hundred tablets (each of three hundred twenty-five mg) of aspirin or any other
analgesic.
Twelve roller bandages ten cms wide.
Twelve roller bandages five cms wide.
One tourniquet.
A supply of suitable splints.
Three packets of safety pins.
Kidney tray.
A snake bite lancet.
One (thirty ml) bottle containing potassium permanganate crystals.
One copy of first-aid leaflet issued by the Directorate General.
Six triangular bandages.
Two pairs of suitable, sterilised, latex hand gloves.
1.7.7.1 Page 462 of 674

Bureau of Indian Standards for PPE
IS : 1179 - 1967 Equipment for eye and face protection during welding.
IS : 1989 -1986 (Part - I & III) Leather safety boots and shoes.
IS : 2925 -1984 Industrial Safety Helmets.
IS : 3521 - 1983 Industrial Safety belts and harness.
IS : 3778 -1975 Rubber knee boots.
IS : 4770 -1968 Rubber gloves for electrical purposes.
IS : 5424 - 1969 Rubber mats for electrical purposes.
IS : 5557 -1969 Industrial and Safety rubber knee boots.
IS : 5983 -1978 Eye protectors.

Code of practice for selections, care and repair of Safety
IS : 6519 -1971
footwear.
IS : 6994 -1973 (Part - I) Industrial Safety Gloves.
IS : 8519 - 1977
body protection.
Guide for selection of industrial safety equipment for eye,
IS : 8520 - 1977
face and ear protection.
Code of practice for maintenance and care of industrial
IS : 8990 - 1978
safety clothing.
IS : 9167 - 1979 Eye protectors.
Recommendations for the selection, use and

IS : 9623 - 1980
maintenance of respiratory protective devices.
IS : 10667 - 1983
protection of fool and leg.
IS : 11226 -1985 Leather Safety footwear having direct moulding sole.
Page 463 of 674

Project: Contractor
Page 464 of 674
Personal Protective Equipment Issue Register
Personal Protective Equipment Signature/

Date of ID Card Inducted
Sl.No Name Discipline Safety Safety Safety Safety Hand Other Thumb Remarks
Issue No on
Helmet Goggles Shoe Harness Gloves PPE Impression
1.7.7.1
Personal Protective Equipment & Safety Equipments Stock Register
Date as on: Contractor:
PPE Quantity
Available in Unit Remarks
Items Procured Issued
Stock
Safety Shoes
Size 6 Pair
Size 7 Pair
Size 8 Pair
Size 9 Pair
Size 10 Pair
Gum Boot Pair
Safety Helmet No
Safety Goggles No
Hand Gloves Pair
Ear Muff No
Ear Plug No
Nose Mask No
Full Body Harness No
Fall Arrestor System No
Life Line No
Welders Hood No
Grinder Visor No
Fire Blanket No
Fire Extinguisher No
Caution Tapes Meter
Name of Stores In-charge Name of Safety Manager

Signature Signature
Date Date
1.7.7.1 Page 465 of 674

Diesel Generator Set Checklist
Project Contractor
Inspection Date : Inspected By:
Location: DG ID:
DG Rating Output Current
Sl.No Particulars Observations Remarks
1 Whether DG is acoustic type

Does proper access exists for DG &
2
Unauthorized entry restricted
3 Whether body & Neutral is earthed
Condition of control panel
Are the doors lockable?
4 Is the termination of I/C cable done properly
with proper size of lugs?
Are the I/C & O/G terminals fixed and tighten
properly
5 Whether voltmeters, Ammeter are working
6 Whether DG panel has MCCB with proper rating
7 Whether Single Line Diagram displayed
8 Is their any spillage around DG
9 Whether fire extinguishers are provided

CRP chart & Danger sign board displayed in
10
English and local languages
Information such as authorized operator details,
11
nearest first aid kit availability displayed
12 Sound level is within limit
Is the spark arrestor in good condition and fixed
13
properly?
Is the emergency stop push button function
14
properly
15 Current months color coded stickers fixed
Name of Electrical Engineer

Signature
Date
1.7.7.1 Page 466 of 674

Excavation Checklist
Project Contractor
Description of work: Dimension of the pit/ trench:

ITEMS
No Date
A) Before excavation
1 Excavation permit no -
Underground/ overhead facilities present are:
2
_______________________________________
3 Underground cable detection done?
Has the exact location of excavation been
4
marked?
Has the operator possess a valid operating
5
license?
6 Whether SPA Prepared and displayed on site
The area to be excavated and hazards are clearly
7
communicated to the operator & the helper?
B) After excavation
Has adequate sloping maintained to prevent soil
8
collapse?
9 Any adjoining structure nearby?
10 Shoring / Sloping required?

Has the excavated pit hard barricaded (if
11
depth>0.6m), else soft barricaded?
12 Warning signs displayed?
Excavated earth stored 1m away from edge of
13
barrication?
14 Vehicle movement restricted?
Access/ egress ladder placed every 15m interval,
15
based on no of workmen?
16 Dewatering required?
Walkovers/ passageway provided at necessary
17
places?
18 Sufficient illumination inside the pit at all times?
Signature
Date: Comments
Hot Work Activity Checklist
Page 467 of 674

Project Contractor
Description of work: Hot work permit no:

ITEMS
No Date
The work area has been barricaded and warning
1
signs displayed?
The work area has been made free from
2
combustible/flammable materials?
The sparks / radiation from the hot work have
3
been adequately contained?
Flammable wastes are disposed in a covered
4
container?
Are adequate number of well-maintained fire
extinguishers and fire blankets, provided at each
5
work area and all workers /supervisors in the work
area are aware of its location?
Fire extinguishers regularly inspected and kept at
6
designated places with clear access?
Are fire hydrant system, fire hose and foam
7
system in ready during critical works?
The contractor has been briefed on all the
8
necessary safety requirements?
Appropriate PPE/ protective clothing has been
9
provided for the job?
10 Tools and machineries to be used are inspected?
11 Fire watcher deployed?
Any hazardous work carried out nearby
12
simultaneously?
13 Gas Monitoring required? Yes (Y) No (N)
Are chances of flammable vapour cloud formation
14 at nearby area or likely to occur during the course
of work? eg: Spray painting?
All workers are trained in the use of fire
15 extinguishers, fire fighting procedure and
emergency response?
16 Whether SPA Prepared and Displayed on site?
17 Any other Fire prevention required?
Signature
Note: Fire Watcher to standby 15 mins after work completed
Date: Comments
Page 468 of 674

ARC WELDING MACHINE CHECKLIST
Project Contractor:
Site supervisor: Welding m/c ID
Date: Location

A WELDING SETS
1 Connections are proper and effectively insulated.
2 ON / OFF switch in good working condition?
3 Voltmeter/ Ammeter connected & working properly?
4 Regulator working properly
5 Welding machine completely covered and no loose
connections?
6 Good earthing and grounding.(Double earthing)
7 Wheels freely rotating?
Compatible Fire extinguisher available for the welding
8
set
B CABLE AND JOINTS
1 Supply cable's length exceeding 5m?
2 Connection taken through ELCBs?
Welding cables of proper rating and in proper
3
condition without any damages?
4 Connecting lugs tightened properly?
5 Well insulated and no exposed parts?
6 Size of cable used are proportional to voltage supply
Return earth cable of sufficient length? Are electrical
7
conductors prohibited from being used to complete
8 Any overloading, whereby cables become hot?
9 Any contact with oil / sharp edges or water?
Are cables properly placed to prevent tripping
10
hazards?
C ELECTRODE HOLDERS
Electrode holders used are in good working
1
condition?
2 Properly insulated and no exposed metal parts?
Holders are kept dried and properly hung up after
3
use?
4 Not in contact with metal parts.
5 Electrodes are detached after welding.
Name of Electrical Manager Name of Safety Manager
Signature Signature
1.7.7.1 Page 469 of 674

Gas Cutting Set Checklist
Project Contractor:
Site supervisor: Gas cutting set ID
Date: Location

A GAS CYCLINDERS
Cylinders used are in upright and secured position,
1
tied with chain and used in a trolley?
Cylinders protected from direct fire, sparks or
2
excessive heat?
3 Double pressure gauges in working condition?
Cylinder valves, regulators, hoses are free from
4
oil/grease?
5
leakage test?
Cylinders are kept away from live electric cables or
6
ground wires.
Empty and full cylinders are properly separated and
7
marked?
Oxygen and fuel cylinders kept separately in a
8
designated storage shed?
B REGULATORS / HOSES / TORCHES
Regulators and torches are in sound working
1
condition?
2
leakage test?
Hoses are free of any tape or wrapping materials
3
used for plugging leaks?
4 Proper connections are used for fastening?
5 All gas hoses are secured with clips at both ends?
6 Are regulators, hoses & fittings free from oil &
grease?
7 Any kinked or tangled hoses?
8 Hoses protected from being run-over?
Are approved flash back arrestors installed at both
9
cylinder and torch ends?
C OTHERS
1 Cylinder keys readily available on cylinder?
2 Proper lighter is used to light the torch?
3 Fire extinguisher & fire blanket readily available?

Signature
Page 470 of 674

Grinding Machine Checklist
Project Contractor:
Site supervisor: Machine ID
Date: Location

A GRINDING MACHINE
1 Any physical damages to the machine?
2 RPM punched/ marked?
3 Guard in place?
4 Double insulated body?
5 Proper size spanner/ key in place?
6 Electrical connection done properly?
7 Is Dead man provided with machine and in working
condition?
8 Handles tightly placed?
B GRINDING WHEEL
1 Appropriate selection of abrasive wheel?
2 Within expiry date?
3 RPM, size and type of the wheel marked?
4 Any cracks/ damps observed in the wheel?
5 Properly stored after use?
Grinding and cutting wheel stored & used
6
accordingly?
C CABLES & CONNECTIONS
1 Cable in proper condition without any damages?
2 Cable with plug tops?
3 Connection used through ELCBS?
Cables routed properly without obstructing the
4
passage ways?
Signature
Page 471 of 674

Fire Extinguisher Monthly Inspection
Project
Contractor:
Inspected by:
Visual Inspection
Sl.NO Date Identification No. Result Location Date of Refill Date of Expiry
OK NOT OK
Checklist for Inspection

Located in its designated place
No obstruction to access or visibility
Operating instructions on the extinguisher label legible and facing outward
Seals and tamper indicators not broken or missing
Determine fullness by weighing
Examine for obvious physical damage, corrosion, leakage or clogged nozzle
Pressure gauge reading or indicator in the operative range or position.
Comments/Remarks
Name of the Inspector

Signature
Date
Page 472 of 674

1.7.7.1 Page 473 of 674
Page 474 of 674
Slings and Lifting Gear Register

Project Contractor
Inspected by: Date: Signature:
Manufacturers Date into service Remarks

Sl.No Type of Sling Type of Gear SWL Diameter Length
Serial Number
1.7.7.1
Monthly Wire Rope Inspection Report
Page 475 of 674

Excess Wear Kinking , Bird-
Diameter 4 Broken 10 random
Sl. Manufacturers Location Thimble of 1/3 caging,
SWL Length Wires in 1 broken wire ropes Remarks
No Serial Number of Sling available diameter in Serious
Size Rope Lay in one lay
outside wires Corrosion
1.7.7.1
Monthly Synthetic Web Sling Periodic Inspection Report
Page 476 of 674

Worn or Slings
Sl. Manufacturers Location Chemical Tears, Snags, Slings Properly
SWL Length Broken Properly Remarks
No Serial Number of Sling Burns Holes or Cuts Stored
Stitches Tagged
Crane Register
Page 477 of 674
Project Contractor
Third Party
Capacity Certificate Date into service Remarks
Sl.No Crane Type Manufacturer Model Year Current Owner
Rating (SWL) Reference
Number
Name of Contractors P& M Manager Name of Contractors Safety Manager

Signature Signature
Date Date
1.7.7.1
Page 478 of 674
Mobile Crane Inspection
Date Time
Contractor Make
Owner Operator
Load Rating Registration No
Sl.No Description Observation Hazards Identified Remedial Measure

Condition of wire rope
1
(Visual Inspection)
2 Safety latch
3 Tyres Condition
4 Reverse horn
5 Limit Switch
Operator
6 License
Competency Certificate
7 Certificate from third party

8 Hook Condition
9 SWL Marked
10 Load Chart Displayed
11 Any oil leakage
12 Wind Screen
13 Out Riggers
Signature Signature
Date Date
1.7.7.1 Page 479 of 674

Pre-Lift Checklist
Project: Date:
Contractor
Lift Description:
Yes No
1. Crane Operator minimum qualification requirements?
2. Lift calculations and rigging plan completed?
3. Are all required approvals/permits signed?
4. Crane inspections up to date (Monthly/Daily)?
5. Weather conditions and wind speed acceptable?
6. Has the stability of the ground been assured?
7. Matting and/or outrigger pads inspected and approved?
8. Electrical equipment and power lines at required distance?
9. Rigging inspected for defects?
10. Connecting/disconnecting means have been developed?
11. Have the safety precautions been reviewed?
12. The total lifted weight is below 95% of crane capacity capacity?
13. Signal person(s) assigned?
14. Safe Plan of Action (SPA) Completed?
15. Pre-Lift Meeting/SPA talk held?
16. Hoist area & load path cleared of non-essential personnel?
17. Crane set up per the lift plan (radius, configuration, etc)?
18. Rigging equipment and tag line(s) installed per plan?

19. Emergency/Contingency plan in place for power failure, plant upset,
power line contact, lifting over operating equipment, etc.
Name of rigging coordinator:
Signature: Date:
Page 480 of 674

Checklist for Construction Vehicles
Date of Inspection Inspected by
Registration No. Make
Driver Name License type
License No License valid up to
PUC Certificate No and Valid up to RC No and Valid up to
3. Sl.No Description Observation Remarks
1. Operator with valid driving permit

Banks man/Helper available to guide the
2
vehicle in construction area
2 Condition of headlights
Condition of indicators
a) Front indicators
3
b) Rear indicators
c) Side indicators
4 Condition of back lights
5 Condition of side lights
7 wipers in good working condition
8 Condition of side mirrors
9 Reverse horn
11 Are all breaking arrangements satisfactory?
12 Condition of tyres
15 Anchoring points &anchoring accessories
16 Spark arrestor fitted
17 Any fuel leakage
18 Wedges availability as wheel stoppers
19 Fire extinguisher availability

Whether parking brake and brake light in
20
working condition
Signature Signature
Date Date
1.7.7.1 Page 481 of 674

Page 1 of 45

CHENNAI, INDIA
CPCL REFINERY - RESID UPGRADATION PROJECT
PART : III
SECTION : B.12
TITLE: GENERAL SPECIFICATION FOR SHOP AND FIELD PAINTING
DOCUMENT NO. : 44NC-4600-0000-V.02-0111-A4
REV ISSUE DATE PAGES REV DESCRIPTION PREPARED CHECKED APPROVED

NO. BY BY BY
0 09.03.2010 48 Issued as general specification MS CR CR

Revised as marked and issued
1 08.07.2010 45 SNK MS HSC
for FEED
Page 482 of 674

CPCL, Chennai GENERAL SPECIFICATION FOR Part III Section B.12
44NC-4600 SHOP AND FIELD PAINTING Page 2 of 45
LSTK Doc. No. 44NC-4600-0000-V.02-0111-A4 Rev. 1
TABLE OF CONTENTS
1.0 General
2.0 Scope
3.0 Codes & Standards
4.0 Equipment
5.0 Surface Preparation
6.0 Paint Materials
7.0 Paint Systems
7.1 Pre-erection / Pre-fabrication and shop priming for carbon steel, low temperature carbon
steel & low alloy steel, un-insulated and insulated steel structures, piping and equipment,
etc.,
7.2 Repair of pre-erection /fabrication and shop priming after erection / welding for carbon steel,
low temperature carbon steel & low alloy steel uninsulated and insulated items in all
environments.
7.3 Repair of all weld joints and damages of galvanized steel, carbon steel and alloy steel
structures, piping and equipment after erection on above ground / overhead areas at site.
8.0 Field paint system for normal corrosive environment (for carbon steel, low temperature
carbon steel and low alloy steel)
9.0 Field paint system for corrosive areas in plant (for carbon steel, low temperature carbon
steel and low alloy steel)
10.0 Field paint system for highly corrosive areas in plant (for carbon steel, low temperature
carbon steel and low alloy steel)external surfaces of piping & equipment
11.0 Field paint system for carbon steel storage tanks (internal & external) for all environment
and areas
12.0 Coating system for external side of underground carbon steel plant piping and tanks
13.0 Painting under insulation for (hot, cold & safety) Carbon Steel plant piping and tanks
14.0 Internal protection of Carbon Steel water boxes and tube sheets of cooler condensers
15.0 Field painting system for GI towers / Non-Ferrous tueb sheet
16.0 Shop & Field painting system for Effluent treatment plant
17.0 Storage
18.0 Color code for piping as per CPCL
19.0 Identification of vessels, piping, etc.,
20.0 Painting for civil defence requirements
21.0 Inspection and testing
22.0 Guarantee
23.0 Qualification criteria of painting contractor
Annexure-1 List of Recommended manufacturers

Annexure-2 Paint colour code for Piping & Equipment as given by CPCL
44NC-4600-0000-V.02-0111-A4 General Specification for Painting.doc
Page 483 of 674

1.0 GENERAL
1.1 These technical specifications shall be applicable for the work covered by the contract and
without prejudice to the various codes of practice, standard specifications, etc. It is understood
that Contractor shall carry out the work in all respects with the best quality of materials and
workmanship and in accordance with the best engineering practice and instructions of Engineer-
in-Charge.
1.2 1 Wherever it is stated in the specification that a specific material is to be supplied or a specific
work is to be done, it shall be deemed that the same shall be supplied or carried out by the
contractor. Any deviation from this standard without written deviation permit from appropriate
authority will result in rejection of job.
2.0 SCOPE
2.1 Scope of work covered in the specification shall include, without being limited to the following
2.1.1 This specification defines the requirements for surface preparation, selection and application of
paints on external surfaces of equipment, vessels, machinery, piping, ducts, steel structures,
external & internal protection of storage tanks for all services. MS chimney without refractory
lining and flare lines etc. The items listed in the heading of tables of paint systems is indicative
only, however the contractor is fully responsible for carrying out all the necessary painting,
coating and lining on external and internal surfaces as per the tender requirement.
2.2 Extent of Work
2.2.1 The following surfaces and materials shall require shop, pre-erection and field painting :
a. All un-insulated C.S & A.S equipment like columns, vessels, drums, storage tanks, heat
exchangers, pumps, compressors, electrical panels and motors etc., and tanks and
equipment in ETP plant.
b. All un-insulated carbon and low alloy piping fittings and valves (including painting of
identification marks), furnace, ducts and stacks.
c. All items contained in a package unit as necessary.
d. All structural steel work, pipe, structural steel supports, walkways, handrails, ladders,
platforms, etc.
e. External surfaces of MS chimneys without refractory lining & flare lines.
f. Identification color bands on all piping as required including insulated aluminum clad,
galvanized, SS and nonferrous piping.
g. Identification lettering / numbering on all painted surfaces of equipment / piping insulated

aluminum clad, galvanized, SS and non-ferrous piping.
h. Marking / identification signs on painted surfaces of equipment / piping hazardous service.
i. Supply of all primers, paints and all other materials required for painting other than Owners
supply.
j. Over insulation surface of equipments and pipes wherever required.
k. Painting under insulation for carbon steel, alloy steel and stainless steel as specified. 1
Page 484 of 674

l. Repair work of damaged / pre-erection / fabrication shop primer and weld joints at field.
m. Internal surfaces of RCC tanks and structures in Effluent Treatment Plant.
2.2.2 The following surfaces and materials shall not require painting in general. However, if there are
any specific requirement by the Owner, the same shall be painted as per the relevant
specifications:
a. Un-insulated austenitic stainless steel

b. Plastic and / or plastic coated materials.
c. Non-ferrous materials like Aluminum, galvanized piping, gratings and Handrails etc.
except G.I. Tower.
2.3 Unless otherwise instructed final painting on pre-erection / shop primed pipes and equipments
shall be painted in the field, only after the mechanical completion, testing on systems are
completed as well as after completion of steam purging wherever required.
2.4 Changes and deviations required for any specific job due to clients requirements or otherwise
shall be referred to Jacobs for deviation permit.
3.0 CODES & STANDARDS
3.1 Without prejudice to the provision of Clause 1.1 above and the detailed specifications of the
contract, the following codes and standards shall be followed for the work covered by the
contract.
Color coding Color coding inspection manual for piping issued by CPCL (Ref.
Annexure-2) 1
IS-101 Methods of test for ready mixed paints and enamels.
ASTM American standard test methods for paints and coatings.
ASA A 13.1-1981 Scheme for identification of piping systems: American National Standards
Institution.
3.2 Surface Preparation Standards
Following standards shall be followed for surface preparations
3.2.1 Swedish Standard SIS-05 5900-1967 (surface preparation standards for painting steel surfaces)
This standard contains photographs of the various standards on four different degrees of rusted
steel and as such is preferable for inspection purpose by the Engineer-in-Charge.
3.2.2 Steel Structures Painting Council, U.S.A (Surface Preparation Specifications (SSPC-SP).
3.2.3 British Standards (Surface Finish of Blast-Cleaned for Painting) BS-4232.
3.2.4 National Association of Corrosion Engineers, U.S.A (NACE).
3.2.5 Various International Standards equivalent to Swedish Standard for surface preparations are
given in Table-I.
3.3 The contractor shall arrange, at his own cost, to keep a set of latest edition of above standards
and codes at site.
Page 485 of 674

3.4 The paint manufacturers instructions shall be followed as far as practicable at all times.
Particular attention shall be paid to the following :
a. Instructions for storage to avoid exposure as well as extremes of temperature.
b. Surface preparation prior to painting.
c. Mixing and thinning.
d. Application of paints and recommended limit on time intervals between coats.
e. Suggested Quality assurance procedures.
4.0 EQUIPMENT
4.1 All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning, inspection
instruments, e.g. surface profile gauges, holiday detectors, pin hole detectors, dry film thickness
gauges, etc. and all equipments, scaffolding materials, shot blasting equipments like hooper, grit
etc & air compressors, etc., required to be used shall be suitable for the work and all in good
order and shall be arranged by the Contractor at site and in sufficient quantity. 1
4.2 Mechanical mixing shall be used for paint mixing operations in case of two pack systems except
that the Engineer-in-Charge may allow the hand mixing of small quantities at his discretion.
5.0 SURFACE PREPARATION, SHOP, COATING APPLICATION & REPAIR AND

DOCUMENTATION
5.1 General
5.1.1 In order to achieve the maximum durability, blast cleaning is considered the most desirable
method to achieve required profile however one or more of following methods of surface
preparation shall be followed, depending on conditions of steel surface and as instructed by
Engineer-in-Charge. Adhesion of the paint film to surface depends largely on the degree of
cleanliness and surface profile of the metal surface. Proper surface preparation contributes more
to the success of the paint protective system.
a) Manual or hand tool cleaning

b) Mechanical or power tool cleaning.
c) Blast cleaning. NO sand shall be used. Only grit blasting shall be allowed. 1
5.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a clean and dry
surface is obtained. The minimum acceptable standard in case of manual or hand tool cleaning
shall be St. 2 or equivalent, in case of mechanical or power tool cleaning it shall be St. 3 or
equivalent in case of blast cleaning it shall be Sa 2-1/2 OR equivalent as per Swedish Standard
SIS-055900-1967 or equivalent. Where highly corrosive conditions exist, then blast cleaning shall
be Sa 3 as per Swedish Standard.
Remove all other contaminants, oil, grease, etc. by use of an aromatic solvent prior to surface
cleaning.
5.1.3 Blast cleaning shall not be performed where dust can contaminate surfaces undergoing such
cleaning or during humid weather conditions having humidity exceed 85%.
Page 486 of 674

5.1.4 Irrespective of the method of surface preparation, the first coat of primer must be applied by
airless spray gun on dry surface No brush shall be used except for touchup. This should be done
immediately and in any case within 4 hours of cleaning of surface. However, at times of
unfavorable weather conditions, the Engineer-In-Charge shall have the liberty to control the time
period, at his sole discretion and / or to insist on re-cleaning, as may be required, before primer
application is taken up. In general, during unfavorable weather conditions, blasting and painting
shall be avoided as far as practicable. 1
5.1.5 The external surface of RCC chimney to be painted shall be dry and clean. Any loose particle of
sand, cement, aggregate etc., shall be removed by scrubbing with soft wire brush if necessary
acid etching with 10-15% HCl solution for about 15 minutes shall be carried and surface must be
thoroughly washed with water to remove acid & loose particles then dry completely before
application of paint.
5.2 Procedure of Surface Preparation :
5.2.1 Blast Cleaning
5.2.1.1 Air Blast Cleaning
The surfaces shall be blast cleaned using one of the abrasives Al2O3 particles chilled cast iron or
malleable iron and steel at pressure of 7 Kg /cm2 at appropriate distance and angle depending of
nozzle size maintaining constant velocity and pressure. Chilled cast iron, malleable iron and steel
shall be in the form of shot or grit of size not greater than 0.055 maximum in case of steel and
malleable iron and 0.04 maximum in case of chilled iron. Compressed air shall be free from
moisture and oil. The blasting nozzles should be venturi style with tungsten carbide or boron
carbide as the materials for liners. Nozzles orifice may vary from 3/16 to . On completion of
blasting operation, the blasted surface shall be clean and free from any scale or rust and must
show a grey white metallic luster. Primer or first coat of paint shall be applied within 4 hours of
surface preparation. Blast cleaning shall not be done outdoors in bad weather without adequate
protection or when there is dew on the metal, which is to be cleaned. Surface profile shall be
uniform to provide good key to the paint adhesion (i.e. 35 to 50 microns). If possible vacuum
collector shall be installed for collecting the abrasives and recycling.
5.2.1.2 Water Blast cleaning
Environmental, health and safety problems associated with abrasive blast cleaning limit the
application of Air Blast Cleaning in many installations. In such case water blast cleaning is
resorted to.
Water Blast Cleaning can be applied with or without abrasive and high pressure water blasting.
The water used shall be inhibited with sodium chromate / phosphate. The blast-cleaned surface
shall be washed thoroughly with detergents and wiped with solvent and dried with compressed
air. For effective cleaning abrasives are used. The most commonly used pressure for high
pressure water blast cleaning for maintenance surface preparation is 3000 to 6000 psi at 35-45
lit/minute water volume and pressures upto 1000 psi and water volume at 45 lit/minute provide
maximum cleaning.
The water blast cleaned surface shall be comparable to SSPC-SP-12/nace No. 5. The operation
shall be carried out as per SSPC guidelines for water blast cleaning. The indicative values for
sand injection is :
Air : 300 to 400 Cu. Ft. / min

Water : 5-10 lit/min. with corrosion inhibitor
Sand : 200-400 lbs/hr.
Nozzle : 0.5 to 1 dia.
Page 487 of 674

Special equipments for water blast cleaning with abrasives, now available, shall be used.
5.2.2 Mechanical or Power Tool Cleaning
Power tool cleaning shall be done by mechanical striking tools, Chipping hammers, grinding
wheels or rotating steel wire brushes. Excessive burnish of surface shall be avoided as it can
reduce paint adhesion. On completion of cleaning, the detached rust mill scale etc. shall be
removed by clean rags and / or washed by water or stream and thoroughly dried with compressed
air jet before application of paint.
5.2.3 Manual or hand tool cleaning
Manual or hand tool cleaning is used only where safety problems limit the application of other
surface preparation procedure and there is approach problem in certain areas and hence does
not appear in the tables of paint systems.
Hand tool cleaning normally consists of the following :
a. Hand descaling and / or hammering

b. Hand scraping
c. hand wire brushing
Rust, mill scale spatters, old coatings and other foreign matter, shall be removed by hammering,
scrapping tools, emery paper cleaning, wire brushing or combination of the above methods. On
completion of cleaning, loose material shall be removed from the surface by clean rags and the
surface shall be bushed, swept, dusted and blow off with compressed air/steam to remove all
loose matter. Finally the surface may be washed with water and dried for effective cleaning.
5.3 Non-compatible shop coat primer
The compatibility of finishing coat should be confirmed from the paint manufacturer. In the event
of use of primer such as zinc rich epoxy, inorganic zinc silicate etc., as shop coat, the paint
system shall depend on condition of shop coat. If the shop coat is in satisfactory condition
showing no major defect, the shop coat shall not be removed. However a non-compatible primer
shall have to be removed before application of compatible paint system for the environment. The
touch up primer and finishing coat(s) shall be identified for application by Engineer-in-Charge.
5.4 Shop coated (coated with primer & finishing coat) equipment should not be repainted unless paint
is damaged.
5.5 Shop primed equipment and surfaces will only be spot cleaned in damaged areas by means of
power tool brush cleaning or hand tool cleaning and then spot primed before applying one coat of
field primer unless otherwise specified. If shop primer is not compatible with field primer then
shop-coated primer should be completely removed before application of selected paint system for
particular environment.
5.6 For Package units / equipment, shop primer should be as per the paint system given in this
specification. However, manufacturers standard can be followed after review.
5.7 Coating Procedure and Application
5.7.1 Surface shall not be coated in rain, wind or in environment where injurious airborne elements
0
exists, when the steel surface temperature is less than 5 F above dew point when the relative
0
humidity is greater than 85% or when the temperature is below 40 F.
5.7.2 Blast cleaned surface shall be coated with one complete application of primer as soon as
practicable but in no case later than 4 hrs. the same day.
Page 488 of 674

5.7.3 To the maximum extent practicable, each coat of material shall be applied as a continuous film
uniform thickness free of probes. Any spots or areas missed in application shall be recoated and
permitted to dry before the next coat is applied. Applied paint should have the desired wet film
thickness.
5.7.4 Each coat shall be in proper state of cure or dryness before the application of succeeding coat.
Material shall be considered dry for recoating when an additional coat can be applied without the
development of any detrimental film irregularities, such as lifting or loss of adhesion of the under
coat. Manufacturer instruction shall be followed for inter-coat interval.
5.7.5 When the successive coat of the same color have been specified, alternate coat shall be tinted,
when practical, sufficiently to produce enough contrast to indicate complete coverage of the
surface. The tinting material shall be compatible with the material and not detrimental to its
service life.
5.7.6 Deleted 1
5.7.7 Airless spray application shall be in accordance with the following procedure : as per steel
structure paint Manual Vol. 1 & Vol. 2 by SSPC, USA. Air less spray relies on hydraulic pressure
rather than air atomization to produce the desired spray. An air compressor or electric motor is
used to operate a pump to produce pressures of 1000 to 6000 psi, paint is delivered to the spray
gun at this pressure through a single hose within the gun, a single paint stream is divided into
separate streams, which are forced through a small orifice resulting in atomization of paint without
the use of air. This results in more rapid coverage with less over spray. Airless spray usually is
faster, cleaner, more economical and easier to use than conventional air spray.
Airless spray equipment is mounted on wheels, and paint is aspirated in a hose that sucks paint
from any container, including drums. The unit shall have inbuilt agitator that keep the paint
uniformly mixed during the spraying. The unit shall consist of inbuilt strainer. Usually very small
quantity of thinning is required before spray. In case of high build epoxy coating (two pack), 30:1
pump ratio and 0.020-0.023 tip size will provide a good spray pattern. Ideally fluid hoses should
not be less than 3/8 ID and not longer than 50 ft. to obtain optimum results.
In case of gun choking, de-choking steps shall be followed immediately.

5.7.8 Brush application of paint shall be in accordance with the following :
a. Brushes shall be of a style and quality that will enable proper application of paint.
b. Round or oval brushes are most suitable for rivets, bolts, irregular surface and rough or pitted
steel. Wide flat brushes are suitable for large flat areas, but they shall not have width over
five inches.
c. Paint shall be applied into all corners.
d. Any runs or sags shall be brushed out.
e. There shall be a minimum of brush marks left in the applied paint.
f. Surfaces not accessible to brushes shall be painted by spray, doubaers or sheepskin.
5.7.9 Manual application by sling (where 6 o clock position of pipe is not approachable)
A canvas strip (alternatively a tinplate strip) about 450mm wide and 1.5m long is held under the
pipe by two men holding this sling move it up and down and walk slowly forward while fresh
coating is poured on the pipe and they manipulate the sling so that an even coating is obtained all
round the bottom. This work shall be done very carefully and by experienced personnel. There
shall not be any formation of Whiskers and holes in the coating. The coating film shall be
inspected by mirror.
Page 489 of 674

5.7.10 For each coat the painter should know the WFT corresponding to the specified DFT and
standardize the paint application technique to achieve the desired WFT. This has to be ensured
in the qualification trial.
5.8 Drying of coated surfaces
5.8.1 No coat shall be applied until the preceding coat has dried. The material shall be considered dry
for re-coating when another coat can be applied without the development of any film irregularities
such as lifting or loss of adhesion of undercoats. Drying time of the applied coat should not
exceed maximum specified for it as a first coat; if it exceeds the paint material has possibly
deteriorated or mixing is faulty.
5.8.2 No paint shall be force dried under conditions which will cause checking, wrinkling, blistering
formation of pores, or detrimentally affect the conditions of the paint.
5.8.3 No drier shall be added to paint on the job unless specifically called for in the manufacturers
specification for the paint.
5.8.4 Paint shall be protected from rain, condensation, contamination, snow and freezing until dry to
the fullest extent practicable.
5.9 Repair of damaged paint surface
5.9.1 Where paint has been damaged in handling and in transportation, the repair of damaged coating
of pre-erection / fabrication shall be as given below.
5.9.2 Repair of damaged inorganic zinc silicate primer after erection / welding.
Quickly remove the primer from damaged area by mechanical scrapping and emery paper to
expose the white metal. Blast clean the surface if possible. Feather the primer over the intact
adjacent surface surrounding the damaged area by emery paper.
0 0
5.9.3 Repair of damaged pre-erection and shop priming in the design temperature of 90 C to 400 C
Surface preparation shall be done as per procedure 5.9.2
One coat of F-9 shall be applied wherever damage was observed on pre-erection / pre-
fabrication / shop primer of inorganic zinc silicate coating (F-9).
5.10 Paint Application
5.10.1 Shop priming / pre-erection priming with F9 or F12 shall be done only on blasted surface.
5.10.2 Shop priming / pre-erection priming with F9 shall be done only with airless spray.
5.10.3 For large flat surface field painting shall be done by airless spray otherwise brush can be used.
5.11 Documentation
5.11.1 A written quality plan with procedure for qualification trials and for the actual work.
5.11.2 Daily progress report with details of weather conditions, particular of applications, no. of coats
and type of materials applied, anomalies, progress of work versus program.
5.11.3 Results of measurement of temperatures relative humidity, surface profile, film thickness, holiday
detection, adhesion tests with signature of appropriate authority.
5.11.4 Particulars of surface preparation and paint application during trials and during the work.
Page 490 of 674

5.11.5 Details of non-compliance, rejects and repairs.
5.11.6 Type of testing equipments and calibration.
5.11.7 Code and batch numbers of paint materials used.
Page 491 of 674

TABLE-1 (FOR CLAUSE 5.0)
SURFACE PREPARATION STANDARDS
VARIOUS INTERNATIONAL STANDARDS

(EQUIVALENT)
SR.
DESCRIPTION BRITISH REMARKS
NO. Swedish SSPC-
NACE STANDAR
Standard SP
USA D
SIS-05- USA
BS-4232
5900
1. Manual or hand tool ST.2 SSPC- -- -- This method is applied
cleaning. SP-2 when the surface is
exposed to normal
Removal of loose rust, atmospheric conditions
loose mill scale and loose when other methods
paint, chipping, scrapping, cannot be adopted and
standing and wire brushing. also for spot cleaning
Surface should have a faint during maintenance
metallic sheen. painting.
2. Mechanical or power tool ST. 3 SSPC- -- --
cleaning. SP-3
Removal of loose rust,
loose mill scale and loose
paint to degree specified by
power tool chipping,
descaling, sanding, wire
brushing and grinding, after
removal of dust, surface
should have a pronounced
metallic sheen.
3. Blast cleaning (air & water)
There are four common
grades of blast cleaning
3.1 White metal SA.3 SSPC- NACE First Where extremely clean
Blast cleaning to white SP-5 #1 Quality surface can be
metal cleanliness. expected for prolong
Removal of all visible rust. life of paint system.
Mill sale, paint & foreign
matter 100% cleanliness
with desired surface profile.
Page 492 of 674

3.2 Near white metal SA 2 SSPC- NACE Second The minimum

SP-10 #2 Quality requirement for
chemically resistant
paint systems such as
epoxy, vinyl,
polyurethane based
and inorganic zinc
silicate paints, also for
conventional paint
systems used under
fairly corrosive
conditions to obtain
desired life of paint
system.
3.3 Commercial Blast SA 2 SSPC- No. 3 Third For steel required
Blast cleaning until at least SP-6 Quality to be painted with
two-third pf each element of conventional paints for
surface are is free of all exposure to mildly
visible residues with corrosive atmosphere
desired surface profile for longer life of the
paint systems.
3.4 Brush-off Blast SA 1 SSPC- No. 4
Blast cleaning to white SP-7
metal cleanliness, removal
of all visible rust, mill scale,
paint & foreign matter.
Surface profile is not so
important.
Page 493 of 674

6.0 PAINT MATERIALS
Paint manufacturers shall furnish the characteristics of all paints materials on printed literature
along with the test certificate for all specified characteristics given in this specification. All the paint
materials shall be on first quality and conform to the following general characteristics. As per the
tables 6.1, 6.2 and 6.3.
TABLE No. 6.1 PRIMERS
Sr.
Description P-2 P-4 P-6
No.
1. Technical Name Chlorinated rubber Etch primer / Epoxy zinc phosphate

Zinc Phosphate primer wash primer primer
2. Type and Single pack, air drying Two pack Two component polyamide
composition chlorinated rubber based polyvinyl butyral cured epoxy resin medium-
medium plasticised with resin medium pigmented with zinc
unsaponifiable plasticizer, cured with phosphate.
pigmented with zinc phosphoric acid
phosphate solution
pigmented with
zinc tetroxy
chromate
3. Volume Solids 40% 7-8% 40%

(approx.)
4. DFT (Dry Film 40-45 8-10 40-50

thickness) per
coat (approx.)
5. Theoretical 8-10 8-10 8-10

covering capacity
2
in M /coat/litre
(approx.)
6. Weight per liter in 1.3 1.2 1.4

kgs/liter (approx)
7. Touch dry at 30 minutes 2 hrs. After 30 min.

0
30 C (approx.)
0
8. Hard dry at 30 C 24 hrs. 24 hrs. 24 hrs.
(approx.)
9. Over coating Min: 8 hrs. Min: 4-6 hrs. Min.: 8 hrs.

interval (approx.) Max. : No limitations Max. : 24 hrs. Max. : 3-6 months
10. Pot life (approx) Not applicable Not applicable 8 hrs.

0
at 30 C for two
component paints
(approx.)
Page 494 of 674

TABLE No. 6.2 FINISH PAINTS
Sr. Description F-2 F-3 F-6A/F-6B F-7

No.
1. Technical Acrylic Chlorinated rubber Epoxy high High build coaltar

Name polyurethane based finish paint build finish paint epoxy coating.
finish paint
2. Type and Two-pack Single pack Two pack Two pack polyamide
composition aliphatic plasticized polyamine (F- cured epoxy resin
isocynate cured chlorinated rubber 6A) / polyamide blended with coaltar
acrylic finish based medium (F-6B) cured medium, suitably
paint with chemical and epoxy resin pigmented.
weather resistant medium suitably
pigments pigmented
3. Volume Solids 40% 40% 62% 65%

(approx.)
4. DFT (Dry Film 30-40 40-45 100-125 100-125

thickness) per
coat (approx.)
5. Theoretical 10-13 8-10 5-6 5.2-6.5

covering
capacity in
2
M /coat/litre
(approx.)
6. Weight per liter 1.3 1.2 1.4 1.5

in kg/liter
(approx)
7. Touch dry at 1 hr. 30 minutes 3 hrs. 4 hrs.

0
30 C (approx.)
8. Hard dry at Overnight 8 hrs. Overnight 48 hrs.

0
30 C (approx.)
9. Over coating Min : Overnight Min : Overnight Min : Overnight Min. : 24 hrs.
interval (12 hrs.) Max. : Unlimited Max : 5 days Max. : 5 days
(approx.) Max. : Unlimited
10. Pot life 6-8 hrs. Not applicable 4-6 hrs. 4-6 hrs.
(approx) at
0
30 C for two
component
paints (approx.)
Page 495 of 674

Sr. Description F-8 F-9 F-11 F-12

No.
1. Technical Name Self priming type Inorganic zinc Heat resistant Heat resistant silicone
surface tolerant silicate coating synthetic medium aluminum paint suitable
0 0
high build epoxy based on two pack upto 500 C / 550 C dry
coating (complete Aluminum paint temp.
rust control suitable upto
0
coating) 250 C dry temp.
2. Type and Two-pack epoxy A two pack air Heat resistant Single pack silicone resin
composition resin based drying self curing synthetic medium based medium with
suitable solvent based based two pack Aluminum flakes.
pigmented and inorganic zinc Aluminum paint
capable of silicate coating suitable upto
0
adhering to 250 C
manually
prepared surface
and old coating.
3. Volume Solids 72% 60% 25% 20%

(approx.)
4. DFT (Dry Film 100-125 65-75 20-25 20-25

thickness) per coat
(approx.)
5. Theoretical covering 6.0-7.2 8-9 10-12 8-10

capacity in
2
M /coat/litre
(approx.)
6. Weight per liter in 1.4 2.3 1.2 1.1

kg/liter (approx)
0
7. Touch dry at 30 C 3 hrs 30 minutes 3 hrs. 30 min
(approx.)
0
8. Hard dry at 30 C 24 hrs 12 hrs. 12 hrs. 24 hrs
(approx.)
9. Over coating interval Min : 10 hrs Min : 8 hrs at Min : 16 hrs Min. : 16 hrs
0
(approx.) Max. : 6 months 20 C & 50% RH Max : Unlimited Max. : Unlimited
Max. : Unlimited
10. Pot life (approx) at 90 min 4-6 hrs Not applicable Not applicable
0
30 C for two
component paints
(approx.)
0 0
11. Temperature - - 250 C 500 C
Resistance
Page 496 of 674

Sl. DESCRIPTION F-14 F-15 F-16

No
1 Technical name Polyamine cured Epoxy phenolic Ambient temperature curing Poly
coal tar epoxy coating Siloxane/ inorganic copolymer
based aluminium coating suitable
for under insulation coating of CS
and SS piping for high
temperature service
2 Type and Specially formulated Two pack ambient Amercoat 738 from Ameron
composition polyamine cured temperature curing Products, USA/ Berger 938 from
coal tar epoxy epoxy phenolic coating Berger Paints Ltd., Kolkata or
suitable for suitable for application Intertherm 751 CSA from Akzo
application under under insulation Nobel coating, Bangalore.
insulation
3 Volume Solids 70% 65% 60%

(approx.)
4 DFT (Dry Film 125 urn 75-100 urn 75-100 urn

thickness) per coat
(approx.)
5 Theoretical covering 5.5 6.5-8.5 6.0- 8.0

capacity in M2/ coat/
litre (approx.)
6 Weight per liter in 1.5 1.7 1.3
kg/ litre (approx.)
7 Touch dry at 30C 4hrs 2 hrs 1hr
(approx.)
8 Hard dry at 30C 168hrs(7days) 168 hrs (7 days) 12 hrs

(approx.)
9 Over coating Min. 6 hrs Min. 36 hrs Max. Min. 16 hrs Max. Not applicable
interval (approx.) Max.5 days 21 days
10 Pot life (approx.) at 4 hrs 1.5 hrs 1hr
30C for two
component paints
(approx.)
11 Temperature -45Cto150C under -45C to 150C under Up to 400 deg. C for CS & SS
Resistance insulation insulation surfaces under insulation
0 0
F-14 Specially formulated polyamide cured Coal-tar epoxy suitable for 45 C to 125 C for application
under insulation.
0 0
F-15 Two pack ambient temperature curing epoxy phenolic coating suitable for 45 C to 125 C for
application under insulation.
F-16A Engineered polysiloxane coating : Amercoat 738 from Ameron Products, USA
F-16B Engineered poly siloxane coating : Berger 938 from Berger Paints Ltd., Kolkatta
Page 497 of 674

NOTES
1 Covering capacity and DFT depends on method of application. Covering capacity specified above
are theoretical. Allowing the losses during application, min. specified DFT should be maintained.
2. All primers and finish coats should be ambient temperature curing and air drying unless otherwise
specified.
3. All paints shall be applied in accordance with manufacturers instructions for surface preparation,
intervals, curing and application. The surface preparation, quality and workmanship should be
ensured.
4. Technical data sheets for all paints shall be supplied at the time of submission of quotations.
6.4 List of recommended Manufacturers
The paints shall conform to the specifications given above and best quality in their products range of
manufacturers listed in Annexure-I.
Page 498 of 674

7.0 PAINT SYSTEMS
The paint system should vary with type of environment envisaged in and around the plants. Three
types of environment as given below are considered for selection of paint system. The paint system
is also given for specific requirements.
PRIMERS & FINISH COATS COVERED IN TABLE NOS. 7.0 TO 15.0
PRIMERS
P-2 : Chlorinated rubber zinc phosphate primer
P-4 : Etch primer / wash primer
P-6 : Epoxy zinc phosphate primer
Finish Coats / Paints
F-1 : First quality corrosion resistant synthetic enamel
F-2 : Acrylic Polyurethane finish paint
F-3 : Chlorinated rubber finish paint
F-6A : High build epoxy finish coating cured with polyamine hardner
F-6B : High Build epoxy finish coating cured with polyamide hardner
F-7 : High build coal tar epoxy coating
F-8 : Self priming surface tolerant high build epoxy coating
F-9 : Inorganic zinc silicate coating
F-11 : Heat resistant synthetic medium based aluminium paint
F-12 : Heat resistant silicone aluminium paint

0
F-14 : Specially formulated polyamine cured coal for epoxy coating suitable upto 150 C
F-15 : Epoxy phenolic coating
F-16A : Epoxy siloxane coating : Amercoat 738
F-16B : Epoxy siloxane coating Berger 938
Page 499 of 674

TABLE 7.1 : SHOP PRIMING, PRE-ERECTION / PRE-FABRICATION FOR STRUCTURES,

PIPING & EQUIPMENT ETC.
Materials : CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL,
STEEL
TYPE : UNINSULATED AND INSULATED
Sr. Design Surface Paint System Total DFT Remarks

0
No. Temperature in C Preparation in Microns
(min.)
7.1.1 -90 to 400 SSPC-SP-10 1 coat of F-9 65-75 No over coating is to be done
7.1.2 401 to 500 SSPC-SP-10 1 coat of F-12 40-50 Finish coat at site
TABLE 7.2 : REPAIR OF SHOP PRIMING, PRE-ERECTION / PRE-FABRICATION AFTER

ERECTION / WELDING FOR ITEMS IN ALL ENVIRONMENTS
Materials : CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL
Sr. Design Surface Preparation Paint System Total DFT in Remarks

No. Temperature Microns (min.)
0
in C
7.2.1 -90 to 400 SSPC-SP-3 (for repair only) 1 coat of F-9 65-75
SSPC-SP-10
7.2.2 401 to 500 SSPC-SP-3 (for repair only) 2 coats of F-12 40-50
SSPC-SP-10
TABLE 7.3 : REPAIR OF ALL WELD JOINTS AND DAMAGES FOR STRUCTURES, PIPING
AND EQUIPMENT AFTER ERECTION ON ABOVE GROUND OVERHEAD AREAS
AT SITE
Materials : GALVANIZED STEEL, CARBON STEEL AND ALLOY STEEL
Sr. Design Surface Preparation Paint System Total DFT in Remarks

No. Temperature Microns (min.)
0
in C
7.3.1 -14 to 80 SSPC-SP-3 1 coat of F-8 100
7.3.2 81 to 500 SSPC-SP-3 1 coat of F-12 20
Page 500 of 674

TABLE 8 : FIELD PAINT SYSTEM FOR NORMAL CORROSIVE ENVIRONMENT IN OFFSITE

AREAS FOR STRUCTURES, PIPING, EQUIPMENT, FLARE LINES ETC. -
UNINSULATED
TYPE : UNINSULATED
Sr. Design Surface Paint System Total DFT Remarks

No Temperat Preparation in Microns
. ure in 0C (min.)
Field Primer Finish paint
-90 to -15 SSPC-SP-10 Repair of None 65-75 No over coating to be

8.1 done. Follow repair
pre-fabrication
primer 1 coat of procedure only on
F-9 @ 65-75 damaged areas of
DFT/coat pre-erection / pre-
fabrication primer /
-14 to 60 SSPC-SP-10 Repair of 2 coats of F-3 225 Coating F-9 / F-12 shall
8.2
pre-fabrication @ 40 DFT/ be ambient
primer 1 coat of Coat 2x40=80 temperature curing
F-9 @ 65-75 type till operating
DFT/coat + 2 temperature is attained
coats of P-2 @ for full curing.
40 DFT/Coat
2x40=80
61 to 80 SSPC-SP-10 Repair of 1 coat of F- 245
8.3
pre-fabrication 6B@ 100
primer 1 coat of DFT/Coat
F-9 @ 65-75
DFT/coat + 2
coats of P-6 @
40 DFT/Coat
2x40=80
81 to 250 SSPC-SP-10 Repair of 3 coats of F-12 125
8.4
pre-fabrication @ 20 DFT/
primer 1 coat of Coat 3x20=60
F-9 @ 65-75
DFT/coat
8.5 251 to SSPC-SP-10 Repair of 2 coats of F-12 105
400 pre-fabrication @ 20 DFT/
primer 1 coat of Coat 2x20=40
F-9 @ 65-75
DFT/coat
8.6 401 to SSPC-SP-10 Repair as per 2 coats of F-12 80
500 7.2.2. @ 20 DFT /
Coat 2x20=40
NOTE 1 : For external surfaces of MS chimney with or without refractory lining 8.3, 8.4 and 8.5 shall
be followed.
NOTE 2 : For external surfaces of RCC chimney: 2 coats of F-6B @ 100 DFT/Coat to obtain
2x100=200 DFT shall be applied after making surface preparation as per guidelines in
5.1.5. The DFT on concrete surfaces can be checked by Tool Gauge or by applying the
same coating system simultaneously on a carbon steel panel of 12"x12" size and measure
the DFT by normal Magnetic gauges/digital electronic gauges for ferrous surfaces.
Page 501 of 674

NOTE 3 : Wherever required S.No.8.3 shall be used for -14C to 80C and S.No.8.2 will be deleted.
TABLE 8 A : FIELD PAINT SYSTEM FOR CORROSIVE ENVIRONMENT IN PLANT AREA

Surface : Un-insulated
Note :
For all corrosive areas above ground where H2S, SO2 fumes or spillages of
acid/Alkali/Salt are likely to come in contact with surfaces such as external surfaces of
un-insulated columns, vessels, heat exchangers, blowers, piping, pumps, towers,
compressors, and structural steel etc.
Sl. Design Surface Paint System Total Remarks
No. Temperature Preparation DFT in
in C Microns
(min.)
Field Primer Finish Paint
9.1 -90 to -15 SSPC-SP-10 Repair of pre- None 65-75 Repair of pre-erection /
fabrication primer pre-fabrication primer shall
1 coat of F-9 @ be done wherever damage
65-75 DFT/coat is observed.
9.2 -14 to 80 SSPC-SP-10 Repair of pre- 1 coat of F- 245
fabrication primer 6A@ 100
1 coat of F-9 @ DFT/coat +
65-75 DFT/coat 1 coatofF-2
+ 1 coats of P-6 @40u
@ 40 DFT/coat DFT/coat.
9.3 81 to 400 SSPC-SP-10 Repair of pre- 2 coats of 105

fabrication primer F-12@20
1 coat of F-9 @ DFT/coat
65-75 DFT/coat 2x20=40
9.4 401 to 500 SSPC-SP-10 Repair as per 2 coats of 80
7.2.2. F-12@20
DFT/coat
2x20=40
Page 502 of 674

TABLE 9 : FIELD PAINT SYSTEM FOR HIGHLY CORROSIVE AREAS IN PLANT AREA
EXTERNAL SURFACES OF UNINSULATED COLUMNS, VESSELS, HEAT
EXCHANGERS, BLOWERS, PIPING, PUMPS, TOWERS, COMPRESSORS,
STRUCTURAL STEEL ETC.
Surface : Un-insulated
Note : Exposed to spillage or fumes of HCL, H2SO4, salty water, water impingement,
chloride etc
Sl. Design Surface Paint System Total DFT Remarks
No. Temperature Preparation In
inC Microns
(min.)
10.1 -90 to -15 SSPC-SP-10 Repair of pre- None 65-75 Repair procedure of
fabrication primer pre-erection/fabri
1c o at of F- 9 @ cation primer shall be
65-75u DFT/coat followed. No
overcoating is
allowed.
Surface preparation is
required only for
repairing of damaged
pre-erection/
fabrication primer.
10.2 -14 to 80 SSPC-SP-10 Repair of pre- 2 coats of F- 345

fabrication primer 6A @ lOOu
1c o at of F- 9 @ 65-DFT/Coat =
75u DFT/coat + 1 2x100=200 +
coats of P-6@ 40u 1coatofF-2
DFT/Coat @40u
DFT/coat.
10.3 81 to 400 SSPC-SP-10 Repair of pre- 2 coats of F- 105
fabrication primer 12@20u
1c o at of F- 9 @ DFT/Coat
65-75u DFT/coat 2x20=40
10.4 401 to 500 SSPC-SP-10 Repair as per 7.2.2. 2 coats of F- 80
12@20u
DFT/Coat
2x20=40
Page 503 of 674

TABLE 10 : PAINTING UNDER INSULATION FOR INSULATED (HOT, COLD & SAFETY) PIPING,
STORAGE TANKS AND EQUIPMENTS IN ALL ENVIRONMENT
Materials : CARBON STEEL, LOW ALLOY STEEL, LOW TEMPERATURE CARBON STEEL &
STAINLESS STEEL
Surface : Insulated
Paint System
Sr. Design Surface Field Primer Finish paint Total Remarks
No. Temperatur Preparation DFT in
0
e in C Microns
(min.)
9.1 Insulated carbon steel, low alloy steel and LTCS piping and equipment and tanks
9.1.1 -45 to 125 SSPC-SP-10 Repair of pre- 2 coats of F-14 315

fabrication primer @ 125 For other temperature
F-9 @ 65-75 DFT/coat = ranges no painting is
DFT. 2x125=250 OR 3 required under insulation
coats of F-15 =
3x80=240
9.1.2 Operating SSPC-SP-10 Repair of pre- 2 coats of F-12 105-115

temperature fabrication primer @ 20 DFT /
45 to F-9 @ 65-75 coat = 3x20 = 60
0
125 C but DFT.
design
temperature
0
126-400 C
9.2 Insulated stainless steel including Alloy-20 piping
9.2.1 Below 00C Aluminium sheeting with aluminium foil and Chloride free mineral If the piping &
to all minus sealant coating barium chromate shall be applied. equipments are already
temperature erected then surface
shall be prepared by
cleaning with emery
9.2.2 0 to 120 SSPC-SP-10 None 2 coats of F-14 @ 250 or
paper and wash / flush
(15-25 surface 125 DFT / coat 240
with chloride free DM
profile) = 2x125 = 250 or 3
water followed by wiping
coats of F-15 =
with organic solvent.
3x80=240
All the coating materials
9.2.3 121 to 400 SSPC-SP-10 None 3 coats of F-12 60 for SS shall be free from
@20 DFT /Coat = leachable chlorides.
3x20=60 or 1 coat
of Poly siloxane or
coating (F-16 A/B)
@ 75 microns
DFT/coat
9.2.4 401 to 600 SSPC-SP-10 None 2 coats of heat 40

resistant silicone
aluminium paint @
20 microns DFT /
coat = 2x20=40
9.3 No painting is required for insulated Monel, Incoloy and Nickel lines
Page 504 of 674

Page 505 of 674

Page 506 of 674

Page 507 of 674

TABLE 12.0 COATING SYSTEM FOR EXTERNAL SIDE OF UNDERGROUND CARBON STEEL
PLANT PIPING AND TANKS
Sl. Design Surface Paint System Total Remarks

No. Temp. C Preparation DFT in
(min.)
12.1 Carbon steel plant piping (underground)

12.1.1 Yard coating
12.1.1.1 25 to 60 SSPC-SP-10 1 coat of 4 mm thick 4 mm CTE coating shall confirm
synthetic fast coaltar to 120/5 as per BS:4164
drying primer coating
type-B as per wrapping as
AWWA-C-203 per AWWA-
(1991) C-203 in 2
layers of
each 2 mm
thickness.
12.1.2 Over the Ditch Coating
12.1.2.1 25 to 60 SSPC-SP-10 1 coat of 2 layers of 4 mm
synthetic fast coal tar
drying primer based tape
type-B as per coating
AWWA-C-203
(1991)
12.2 Carbon plant piping (underground).

12.2.1 61 to 225 SSPC-SP-10 1CoatofF-15@ 75 2 Coat of F- 225 Cold and hot insulation
DFT/coat 15 @ 75 shall be provided
DFT/coat
12.2.2 221 to 400 SSPC-SP-10 1CoatofF-16@ 75 1 Coat of F- 175 Cold and hot insulation
DFT/coat 16@ 100 shall be provided
DFT/coat
12.3 External side of un-insulated underground storage tanks:

12.3.1 -40 to 80 SSPC-SP-10 1CoatofF-9@ 65- 3 coats of 365
75 DFT/coat F-7 @100
DFT/coat
3x100=300
12.3.2 81 to 180 SSPC-SP-10 1CoatofF-15@ 75 2 Coat of F- 225
DFT/coat 15 @ 75u
DFT/coat
12.3.3. 181 to 400 SSPC-SP-10 1CoatofF-9@ 65- 2 Coat of F- 215-225
75 DFT/coat 16 @ 75
DFT/coat
2x75=150
Note: No Coating and Wrapping systems are available for underground high temperature services
Page 508 of 674

TABLE 13.0 PAINTING UNDER INSULATION FOR INSULATED (HOT, COLD & SAFETY) CARBON
STEEL, LOW ALLOY STEEL, LOW TEMPERTURE CARBON STEEL & STAINLESS STEEL
PIPING, STORAGE TANKS AND EQUIPMENTS IN ALL ENVIRONMENT.
Sl. Design Surface Paint system Total

No. Temp. C Preparation DFT in
(min.)
Primer Finish Paint
13.1 Insulated carbon steel, low alloy steel and LTCS piping and equipment & tanks
13.1.1 -45 to 125 SSPC-SP-10 Repair of 2 coats of F- 315 For other temperature ranges no
pre- 14 @125 painting is required under
fabricatio DFT/coat = insulation F-12 shall be ambient
n primer 2x125=250 temperature curing type till
F-9 @ 65- OR 3 coats of operating temperature is attained
75 DFT. F-15= for full curing. F-16 is completely
3x80=240 ambient temperature curing.
13.1.2 Operating SSPC-SP-10 Repair of 2 Coats of 125-135
temperature pre- F-12 @20
-45 to 125C fabricatio DFT/coat
but design n primer 3x20=60 (or)
temperature F-9 one coat of
126-400C @65-75 Poly-siloxane
DFT coating @ 75
DFT/coat
13.2 Insulated stainless steel including Alloy-20 piping

13.2.1 Below 0C to Aluminum sheeting with aluminum foil and If the piping & equipments are
all minus "Chloride free mineral sealant coating barium already erected than surface
temp. chromate" shall be applied. shall be prepared by cleaning with
emery paper and wash/flush with
chloride free DM water followed
by wiping with organic solvent. No
pre-erection primer to be applied.
F-12 shall be ambient temp
curing type till final curing is
obtained during operating temp.
F-16 is completely ambient temp
curing type.
13.2.2 0 to 120 SSPC-SP-10 None 2 coats of F- 250

(15-25 14@125 or
surface DFT/COAT 240
profile) 2x125=250 or
3 coats of F-15
= 3x80=240
Page 509 of 674

13.2.3 121 to 400 SSPC-SP-10 None 3 coats of F- 60-75

12@20
DFT/COAT
3x20=60 or 1
coat of F-16 Poly
Siloxane coating
@ 75 microns
DFT/coat
13.2.4 401 to 600 SSPC-SP-10 3coatsofF-12@ 60
20 DFT/coat 60
13.2.5 Cyclic SSPC-SP-10 None 2 coats of DFT/coat 150

service-196 F-16 Poly
to 480 Siloxane coating
excepting - @ 75 DFT/coat
45 to 120 = 2x75=150
13.3 No painting is required for insulated Monel, Incoloy and Nickel lines.
Page 510 of 674

TABLE 14.0 INTERNAL PROTECTION OF CARBON STEEL WATER BOXES AND TUBE SHEETS OF
COOLERS / CONDENSERS
Water boxes, channels, partition plates, end covers and tube sheets etc.
Sl. Design Surface Paint system Total DFT Remarks

No. Temperature Preparation in Microns
inC (min.)
Primer Finish paint
14.1 Upto 80 SSPC-SP-10 1 coat of P-6 @ 2 coats of F-7 290 For C.S.
40 DFT/coat @125
DFT/coat
2x125=250
14.2 Upto 80 Non SSPC-SP-3 1coatofP-4@ 8-1 2 coats of F-7 300 For non ferrous
ferrous and On DFT/coat. @125 surfaces
brass tube 1coat of P-6 @ DFT/coat
sheets 40 DFT/coat. 2x125=250
TABLE 15.0 FIELD PAINTING SYSTEM FOR GI TOWERS/NON-FERROUS TUBE SHEET
Sl. Design Surface Paint System Total DFT Remarks

No. Temperature Preparation in Microns
inC (min.)
Primer Finish Paint
15.1 Upto 80 SSPS-SP-3 1 coat of P-4 @ 2 coats of F-2 130 Shade as per
8-10 DFT/coat @40 defence
+ 1 coat of P-6 @ DFT/coat Requirements.
40u DFT/coat 2x40=80
15.2 Upto 80 Non SSPS-SP-3 lcoatofP-4@8u 2 coats of F-7 300

ferrous and DFT/coat @125
brass tube 1coat of P-6 @ DFT/coat
sheets 40u DFT/coat 2x125=250
Page 511 of 674

TABLE 16.0 SHOP & FIELD PAINTING SYSTEM FOR EFFLUENT TREATMENT PLANT
Sl. Design Temp. C Surface Paint System Total DFT Remarks

No. Preparation in Microns
(min.)
Primer Finish Paint
16.1 -14 to 80(for SSPS-SP-10 1 3 coats of F- 365
C.S./M.S. items): coatofF-9 6A @100u
Screens, Walk way @ 65-75u DFT/coat
bridges, Baffles, Dual DFT/coat 3x100=300
media filters
(external) Vertical
pumps, piping in
treated effluent sump
and pump house,
external side lining of
Slop oil MS tank
16.2 -14 to 80(CS/MS SSPS-SP-10 1 2 coats of F- 265

Items) for Vertical coatofF-9 6A @100u
pump and piping in, @ 65-75u DFT/coat
Bio-sludge sump and DFT/coat.
pump, Filter feed
sump and pump,
Process sump,
Sanitary sump;
Transfer sump,
Sludge, MS Slop oil
tank internal,
scrapping
mechanism in
Clarifier, Screw pump
16.3 -14 to 80 deg.C :All Blast cleaning Epoxy Epoxy 3mm Epoxy screed lining
R.C.C. surfaces such t o SSPC- SP screed screed shall be used as per
as tanks, structures, guide lines and lining lining specific instructions
drains etc.) in Acid etching from Engineer-in-
Process sump, TPI with 10-15% Charge at site.
HCl acid
separator (Process
followed by
and Oil), Aeration thorough water
Tank, Transfer sump washing.
etc.
16.4 U p t o 6 0 d e g . C SSPC-SP-10 Rubber 4.5mm
C.S/M.S Dual media Lining
filters (Internal),
Chemical dosing
tanks(internal such
as DAP, Urea)
Page 512 of 674

17.0 STORAGE
1 All paints and painting materials shall be stored only in rooms to be arranged by
contractor and approved by Engineer-in-charge for the purpose. All necessary precautions
shall be taken to prevent fire. The storage building shall preferably be separate from adjacent
building. A signboard bearing the word "PAINT STORAGE - NO NAKED LIGHT - HIGHLY
INFLAMABLE" shall be clearly displayed outside.
18.0 PIPING COLOR CODE
The color code shall be followed as given in Annexure-II.
19.0 IDENTIFICATION OF VESSELS, PIPING ETC.: As per color coding given in

Annexure-II
20.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS
20.1 Following items shall be painted for camouflaging if required by the client.
a. All columns
b. All tanks in off sites
c. Large Vessels
d. Spheres
20.2 Two coats of selected finishing paint as per defence requirement shall be applied in a
particular pattern as per 20.3 and as per the instructions of Engineer-In-Charge.
20.3 Method of Camouflaging
20.3.1 Disruptive painting for camouflaging shall be done in three colors in the ratio
of
5:3:2 (all matt finish).
Dark Green Light Green Dark Medium Brown

5: 3: 2
20.3.2 The patches should be asymetrical and irregular.
20.3.3 The patches should be inclined at 30 Deg.. to 60 Deg. to the horizontal.

20.3.4 The patches should be continuous where two surfaces meet at an angle.
20.3.5 The patches should not coincide with corners.
20.3.6 Slits and holes shall be painted in dark shades.
20.3.7 Width of patches should be 1 to 2 meters.
21.1 All painting materials including primers and thinners brought to site by contractor for
application shall be procured directly from manufactures as per specifications and
shall be accompanied by manufacturer's test certificates. Paint formulations without
certificates are not acceptable.
21.2 Engineer-In-Charge at his discretion may call for tests for paint formulations. Contractor
shall arrange to have such tests performed including batch-wise test of wet paints for
physical & chemical analysis. All costs there shall be borne by the contractor.
Page 513 of 674

21.3 The painting work shall be subject to inspection by Engineer-In-Charge at all times. In
particular, following stage-wise inspection will be performed and contractor shall offer the
work for inspection and approval of every stage before proceeding with the next stage. The
record of inspection shall be maintained in the registers. Stages of inspection are as
follows:
(a) Surface preparation

(b) Primer application
(c) Each coat of paint
In addition to above, record should include type of shop primer already applied on equipment
e.g. Red oxide zinc chromate or zinc chromate or Red lead primer etc.
Any defect noticed during the various stages of inspection shall be rectified by the contractor
to the entire satisfaction of Engineer-In-Charge before proceeding further. Irrespective of the
inspection, repair and approval at intermediate stages of work, contractor shall be
responsible for making good any defects found during final inspection/guarantee
period/defect liability period as defined in general condition of contract. Dry film thickness (D
F T)) shall be checked and recorded after application of each coat and extra coat of paint
should be applied to make-up the DFT specified without any extra cost to owner, the extra
cost should have prior approval of Engineer-in-charge.
21.4 Primer Application
After surface preparation, the primer should be applied to cover the crevices, corners, sharp
edges etc. in the presence of inspector nominated by Engineer-In-Charge.
21.4.1 The shades of successive coats should be slightly different in color in order to ensure
application of individual coats, the thickness of each coat and complete coverage should
be checked as per provision of this specification. This should be approved by
Engineer-In-Charge before application of successive coats.
21.4.2 The contractor shall provide standard thickness measurement instrument with appropriate
range(s) for measuring.
Dry film thickness of each coat, surface profile gauge for checking of surface profile in case
of sand blasting. Holiday detectors and pinhole detector and protector whenever required
for checking in case of immersion conditions.
21.4.2 Prior to application of paints on surfaces of chimneys, the thickness of the individual coat
shall be checked by application of each coat of same paint on M.S.test panel. The
thickness of paint on test panels shall be determined by using gauge such as
'Elkometer'. The thickness of each coat shall be checked as per provision of this
specification. This shall be approved by Engineer-In-Charge before application of paints on
surface of chimney.
21.4.3 At the discretion of Engineer-In-Charge, the paint manufacturer must provide the expert
technical service at site as and when required. This service should be free of cost and
without any obligation to the owner, as it would be in the interest of the manufacturer to
ensure that both surface preparation and application are carried out as per their
recommendations.
21.4.4 Final inspection shall include measurement of paint dry film thickness, Adhesion, Holiday
detection check of finish and workmanship. The thickness should be measured at as
many points/ locations as decided by Engineer-In-Charge and shall be within + 10% of the
dry film thickness, specified in the specifications.
Page 514 of 674

21.4.5 The contractor shall arrange for spot checking of paint materials for Sp.gr., glow time (ford
cup) and spreading rate.
22.0 GUARANTEE
22.1 The contractor shall guarantee that the chemical and physical properties of paint
materials used are in accordance with the specifications contained herein/to be
provided during execution of work.
22.2 The contractor shall produce test reports from manufacturer regarding the quality of the
particular batch of paint supplied. The Engineer-in-Charge shall have the right to test wet
samples of paint at random for quality of same, as per the paint materials specification.
Batch test reports of the manufacturer's for each batch of paints supplied shall be
made available by the contractor. The contractor shall stand guarantee for carrying
out the rectification/repair/re-painting of the defects/ failures of painting found during the
execution of painting job and till the expiry of the defect liability period of total project as
per the directions of the Engineer-in-Charge of CPCL/JE
23.0 QUALIFICATION CRITERIA OF PAINTING CONTRACTOR
Painting contractor who is awarded the job under this standard must have necessary
equipments, machinery, tools and tackles for surface preparation, paint application and
inspection. The contractor mush have qualified, trained and experienced surface
preparator, paint applicator, inspector and supervisors. The contractor's supervisor,
inspector, surface preparator and paint applicator must be conversant with the
standards referred in this specification. The painting job shall be carried out by the approved
agencies of paint manufacturers and supervised by the approved paint manufacturers own
representative or paint manufacturer their scheme( supply and apply basis).
Page 515 of 674

ANNEXURE-I
LIST OF RECOMMENDED MANUFACTURERS
Indian Vendors
1. Asian Paints (I) Ltd., Mumbai

2. Berger Paints Ltd., Kolkata
3. Goodlass Nerolac Paints Ltd., Mumbai
4. Chemguard Coatings, Mumbai(For Ameron, USA Products only)
5. Chokugu Marine paints Pte. Ltd., Mumbai/Singapore
6. Shalimar Paints Ltd., Kolkata
7. Sigma Coatings, Mumbai.
8. CDC Carboline Ltd., Chennai
9. Premier products Ltd., Mumbai
10. Coromandel Paints & Chemicals Ltd., Visakhapatnam
11. Anupam Enterprises, Kolkata
12. Grand Polycoats, Vadodata
13. Bombay Paints Ltd., Mumbai
14. Akzo Nobel Coatings and Sealants Pvt. Ltd., Bangalore
15. Cipy Polyurethanes Pvt. Ltd., Pune
16. Gunjan Paints Ltd., Ahmedabad
17. Advance Paints Ltd., Mumbai
18. VCM Polyurethane Paints (for polyurethane paints only)
19. Jotun Paints, Chennai(Singapore)
20. Chembond Chemicals Ltd., Navi Mumbai
Foreign Vendors
1. Sigma Coatings, Singapore

2. Ameron, USA
3. Kansai Paints, Japan
4. Hempel Paints, USA
5. Valspar Corporation, USA
6. Akzo Nobel/International Coatings, UK
7. Jotun Paints, Singapore
For De-humidification equipment (on Rental Basis)
1. Technical Drying Equipment (Asia) Pvt. Limited, Gurgaon, Haryana
The following are approved vendors for speciality items (phosphating chemical) only.
1. Mark-chem Incorporated, Mumbai.
2. Chemtreat India Ltd., Navi Mumbai
Page 516 of 674

Annexure-II
Paint Color Code for Piping & Equipment given by CPCL Document No. 00-ES-100-004, Rev. 5
dated 24/12/2006 to Specification No.6782-0642-PT-L06 Rev.2
This section of the standard deals with the color coding to he given to in service piping for easy
identification bused on the liqui d contained in the line.
1. Where ever paint is required for piping external surfaces, the finish coat color shall be as follows
except for paragraph 2, Type of paint, surface preparation. DFT etc. shall he as per the
painting specification.
a) 1 lent resistant paint - Alum inn in

b) Other grades of paint - White or Al. in Color
Insulated and austenitic stainless steel lines will he having only color coding for fluid
discrimination as given in 3 below.
2. Fire water lines shall he painted " Red '" as per IS 536 through out the line.
3. All lines, in general, shall he provided with discrimination color coding mark over the final coat or
on the cladding / jacketing surface of insulated piping as mentioned in 1 above . as
well as on the surfaces on which any paint is not provided. The color coding shall be as per the
attachment to this standard and in the following manner. Color codes on Austenitic SS lines should
he done only wit chloride free paint suitable for application on stainless steel surfaces.
As far as possible, paint used for color bands should he of the same specification as the finish
coat. If for some reason a deviation is required for this, then enamel paint can be used over finish
coat after taking approval from the engineer In - Charge'
3.1 The system of color coding shall consist o f a primary identification color band and other color
hand (s) superimposed on the primary band. All the bands shall be painted circumferential!;
around the line.
The primary color hand identifies the basic nature of the fluid carried in the line. The second and
the third color hands will identify the exact fluid carried in the line. The various primary color
bands included in t h i s standard are explained below:
Basic fluid Color of primary band
Water Sea Green

Steam Signal Red
Air Sky Blue
Gases Canary Yellow
Acids and acid producing, gases Dark Violet
Hydrocarbons Dark Grey
Alkalies Light Brown
Chemicals Light Orange
No identification required Black
Page 517 of 674

3.2 Painting of color bands
3.2.1 Primary colorblind / color band ( s ) (see Fig I) arc required to be located at
- battery limit points

- intersection points in the piping system
- start and terminal points
- at spec i lied intervals as given below
- specific points on the l i n e as directed by the "Engineer - In - Charge "
3.2.2 Primary color band shall he intermittently coated along respective lines with primary color
bands of 2V1 length with the following maximum center to center distance between two
adjacent color bands.
15 M for lines with in battery limits of respective units

50 M for lines on interconnecting pipe rack and in lower plateau
Center to center distances at lesser intervals may be given. if" so desired by unit head.
3.2.3 Sizing of II &. Ill color bund (s)
Size II color band I I I Color band

3" and below 100 mm 50 mm
> 3" upto ft" 200 mm 100 mm

> 6" upto 12" 300 mm 150 mm
> 12" 400 mm 200 mm
Page 518 of 674

SR CONTENTS Primary II Color Band 111 Color

NO Color Band Band
1 ALL KINDS OF WATER

Drinking water Sea green French Blue Signal rod
De-mineralized water Sea green Light Orange
Cooling water Sea green French blue
Boiler feed water Sea green Gulf Red
Condensate Sea green Light Brown
Quench water Sea green Dark grey Signal rod
Wash water Sea green Canary Yellow
Process water Sea green Light grey
Raw water ( from river } Sea green
Page 519 of 674

Fire water ( Full color, not band ) Fire red

2 STEAM
Very high pressure steam Signal Red Silver Grey
High pros sure steam Signal Red French Blue
Medium Pressure steam Signal Red Gulf Red
Low Pressure steam Signal Red Canary Yellow
Dilution steam/ Purge steam Signal Red Silver Grey Canary Yellow
3 AIR
Plant Air Sky Blue Silver Grey
Instrument Air Sky Blue French Blue
Process air ( ex: bitumen, Sky Blue Signal Red
Mereox)
Combustion air Sky Blue Canary Yellow

4 GASES
Hydrogen Canary Yellow Signal red French Blue
Nitrogen Canary Yellow Black
Flare gas Canary Yellow
Hydrogen sulfide/ Acid gas Canary Yellow Gulf Red
Fuel gas Canary Yellow Light Brown While
Regeneration gas Canary Yellow While Dark Violet
LPG (as gas) Canary Yellow Brilliant Green While
Propane ( as gas ) Canary Yellow Signal Red Black
Sulfur Dioxide Dark Violet Brilliant Green
Ammonia Dark Violet
Chlorine Dark Violet Signal Red
HCN Dark Violet Trench Blue
5 AC IDS
Sulfuric Acid Dark Violet Brilliant Green Light Orange

Nitric Acid Dark Violet French Blue Light Orange
1 Hydrochloric Acid Dark Violet Signal Red Light Orange
Acetic acid Dark Violet Silver Grey
6 LIQUID HYDROCARBONS
LPG ( as liquid ) Dark Grey Brilliant Green While

Naphtha. Dark Grey Brilliant Green
MS Dark Grey Sky Blue
Reformate Dark Grey While
SKO Dark Grey Light Brown
ATF Dark Grey Light Brown Sky Blue
USD Dark Grey Light Orange
FO Dark Grey Signal Red
LSHS / Low Sulfur fuel Dark Grey Signal Red Black
Bitumen Dark Grey Black
Page 520 of 674

Other Hydrocarbons not defined Dark Grey

Above
Crude Dark Grey Canary Yellow
7 ALKALIES Light Brown

8 CHEMICALS-GENERAL Light Orange
Sulfur Light Orange Black
9 All other items which do no Black

require individual identification
Surface Part Color Remarks

Tanks A.C. Grey
Spheres White
Vessels, drums, heat exchangers D.A. Grey
etc.
Furnace casing Silver
Machinery - Pumps. Silver
Compressors, blowers etc)
Steam Turbine Silver
Generator' Mfr. Std.
Motor Light grey ISC 631
Packaged dosing system Mfrs. Std
DG Set Mfrs. Std
Cable duct Silver
Instrument Panel
Instrument Panel including DCS Indoor
Cabinet Front Opaque Beige With leather lone
Other Neutral Grey With leather lone
sides Neutral Grey
Inside
Control Valve
C:S Body Light grey ISC 631
SS Body No paint
Low alloy body Canary Yellow ISC 309
Control Valve Actuators
Normally Brilliant Green ISC 221
Closed
Normally Open Signal Red \SC 537
Instruments. Transmitters Mfrs Sid
Page 521 of 674

Sr. No. Content Final Color ISC

No:
1 Gantry girder and monorail Brilliant Green 221
2 Stopper for gantry girder and monorail Signal Red 537
3 Pipe rack structural steel and trestle including that Dark Admiralty Grey 632
for equipment and platform
4 Chequered Plates Dark Admiralty Grey 632
Ladder rungs, verticals and cage Canary Yellow 309
6 Hand railing. middle rail, toe pi ale and Canary Yellow 309
vertical post
7 Platforms : Structural sled parts other Dark Admiralty Grey 632
than grating and hand railing
8 Staircase : Structural steel parts other Dark Admiralty Grey 632
than hand railing and steps using galvanized
9 Safety Gate Signal Red 537

10 Miscellaneous Structural Part Dark Admiralty Grey 632
Notes : 1) Wherever Dark Admiralty Grey is not available due to the nature of the final coat of
paint ( eg: Coal Tar epoxy in high H2S environments ) . Black can be used.
2) Canary Yellow for ladders etc. has been selected for visibility.
1. Equipment number shall be stenciled in black (after initial painting if any) on each vessel,
column, equipment, machinery till a visible location as directed by the "Engineer - in -
charge "'
Size of letters is as below:
Column, vessel. exchanger, other stationary equipment : 150 mm height
Pump. Compressor and other machinery including : 50 mm height HT

motors
Rotating equipment shall have tin arrow showing the direction of rotation painted on the
equipment.
In case of small auxiliary equipment in packaged unit, separate identification by stenciling is

not required as long as name plate or tag bearing item number is duly attached to the aux.
equipment.
2. Line number, service, source and destination shall be stenciled in black on respective
pipe lines at
start and terminating points of line next to the color code
battery limit points next to the color code,
Page 522 of 674

Additional stenciling of line numbers and service will be required and shall be provided on
the lines at the direction of Engineer- In - Charge"
Sizing of letters shall be :
OD of pipe Height of letters
80- 150 mm 40 mm
150-250 mm 60 mm
> 250 mm 90 mm
Auxiliary piping in packaged units or on base plates of pumps / compressors wilh in the
scope of vendors do not need numbering at site.
However, an auxiliary line with operational significance (where it is referenced specifically in

the operation manual by a line number) shall he provided with a number by stenciling hi-
other suitable means.
3. The following details are to he painted on the Lank shell in black color, letter size 50 mm
high, at the entrance point of the staircase.
Tank number
Reference height
Stile filling height
Critical /one ( in ease of floating roof tanks only )
Dale of commissioning
Date of last cleaning
4. The following details are to be painted on the tank shell near the top landing platform of the
staircase, in letter size 50 mm high, black color.
Reference height
Sale filling height
Critical zone ( in case of floating roof tanks only )
5. The following details shall he painted on the kink at 2!3 the height of the tank at a
location facing the road, from where normal approach lo the Tank is provided. In addition,
the same details shall be provided on two additional points in the lank 120 degrees apart.
Tank number
Capacity
Service.
The size of the above lettering shall be 500 mm for 20 M high tanks and 300 mm for
smaller tanks.
DGCA requirements for a l l shall be followed in addition to the above.
Page 523 of 674

1.0 The part of the standard covers the method of identification of STORED piping material by
color coding. This standard is applicable to storage during project Stage as well.
2.0 General guide lines of identification by color coding:
a) Piping shall be painted with one color or a combination of two color as
enclosed.
b) Color identification is not required on galvanized material and mm ferrous
material such as Copper. Aluminum etc. because of their peculiar color and
Page 524 of 674

Jacobs
character
e) Special items l i k e bellow, strainers, steam Imps etc. should be lagged and hence do
mil require color identification.
d) Color identification of Austenitic Stainless Steel is not desirable due to r i s k
of contamination from paint material.
e) Ends of piping to be welded shall not be painted. The color band shall start
2" from the pipe ends.
f) Width of color strips shall be 25 mm for .V nominal pipe dia and above. Secondary
color strip where required, shall be half the size of primary strips. For less than 3" size
color strip shall be 12 mm < 1/2") or maximum practical.
Carbon Steels
API 5L Gr B Pink Seamless

API 5L Gr B Pink / White Welded
A 106 Gr B Red [BR
A 106 Gr B Yellow Non IBR
Welded and seamless fittings Red IBR
Welded and seamless fittings Yellow Non IBR
Welded fittings Yellow / White Normalized
Miters Silver
Class 22 fittings Silver / Pink Stress relieved at s h o p
IS 3589- IS 12239 No Paint Non critical
Alloy Steels
P1, F1. WP1, WP1W etc. Green / Red
P12, F12, W12 etc Green / Yellow
P22, F22, WP22. etc Green / Silver
P11, F11, WP11 etc. Green / Orange
P5, F5, WP5 etc. Green / Blue
P9, F9, WR9 etc. Green / Pink
Page 525 of 674

Jacobs
Color ( In alphabetical order ) ISC No:

Black
Brilliant Green 221

Canary Yellow 309
Dark Grey 632
Dark Violet 796
Fire Red 536
French Blue 166
Golden Yellow 356
Gulf Red 473
Jasmine Yellow 397
Light Brown 410
Light Grey 631
Light Orange 557
Sea Green 217
Signal Red 537
Silver 110
Silver Grey 628
Sky Blue 101
White -
Page 526 of 674

SCOPE OF WORK & JOB DOCUMENT No.
SPECIFICATION FOR A133-086-16-50-SP-4140 Rev A
COKE DRUM STRUCTURAL
SCOPE OF WORK & JOB SPECIFICATION

(ELECTRICAL)
FOR
COKE DRUM STRUCTURAL ELEVATOR (LIFT)
(MR No. A133-086-LZ-MR-4140 Rev A)

JOB NO. : A133
A 16.09.13 Issued with MR VB ANPS SA

Rev.
Date Purpose Prepared by Checked by Approved by
No
Page 527 of 674
SPECIFICATION FOR
A133-086-16-50-SP-4140 Rev A
CONTENTS
S. NO. DESCRIPTION
1.0 GENERAL
2.0 SITE CONDITIONS
3.0 UTILITY POWER SUPPLY
4.0 BRIEF DESCRIPTION OF ELECTRICAL SYSTEM
5.0 SCOPE OF WORK
6.0 AREA CLASSIFICATION
7.0 GENERAL REQUIREMENTS
8.0 EXCLUSIONS
9.0 MAKE OF EQUIPMENT/COMPONENTS
10.0 LIST OF ATTACHMENTS
Page 528 of 674
SPECIFICATION FOR
A133-086-16-50-SP-4140 Rev A
1.0 GENERAL
This specification defines the scope of work and the minimum basic requirement for electrical
system design, engineering, equipment selection, sizing, procurement, testing at manufacturer
works, supply, erection, testing and commissioning of electrical system including supply of
mandatory spares, commissioning spares for Coke Drum Structure Elevator (Lift) Package
system for DCU Project of M/s CPCL at CPCL Refinery, Manali, Tamilnadu.
2.0 SITE CONDITIONS

Maximum Ambient Temp. : 450C
Minimum Ambient Temp. : 180C
Relative Humidity : 80% at tmax
Equipment Design Temp. : 450C
For other site conditions, refer elsewhere in the MR.
3.0 UTILITY POWER SUPPLY
3.1 System Conditions

Supply voltage : 415 V 10%
Frequency : 50Hz 5%
Combined Voltage & Freq. variation : 10%
System fault level (415 V) : 50 kA (1 sec.)
System earthing (415 V) : Solidly earthed
3.2 Utilization Voltages

The rated voltage for various electrical equipments shall be chosen by the bidder as given
below:
Purpose Voltage Rated Value

Motors up to and including 160kW 415 V AC, 3 Phase
Anti-condensation heaters 240 V AC, 1 Phase
Normal/Emergency Lighting 240 V AC, 1Phase
AC Lighting/power panels 415 V AC, 3 Phase
4.0 BRIEF DESCRIPTION OF ELECTRICAL SYSTEM

4.1 Bidder shall provide PDB with two incomers and outgoing feeders for feeding all electrical
loads of the package. Owner will provide power supply at both the incomers of bidders
PDB, including supply, laying, and termination of power cable up to bidders PDB.
4.2 The system shall be complete in all respects with required interlocks, for the desired
sequence of operation and controls, selections, indications and alarms etc.
5.0 SCOPE OF WORK

Bidder's scope includes detail engineering, equipment sizing, selection, procurement, supply,
erection, testing, commissioning and handing over to M/s EIL / M/s CPCL the complete
electrical system of Coke Drum Structure Elevator (Lift) Package.
5.1 System design and detail engineering:

Bidder shall perform the design and detail engineering activities including but not limited to
following:
a. Preparation of electrical load data.
b. Preparation of single line diagram.
c. Equipment sizing.
Page 529 of 674
SPECIFICATION FOR
A133-086-16-50-SP-4140 Rev A
d. Preparation of control and protection schematics.

e. Preparation of interconnection diagrams.
f. Preparation of cable schedule & MTOs.
Also refer Cl. No. 4.0 of Specification for Electrical Content of Package Unit Doc.No.44NC-
4600: ESS 027.
5.2 Supply of equipment/material:

Bidder shall supply all equipment/material required including but not limited to the following:
5.2.1 All MV motors
5.2.2 Other MV Loads
5.2.3 Power Distribution Board
5.2.4 Microprocessor Controller with VVVF drive for Lift control.
5.2.5 Automatic Rescue Device with inverter and DC Batteries (Ni-Cd Vented type).
5.2.6 Lighting Panel / JB
5.2.7 Lighting within Lift Car, Hoistway, machine room & Pit
5.2.8 All cables & cabling for elevator package including all armoured cables for power, control,
signaling, communication and lighting from Machine room Junction Box (JB) to Hoistway JB
including JBs and all braided trailing cables for power, control, signaling, communication &
lighting from Hoistway JB to Lift Car
5.2.9 GI Cable Trays
5.2.10 FLP Emergency communication handsets with speaker
5.2.11 Equipment earthing upto earth plate (in machine room)
5.2.12 Earthing of electrical equipment within the package.
5.2.13 All special cables, if required for interconnecting equipment supplied by the bidder and for
interconnecting bidders equipment to purchasers equipments.
5.2.14 Any other field electrical devices not mentioned above but required for normal operation of the
package equipment.
5.3 Spares and special tools & tackles.

5.3.1 Two years operation & maintenance Spares for all electrical items (i.e. MV motor, local
control station, PDB, VVVFD, any other electrical items, etc.) for the complete electrical
system, as recommended by bidder, along with unit rates shall be furnished with the offer.
5.3.2 Commissioning spares for all electrical items shall be included in the base price. List of the
commissioning spares shall be furnished.
5.3.3 Bidder shall supply the mandatory spares for all the electrical items, as applicable. In case
any other minimum electrical item over & above is applicable for this package, bidder shall
identify the same in order to enable the owner to identify the mandatory spares. Prices for
Page 530 of 674
SPECIFICATION FOR
A133-086-16-50-SP-4140 Rev A
the same shall be as a separate lumpsum price. As a minimum, mandatory spares for the
electrical equipment related to this package shall be as per the list below:
a) MV motors
i) Set of bearings (NDE+DE) : 1 No.
ii) Cooling fans : 1 No.
iii) Inner and outer grease cups : 1 No.
iv) Termination board : 1 No.
v) Fan cover : 1 No.
vi) DE & NDE shields : 1 No.
b) VVVFD
i) Rectifier Control Module : 1 Set
ii) Thyristor module : 1 Set
iii) Inverter Control Unit : 1 Set
iv) IGBT driver card : 1 Set
v) IGBT : 10% with min. 1 No. for each rating
vi) PCB of each type : 1 No.
vii) All fuses : 20% of each rating of fuse
viii) Control cards : One set
xi) Power supply card : One set
x) Relays : 10% with min. 1 No. for each type
xi) Contactors : 10% with min. 1 No. for each rating
xii) CT/PT : One No. for each type & rating
xiii) Cooling Fans : One set
xvi) Limiters & protection devices : One set
xv) Indicating lamps : 20% with Min. 3 Nos.
xvi) Indicating lamps covers : 2 nos. of each colour.
5.3.4 Special tools & tackles for electrical items (if required) are included in the bidders scope,
and the price for the same is to be included in the base price. List of these equipments shall
be furnished along with the offer.
5.4 Erection, Testing and commissioning:

Refer elsewhere in the MR.

6.1 Area classification for Coke Drum Structure Elevator (Lift) Package: Zone 2, Zone 22-dust,
Gas Group: IIA/IIB, Temp. Class T3.
6.2 All motors and electrical items of the package shall be flameproof (Ex d).
6.3 Flameproof (Ex d) equipment shall meet the requirement of IS/IEC: 60079-1. All indigenous
flameproof equipment (type Ex d) shall be manufactured under BIS licence.
6.4 All electrical equipment for use in hazardous areas shall be certified by CIMFR (formerly
CMRI), PTB, Baseefa, UL, FM or equivalent independent testing agency for the service and
the area in which it can be used and shall be approved by PESO/CCOE. Copies of
Hazardous area test certificates & CCOE approval will be furnished with the offer.
In addition to the specifications, following specific requirements shall also be met:
7.1 MV Induction Motors
7.1.1 All offered induction motors shall comply to specification no. 44NC-4600: ESS 01A
Page 531 of 674
SPECIFICATION FOR
A133-086-16-50-SP-4140 Rev A
7.1.2 All motors shall be high energy efficient type EFF2 as per IS: 12615.
7.1.3 All motors shall be totally enclosed fan cooled type having degree of protection IPW-55,
suitable for outdoor installation. The bidder shall furnish a copy of test certificate for IPW-55
degree of protection.
7.1.4 All valid certificates as per standard specification requirements for Ex n motors shall be
furnished for Owners review/records.
7.1.5 All the motors shall be with class F insulation with temperature rise limited to class B.
7.1.6 All nuts and bolts shall be of stainless steel SS-304.
7.1.7 The winding shall be suitably treated for corrosive atmosphere with Epoxy gel treatment on
winding overhang.
7.1.8 Starting current for motors rated up to 75kW shall be limited to 600% (inclusive of +ve
tolerance).
7.1.9 Suitable double compression cable glands and nickel plated tinned copper lugs for motors
shall be in bidders scope of supply.
7.1.10 All motors rated 22KW & above shall be provided with space heater. Separate terminal box
shall be provided for the same.
7.1.11 All motors shall be earthed by two different connections using flexible braided GI wires with
proper lugging.
7.1.12 MV motors shall be suitable for starting under specified load conditions with 85% of the rated
voltage at the terminals. Hot withstand time shall be minimum 2 sec. more than the
acceleration time at reduced voltage.
7.1.13 Induced voltage across the shaft ends of motor shall not exceed 250mV (rms) for ball and
roller bearings and 400mV (rms) for sleeve bearings. Wherever it exceeds the specified limit,
the NDE bearing shall be insulated from the motor frame to avoid circulating currents. The
insulated bearing end shield or pedestal shall bear a prominent warning.
7.1.14 Motors shall have type test certificates as required in the standards for conforming
compliance to the testing requirements.
7.2 Power Distribution Board
7.2.1 Power Distribution Board (PDB) shall be flameproof type. It shall have two incomers and
outgoing feeders for feeding all the electrical loads of the package including
microprocessor controller with VVVF Drive, ARD panel etc. Transfer of incomers shall be
manual.
7.2.2 PDB shall be single front, compartmentalized and fixed type. PDB shall be suitable for
415V, 50Hz, TPN, 50 kA (1 sec.). PDB incomer shall consist of SFU, Voltmeter, CT,
ammeter. Power supply ON indicating lamps (3 Nos.) shall also be provided on the PDB.
The number of outgoing feeders in the PDB shall be as per the electrical loads. Control
supply for motor starter feeders shall be 240V AC. All outgoing feeder (except motor
feeder) shall be provided with SFU and CBCT with ELR for all power feeders rated above
5KW. All motor feeders upto 55 kW shall be provided with SFU, contactor, CBCT with ELR
and Bi-metal relay. Field ammeter shall be provided in LCS for motors above 5.5 kW.
Page 532 of 674
SPECIFICATION FOR
A133-086-16-50-SP-4140 Rev A
7.2.3 PDB shall be located in the Non-pressurised machine room. PDB shall be fixed type
requiring no rear access for maintenance. Clear working space for PDB in Front shall be
1000mm with rear flush mounted.
7.2.4 At least 20% spare feeders, subject to minimum one of each rating, shall be provided in
the PDB. Also, outgoing feeders in power distribution board (PDB) shall be sized suitably
considering 20% margin.
7.2.5 The Power distribution boards (PDB) shall be suitable for top cable entry. All cables shall
enter the PDB from top front side. Top Rear side of PDB shall house horizontal busbars.
7.2.6 All indicating lamps shall be LED type.
7.3 Miscellaneous
7.3.1 All motors shall be suitable for S4 duty and number of hourly start/ stops as per
mechanical specifications. Standard motor KW ratings & frame sizes shall be considered
by the bidder.
7.3.2 All electrical equipment shall be earthed by bidder and connected to an earth plate in
machine room which shall be interconnected to main plant earth grid.
7.3.3 Lighting of complete Lift Car, hoistway, machine room & pit is included in the bidders
scope. One no. plug and socket (as a minimum) shall be provided in the machine room by
the bidder. In addition to the normal lighting, emergency light with battery shall be provided
for the lift car.
7.3.4 All cabling from machine room junction box / PDB to the hoist way junction box shall be
done with PVC insulated armoured cables where as cabling between hoist way junction
box to the lift car shall be done with copper conductor, braided trailing cables. Separate
and distinct trailing cable shall be provided for power, control, signaling, and lighting circuit.
Minimum conductor size for power cable shall be 4 sq. mm and for control cables shall be
2.5 sq. mm copper. Power cables up to 16 sq. mm conductor size shall be of copper
conductor. All cables shall be FRLS type.
7.3.5 Hoist way lighting shall be provided at regular interval in the hoist way for carrying out
maintenance. One number of 36W CFL lamp fixture in Flameproof enclosure (Ex d), shall
be provided at each landing in the hoist way, as a minimum. Machine room lighting shall
be done with Flameproof and weatherproof well glass lighting fixture with 125W HPMV
lamp.
7.3.6 Microprocessor Controller with Variable Voltage Variable frequency drive (VVVFD) shall be
provided by the bidder for elevator motor smooth control and energy saving.
Microprocessor Controller with VVVFD unit shall be in flameproof enclosure, Ex d, suitable
for gas group IIA/IIB, temperature class T3.
7.3.7 The control of elevator shall be achieved by automatic activation of operation such as
starting, moving, stopping, emergency stopping, application of brake. For the ARD
(Automatic Rescue Device), being provided by the bidder for safe exit from car in case of
power outage, DC Battery-fed inverter device (Ex d) shall be provided. On power outage, it
shall feed power to the elevator motor, for inching operation, in order to align the car with
the nearest landing.
7.3.8 An emergency alarm push button shall be provided which shall activate a hooter (included
in Bidders scope) to signal an emergency in the elevator. Also, an intercom shall be
provided in the machine room.
Page 533 of 674
SPECIFICATION FOR
A133-086-16-50-SP-4140 Rev A
7.3.9 For the FLP handset being provided in the car, Tag block / JB and wiring upto the car shall
be provided by the bidder. Incoming cable upto Tag block/ JB from Telephone JB at plant
battery limit shall be provided by the bidder.
7.3.10 Fan being provided, shall be flameproof type.
7.4 Cables
7.4.1 Low-Voltage cables shall comply to specification no. 44NC-4600: ESS 008
7.4.2 Requirements of Low-voltage cables:
i) Voltage Grade : 1100V

ii) Conductor Material : Copper upto 16 sq.mm, Al. above 16 sq. mm
iii) Armouring : Required
iv) Type of inner sheath : Extruded, FRLS PVC
v) Type of inner sheath : Extruded, FRLS PVC
vi) Power Cables : 3.5/4 cores
vii) Control Cables : 2.5 sq. mm stranded copper conductor,
PVC insulated, FRLS cables
viii) Spare Cores in Control Cables : 20%
ix) Type and material of cable lugs : Heavy Duty Crimping Type, Tinned Copper
x) Type of Cable Glands : Ex d - Double Compression Type
8.0 EXCLUSIONS
8.1 All cabling between bidders equipment and Purchasers equipment except for special
cables which shall be in bidders scope.
8.2 All cable trenches, cable tray work outside the package, for installation of cables
interconnecting bidders equipment to purchasers equipment.
8.3 415V feeder for power distribution board for the package.
8.4 Earth plate interconnection to plant earth grid.
9.0 MAKES OF ELECTRICAL EQUIPMENT / COMPONENTS
Makes of the equipments/components shall be strictly as per attached vendor list (Doc.
no. 44NC-4600: 00:R:01:0005:A4 Rev.4)
10.0 LIST OF ATTACHMENTS
S. No Description Doc. No.

1. MV Motor Data Sheet A133-086-50-DS-4140 Rev.A
2. Datasheet for variable frequency A133-086-50-DS-4141 Rev.A
drive
3. Electrical Load data A133-086-16-50-DS-4142
Rev A
4. Vendor Data Requirement A133-086-16-50-VR-4140
Rev A
Page 534 of 674
SPECIFICATION FOR
A133-086-16-50-SP-4140 Rev A
5. Specification for MV Induction 44NC-4600: ESS 01A Rev.0

Motors
6. Specification for Medium & High 44NC-4600: ESS 008 Rev.0
voltage heavy duty Cables
7. Specification for Electrical Installation 44NC-4600: ESS 026 Rev.0
8. Specification for Electrical Content of 44NC-4600: ESS 027 Rev.0

Package Unit
9. Specification for AC Variable 44NC-4600: ESS 031 Rev 0
speed drive system
10. Specification for Flameproof 44NC-4600: ESS 067 Rev.0
Distribution Panel, Plugs, Sockets,
Lamps and Light Fittings for
Hazardous locations.
11. ITP for MV Induction Motors 44NC-4600: ITP 01A Rev.0
12. ITP for Medium and high voltage 44NC-4600: ITP 08 Rev.0
heavy duty cables
13. ITP for AC/ DC drives 44NC-4600: ITP 031 Rev.0
14. Vendor List-Electrical 44NC-4600:00:R:01:0005:A4

Rev.4
Page 535 of 674
DOC. NO. A133-086-16-50-DS-4140 REV.A
DATA SHEET FOR REQN. NO. A133-086-LZ-MR-4140 REV.A
LV INDUCTION MOTOR
APPD. BY SA
PROJECT NO A133 CHKD. BY ANPS
PROJECT LOCATION MANALI PRPD. BY VB
PROJECT TITLE RESID UPGRADATION PROJECT DATE 16.09.13
CLIENT CPCL REV. A 0 1 2
A SERVICE CONDITIONS
1 DRIVEN MACHINE REF. NO.
2 DRIVEN MACHINE TYPE
3 DESIGN AMBIENT TEMP. (MIN. & MAX) 18 DEG. C AND 45 DEG C
4 ALTITUDE ABOVE M.S.L. 3.5 M
5 RELATIVE HUMIDITY ( MIN & MAX. ) 80 % AT tmax
6 MAX. RAIN FALL PER DAY LATER
7 ENVIRONMENT CORROSIVE
8 SEISMIC ZONE ZONE - III
B AREA CLASSIFICATION : i) UNCLASSIFIED SAFE / ZONE 1 / ZONE 2, ZONE-22
ii) GAS GROUP OF ENCLOSURE: I / IIA / IIB / IIC (as applicable)
iii) TEMPERATURE CLASS : T1 / T2 / T3 / T4 / T5 / T6
C SYSTEM CHARACTERISTICS
1 SYSTEM VOLTAGE, FREQUENCY, PHASES 415 V, 50 HERTZ, THREE PHASE
2 VOLTAGE VARIATION 10 %
3 FREQUENCY VARIATION 5%
4 COMBINED VARIATION 10 %
5 EARTHING SYSTEM SOLIDLY EARTHED
D MOTOR TYPE & RATING
1 TYPE WOUND ROTOR/SQUIRREL CAGE INDUCTION MOTOR
2 DUTY
3 CLASS OF INSULATION CLASS F WITH TEMP. RISE LTD. TO CLASS B
4 RATED SPEED ( SYN.) AT RATED RPM
FREQ. & VOLTAGE
5 SPEED VARIATION REQUIRED / NOT REQUIRED TO SUIT APPLICATION
5.1 IF REQUIRED BY VVVFD/SOFT STARTER/MULTISPEED BY CHANGE OF MOTOR CONNECTION
5.2 SPEED RANGE
5.3 DRIVE CONTROL CONSTANT TORQUE / VARIABLE TORQUE / CONSTANT HP
6 WINDING TREATMENT MOISTURE PROTECTION VARNISH / ANTI CORROSIVE TREATMENT (SEE JOB SPEC.)
7 STARTING
7.1 METHOD DIRECT ON LINE

7.2 STARTING CURRENT (INCLUSIVE OF +VE TOLE.) 600%
8 STARTING PERFORMANCE
9 SHAFT EXTENSION STANDARD/ MM
10 EARTH TERMINALS TWO NOS. EXTERNAL
11 DIRECTION OF ROTATION ( VIEWED BI-DIRECTIONAL / CLOCKWISE / ANTI-CLOCKWISE (REFER Cl. 5.1.15 OF STD. SPEC.)
FROM COUPLING)
12 GREASING ARRANGEMENT GREASE NIPPLES WITH GREASE RELIEF VALVE OR PLUG / SELF LUBRICATED
13 MAIN NAME PLATE STAINLESS STEEL (300 SERIES) / ANY OTHER NON-CORROSIVE METAL
14 AUXILIARY NAME PLATE REQUIRED / NOT REQUIRED (STAINLESS STEEL)
15 TYPE OF COUPLING
16 BED PLATE / SOLE PLATE REQUIRED / NOT REQUIRED
E ENCLOSURE
1 FEATURE OF PROTECTION FLP ( Ex'd' ) / NON-SPARKING ( Ex'n' )
( W.R.T. TO AREA CLASSIFICATION ) TEFC / SPDP / CACA
2 DEGREE OF PROTECTION OF ENCLOSURE IPW-55 (MIN.)
3 TYPE OF MOUNTING TO SUIT DRIVEN EQUIPMENT
APPLICABLE STANDARD SPECIFICATION ; E SS 001
Page 536 of 674 PAGE : 1 OF 4

DOC. NO. A133-086-16-50-DS-4140 REV.A
LV INDUCTION MOTOR
APPD. BY SA
F TERMINAL BOX ( SUITABLE FOR
SPECIFIEDCABLE SIZE / TYPE )
1 TERMINAL Nos. NOS. TERMINALS TO BE BROUGHT OUT FOR
MOTOR ABOVE Kw (AS PER CL. 5.5.3 OF STD. SPEC. ESS001A)
2 SIZE OF TERMINALS
3 LOCATION OF TERMINAL BOX SEEN FROM

RIGHT HAND SIDE
DRIVEN END
4 SEPARATE TERMINAL BOX FOR SPACE REQUIRED FOR VFD DRIVEN MOTORS FOR PTC THERMISTORS AND FOR SPACE
HEATER & PTC THERMISTORS HEATERS IN MOTORS ABOVE 22 KW : RHS / LHS
G INSPECTION FINAL
TESTS -- ROUTINE TESTS SHALL BE WITNESSED AS PER MENTIONED ELSEWHERE IN FEED DOCUMENT
-- TYPE TESTS SHALL / SHALL NOT BE WITNESSED ( SUBJECT
TO APPROVAL OF TYPE TEST CERTIFICATE )
H SPECIAL REQUIREMENTS :
1 ANTICONDENSATION HEATERS FOR RATING ABOVE 22 KW
2 PTC THERMISTORS FOR VFD FED MOTORS
3 VOLTAGE RATING OF SPACE HEATER 240V, 1-PHASE, AC SUPPLY

4 RTDs NOT APPLICABLE
5 EARTH TERMINALS REQUIRED ON MOTOR FRAME AND IN THE TERMINAL BOX
I PAINTING
-- TYPE 632 AS PER IS-5

-- SHADE
J CABLES
TYPE & SIZE
CABLE LUGS -- TYPE HEAVY DUTY CRIMPING TYPE, TINNED COPPER

CABLE GLANDS -- TYPE Ex(d) - DOUBLE COMPRESSION TYPE
K DRAWINGS & DATA ( TO BE
FURNISHED BY MANUFACTURER) i) DULY FILLED UP DATA SHEET
ii) GA DRAWING OF MOTOR WITH DIEMENSIONS, FRAME SIZE & FOUNDATION DETAILS
iii) GA DRAWING OF MOTOR TERMINAL BOX WITH SIZE OF CABLE ENTRIES AND
TERMINAL ARRANGEMENT DETAILS
iv) T-S CURVES AT 80 %, 100 % & 110 % VOLTAGE SUPERINMPOSED ON
EQUIPMENT T-S CURVES & CALCULATION OF ACCELERATION TIME.
v) STARTING CURRENT -TIME CURVES AT 80 %, 100 % & 110 % VOLTAGE.
vi STARTING CURRENT -SPEED CURVES AT 80 %, 100 % & 110 % VOLTAGE.
vii) THERMAL WITHSTAND CURVE ( HOT & COLD ) AT 100 % VOLTAGE.
viii) PERFORMANCE CURVES SUCH AS LOAD VS EFFICIENCY, VS POWER
FACTOR , VS CURRENT, VS %SLIP.
ix) NECESSARY CERTIFICATION
x) LIST OF OPERATIONAL AND COMMISSIONING SPARES
xi) CALCULATON FOR ACCELERATION TIME AT 85% VOLTAGE.

DOC. NO. A133-086-16-50-DS-4140 REV.A
LV INDUCTION MOTOR
APPD. BY SA
L PERFORMANCE PARTICULARS (BY MANUFACTURER)
1 MOTOR TAG NO. & MAKE
2 ENCLOSURE
3 RATED OUTPUT AT DESIGN AMBIENT
TEMPERATURE kW A
4 CURRENT AT 50%, 75% & FULL LOAD SEC.
5 ACCELERATION TIME TO RATED SPEED
WITH RATED LOAD AT 75 % & 100 % RATED VOLATGE
6 FRAME SIZE & WEIGHT RPM
7 RATED SPEED AT RATED FREQUENCY &
VOLTAGE
8 LOCKED ROTOR CURRENT ( % OF FULL
LOAD CURRENT FOR SLIPRING MOTOR
WITH SLIPRING SHORTED) %
9 POWER FACTOR OF STARTING CURRENT
WITH 100 % FULL VOLTAGE C
10 TEMPEARURE RISE OVER DESIGN AMBIENT
TEMPERATURE AT FULL LOAD A
11 NO LOAD CURRENT N-M
12 STARTING TORQUE N-M
13 FULL LOAD TORQUE N-M
14 BREAKDOWN TORQUE N-M
15 STALLING TORQUE %
16 EFFICIENCY : 50 % LOAD %
: 75 % LOAD %
: 100 % LOAD
17 POWER FACTOR : 50 % LOAD
: 75 % LOAD
: 100 % LOAD
18 NO. OF PERMISSIBLE SUCCESSIVE D.O.L.
STARTS WITH MOTOR IN ' HOT ' CONDITION
19 SAFE STALL TIME WITH MOTOR IN ' HOT
CONDTION
20 LOCKED ROTOR WITHSTAND TIME AT 100 % OF
RATED VOLTAGE IN HOT & COLD CONDITION
21 NO. OF DOL STARTS PER HOUR WITH
ALLOWABLE MINIMUM INTERVAL
BETWEEN STARTS
22 THERMAL TIME CONSTANT
23 COOLING TIME CONSTANT
24 DETAILS OF RATING OF SPACE HEATERS
25 STATOR WINDING CONNECTION
26 GD OF ROTOR
27 DETAILS OF EMBEDDED DETECTOR
27.1 TYPE
27.2 NO. & LOCATION
27.3 MATERIAL
27.4 RESISTANCE VALUE
28 HEATING UP TIME (tE) IN CASE OF
29 INCREASED SAFETY MOTORS

DOC. NO. A133-086-16-50-DS-4140 REV.A
LV INDUCTION MOTOR
APPD. BY SA
L PERFORMANCE PARTICULARS (BY MANUFACTURER)
(CONTD.)
30 TYPE OF BEARINGS & RECOMMENDED
LUBRICANT
30.1 INTERVAL OF LUBRICATION
31 PAINT SHADE
32 VIBERATION LEVEL ON MOTORS AT NO LOAD & FULL
LOAD
33 NOISE LEVEL
31 COOLING FAN ROTATION UNIDIRECTIONAL / BIDIRECTIONAL
32 COOLING FAN ROTATION
33 ACCESSORIES
33.1 SPACE HEATER, SHAFT KEY
33.2 LIFTING EYE BOLT
33.3 NALE PLATE DETAILS
33.4 CANOPY
35 MAXIMUM AXIAL PLAY (BOTH HORIZONTAL & VERTICAL)
NOTE : 1) THE EXPLOSION PROTECTION FOR LV INDUCTION MOTORS SHALL BE AS INDICATED IN JOB SPECIFICATION.
2) MOTOR SHALL BE ENERGY EFFICIENT CLASS 'IE 2' AS PER IS 12615.
3) SAFE STALLING TIME OF MOTOR SHALL BE 2.5 SECS MORE THAN THE STARTING TIME OF MOTOR
AT 80% VOLTAGE.

DOC. NO. A133-086-16-50-DS-4141 REV A
DATA SHEET FOR REQN. NO. A133-086-LZ-MR-4140 REV A
VARIABLE SPEED AC DRIVE

APPD. BY SA
PROJECT NO. A133 CHKD. BY ANPS
CLIENT CPCL REV. A
1 DESIGNATION
2 SERVICE CONDITIONS
2.1 DESIGN AMBIENT TEMPERATURE

MAXIMUM 45 DEG C
MINIMUM 18 DEG C
2.2 RELATIVE HUMIDITY
MAXIMUM -
MINIMUM 80 % AT tmax
2.3 ALTITUDE ABOVE M.S.L. 3.5 M ABOVE SEA LEVEL
2.4 MAXIMUM RAIN FALL LATER
2.5 ENVIRONMENT CORROSIVE
3 INSTALLATION
3.1 MAIN CONTROL PANEL ( MCP ) PANEL : INDOOR

3.2 LOCAL OPERATING PANEL (LOP) INDOOR / OUTDOOR
4 SYSTEM PARTICULARS
4.1 RATED VOLTAGE 415 V +/- 10%
4.2 RATED FREQUENCY 50Hz +/- 5%
4.3 COMBINED VOLTAGE & FREQUECY VARIATION +/- 10%
4.4 NO. OF PHASES / WIRE

4.5 SYSTEM EARTHING SOLIDLY EARTHED
4.6 FAULT LEVEL 50 kA FOR 1 SEC , 3 Ph , SYMM.
5 MECHANICAL DATA
5.1 DRIVE APPLICATION VARIABLE TORQUE / CONSTANT TORQUE

W TORQUE/
5.2 DRIVE CONTROL CONSTANT TORQUE/ VARIABLE TORQUE/ SQUARE LA
CONSTANT HP/ SERVO CONTROL
5.3 DRIVEN EQUIPMENT SHAFT POWER
5.4 OPERATING TORQUE RANGE

5.5 OPERATING SPEED RANGE
5.6 STARTING TORQUE
2
5.7 GD VALUE OF LOAD
5.8 SPEED CONTROL ACCURACY
5.9 REVERSING DUTY REQUIRED / NOT REQUIRED
5.10 JOGGING DUTY REQUIRED / NOT REQUIRED
5.11 REGENERATIVE BRAKING REQUIRED / NOT REQUIRED
5.12 VIBRATION ANALYSIS REQUIRED / NOT REQUIRED
5.13 TEMPERATURE MONITORING REQUIRED / NOT REQUIRED
5.14 TACHOGENERATOR VENDOR TO SPECIFY
5.15 POWER LOSS RIDE THROUGH REQUIRED / NOT REQUIRED
APPLICABLE STANDARD SPECIFICATION : E SS 0

DOC. NO. A133-086-16-50-DS-4141 REV A

APPD. BY SA
CLIENT CPCL REV. A
6 MOTOR / DRIVE COORDINATION
6.1 MOTOR SUPPILED BY PURCHASER / VENDOR

6.1.1 IF BY VENDOR THEN : MOTOR DATA SHEET REF
6.1.2 MOTOR SUPPLIER ( RECOMMENDED )

6.2 SPECIAL REQUIREMENTS :
6.2.1 SEPARATE FIXED SPEED COOLING FAN TO BE DECIDED BY VENDOR & SHALL BE PROVIDED IF REQUIRED
6.3 MOTOR DERATING FACTOR DUE TO LESS
COOLING AT LOWER SPEEDS / HARMONICS
6.4 THERMISTER PROVIDED IN MOTOR YES (VSD SHALL HAVE FACILITY TO ACCEPT INPUT FROM THERMISTOR)/NO
7 DRIVE PANEL REQUIREMENTS
7.1 ENCLOSURE TYPE FOR VSD PANEL(VSD) INDUSTRIAL / Ex d/ Ex e/ SAFE

LOCAL OPERATING PANEL(LOP) INDUSTRIAL / Ex d/ Ex e/ SAFE
7.2 DEGREE OF PROTECTION FOR VSD PANEL(VSD) IP 52(min)
FOR LOP IP 55 (min)
8 DRIVE OPERATION & CONTROL
8.1 TYPE OF DRIVE CONTROL OPEN LOOP V/F/ SENSORLESS VECTOR/ CLOSED LOOP VECTOR /
SERVO
8.2 TYPE OF INVERTER VOLTAGE SOURCE / PWM / CURRENT SOURCE
8.3 BRAKING OPERATION DC INJECTION/ REGENERATIVE/ BRAKE RESISTOR
8.4 DISPLAY & KEYPAD YES / NO
8.5 SERIAL INTERFACE YES / NO
8.6 CONNECTION TO AUTOMATION SYSTEM THROUGH PROFIBUS / MODBUS / OTHERS
FIELD BUS
8.7 INCOMING LINE DEVICE
8.8 LINE CONTACTOR REQUIRED / NOT REQUIRED

8.9 EMERGENCY STOP PB ON PANEL REQUIRED / NOT REQUIRED
8.10 BYPASS CIRCUIT ARRANGEMENTS REQUIRED / NOT REQUIRED
AUTOMATIC & MANUAL CHANGEOVER
8.11 STARTER FOR MOTOR COOLING FAN TO BE DECIDED BY VENDOR & SHALL BE PROVIDED IF REQUIRED
8.12 COOLING FAN IN PANEL / VSD PANEL & LOP ( VENDOR TO DECIDE THE FAN REQUIREMENT)
8.13 CONTROL SUPPLY OF VSD PANEL(VSD) EXTERNALLY / INTERNALLY DERIVED
8.14 LENGTH AND SIZE OF MOTOR CABLE
8.15 PROCESS CONTROL
8.15.1 EXTERNAL RAISE/ LOWER INPUTS REQUIRED / NOT REQUIRED CURRENT /

8.15.2 4-20 mA FEEDBACKS SPEED/ KW CONTROL MAINTAINED
8.15.3 EXTERNAL START INPUT CONTACT/ PULSE CONTACT
8.15.4 EXTERNAL SET POINT 4-20 mA / 0-10V

DOC. NO. A133-086-16-50-DS-4141 REV A

APPD. BY SA
CLIENT CPCL REV. A
8.16 PROTECTIONS
8.16.1 EARTH LEAKAGE AT OUTPUT LINE REQUIRED / NOT REQUIRED

8.16.2 SHORT CIRCUIT REQUIRED / NOT REQUIRED
8.16.3 EARTH FAULT REQUIRED / NOT REQUIRED
8.16.4 UNDER & OVERVOLTAGE REQUIRED / NOT REQUIRED
8.16.5 MOMENTARY MAINS FAIL REQUIRED / NOT REQUIRED
8.16.6 PHASE UNBALANCE REQUIRED / NOT REQUIRED
8.16.7 MOTOR OVERLOAD REQUIRED / NOT REQUIRED
8.16.8 CURRENT LIMIT TRIP REQUIRED / NOT REQUIRED
8.16.9 DRIVE OVERSPEED & UNDERSPEED TRIP REQUIRED / NOT REQUIRED
8.16.10 ROTOR STALL TRIP REQUIRED / NOT REQUIRED
8.16.11 MOTOR OVER TEMPERATURE REQUIRED / NOT REQUIRED
8.16.12 HEAT SINK OVER TEMPERATURE REQUIRED / NOT REQUIRED
8.16.13 ENCODER FAILURE REQUIRED / NOT REQUIRED
8.16.14 FIELD BUS FAILURE REQUIRED / NOT REQUIRED
8.16.15 LOSS OF CONTROL VOLTAGE SUPPLY REQUIRED / NOT REQUIRED
8.16.17 AUXILIARY SYSTEM FOR PROTECTION AND FAILURE REQUIRED / NOT REQUIRED
IDENTIFICATION `
8.17 LOP REQUIREMENTS
8.17.1 EMERGENCY STOP PB REQUIRED / NOT REQUIRED
8.17.2 START PB REQUIRED / NOT REQUIRED
8.17.3 STOP PB REQUIRED / NOT REQUIRED
8.17.4 LOCAL / REMOTE SELECTOR SW REQUIRED (AUTO / MANUAL SW & LOCAL / REMOTE SW)
8.17.5 SPEED RAISE / LOWER PBS REQUIRED / NOT REQUIRED
8.17.6 METERING (tick all that are applicable) SPEED / CURRENT/ KW

8.17.7 INDICATING LAMPS (tick all that are applicable) RUN / STOP / TRIP / READY TO START/ AUTO MODE
9 DRIVE PANEL PARAMETERS (Vendor to furnish)

RATING & PERFORMANCE
9.1 MAKE & MODEL NO.

9.2 QUANTITY
9.2 TYPE (REFER 8.1 & 8.2)
9.3 INPUT VOLTAGE RANGE

9.4 INPUT FREQUENCY RANGE
9.5 NOMINAL CURRENT RATING
9.6 ACTUAL CURRENT RATING AT OPERATING TEMP. &
SWITCHING FREQUENCY
9.7 FAULT LEVEL IN Ka
9.8 CONFIGURATION
9.8.1 RECTIFIER
9.8.2 INVERTER
9.9 IGBT
9.9.1 PULSE NUMBER
9.9.2 OVER CURRENT CAPABILITY AS MULTIPLE OF
RATED CURRENT

DOC. NO. A133-086-16-50-DS-4141 REV A

APPD. BY SA
CLIENT CPCL REV. A
RATING & PERFORMANCE (CONTD....)
9.10 RECTIFIER
9.10.1 PULSE NUMBER
9.10.2 HARMONIC CONTENT

9.10.3 OUT PUT POWER FACTOR
9.11 RATED OUTPUT VOLTAGE (RANGE & TOLERANCES)
9.12 CONTINUOUS OUTPUT
9.13 RATED OUTPUT CURRENT
9.14 RATED OUTPUT FREQUENCY

9.14.1 RANGE
9.14.2 TOLERANCES
9.14.3 RESOLUTION
9.15 RATED EFFICIENCY

9.16 MOTOR DERATING APPLICABLE FOR CONTINOUS USE
9.16.1 AT FULL LOAD

9.16.2 LOW SPEED
9.17 OVERLOAD CAPACITY
9.18 DISTROTION FACTOR OF OUTPUT VOLTAGE
9.18.1 HARMONIC SUPRESSION FILTERS USED
9.18.2 MAXIMUM AND MINIMUM VALUES

9.19 SWITCHING FREQUENCY RANGE
9.20 SPEED CONTROL RANGE
9.20.1 SPEED CONTROL ACCURACY
9.20.2 TORQUE CONTROL ACCURACY

9.21 RAMP UP/ DOWN TIME RANGE
9.22 MAX TORQUE AT ZERO SPEED

9.23 VOLTAGE/ FREQUENCY CHARACTERSTICS
9.24 FULL LOAD POWER FACTOR
9.25 HEAT LOAD FROM VSD AT FULL LOAD AND NO LOAD
9.26 NOISE OUTPUT FROM VSD

9.27 VIBRATIONS FROM VSD
9.28 COOLING REQUIRED FOR VSD
9.29 COOLING TEMPERATURE

9.30 OVER TEMPERATURE SHUT DOWN AT
9.31 ELECTRO MAGNETIC CAPABILITY

9.32 POWER LOSS RIDE THROUGH
9.33 CABLE FROM VSD TO MOTOR
9.33.1 MAXIMUM MOTOR CABLE LENGTH (State limitation if any)

9.33.2 MAXIMUM MOTOR CABLE SIZE (State limitation if any)
9.34 ACCESSORIES
9.34.1 INPUT CHOKE PROVIDED / NOT PROVIDED
VALUE OF INDUCTANCE
MATERIAL

DOC. NO. A133-086-16-50-DS-4141 REV A

APPD. BY SA
CLIENT CPCL REV. A
RATING & PERFORMANCE (CONTD....)
9.34.2 OUTPUT CHOKE PROVIDED / NOT PROVIDED

VALUE OF INDUCTANCE
MATERIAL
9.34.3 MAINS FILTER PROVIDED / NOT PROVIDED
9.34.4 INPUT ISOLATION TRANSFORMER PROVIDED / NOT PROVIDED
9.35 CURRENT HARMONICS

THD
OTHER PROMIENT HARMONICS

10 VSD PANEL / LOP DETAILS
VSD PANEL
10.1 MATERIAL
10.2 DEGREE OF PROTECTION
10.3 PAINT
10.4 MAX. TEMP RISE ALLOWED
10.5 COOLING FAN REQUIRED YES / NO
10.6 SPACE HETER PROVIDED YES / NO
10.7 COMPONENTS AS SPECIFIED PROVIDED YES / NO
10.8 CABLE ENTRY
10.9 CHOKE / FILTER / ISOLATION TRANSFORMER

LOCAL OPERATOR PANEL
10.10 MATERIAL
10.11 DEGREE OF PROTECTION
10.12 TYPE FLAMEPROOF

10.13 PAINT
10.14 COMPONENTS AS SPECIFIED PROVIDED YES / NO
10.15 CABLE ENTRY BOTTOM
10.16 DIMENSION (ALL PANELS)

10.16.1 VSD PANEL
LENGTH
HEIGHT
DEPTH
WEIGHT OF SHIPPING SECTION/ CUBICLE/ PANEL

10.16.2 LOCAL OPERATING PANEL (LOP)
LENGTH
HEIGHT
DEPTH
WEIGHT OF SHIPPING SECTION/ CUBICLE/ PANEL
NOTE : -

The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited or used, except in the limited way
permitted by a written consent given by the lender to the borrower for the intended use.EIL-1650-1281, Rev 1 A4-210x297.
ELECTRIC LOAD DATA
Note: Bidder to furnish the filled-in Electric load data (Equipment-wise) along with the offer.
ANPS
A 16.09.13 Issued with MR VB SA
REV DATE PURPOSE BY CHECKED APPROVED
ENGINEERS INDIA LIMITED Plant: CPCL-DCU

NEW DELHI Electric Load Data DATA SHEET NO. Date Rev
Location: Manali, Tamilnadu
Client: M/s CPCL. A133-086-16-50-DS-4142
Sheet 1 of 2
16.09.13 A
Page 545 of 674
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
S.no Tag no. Service Nor- Type of Manufacturer Eqpt. Mounting Drive Rated GD of Desi- End Min Dri Mot. Motor
mal / eqpt.:Pump/Cen of equipment Statu arrgmt. speed Rot. gn of Rec. ver dir.
Std.by t.comp./Recip.c s r.p.m. Part kg- abs. curve kW of incl of Rated Speed
omp./blower etc. m Shaft /max motor Yes rot. kW rpm
kW KW /No (from
nde)
Legend for Equipment status: # : Based on offer @ : Based on formal data * : Estimated Sheet 2 of 2
DRAWING NO.
Plant: CPCL-DCU Date Rev
ENGINEERS INDIA Location: Manali, Tamilnadu
LIMITED Client: M/s CPCL
Electric Load Data A133-086-16-50-DS-4142 16.09.13 A
NEW DELHI Sheet 2 of 2
Page 546 of 674

Document No.
VENDOR DATA REQUIREMENTS A133-086-16-50-VDR-4140
FOR Rev. A
COKE DRUM STRUCTURE ELEVATOR Page 1 of 4

FOR
A 17-SEP-2013 ISSUED WITH MR VB ANPS SA

Rev. Date Purpose Prepared by Checked by Approved by
No.
Page 547 of 674

Document No.
FOR Rev. A
The following drawings/documents marked " " shall be furnished by the bidder.
PACKAGED EQUIPMENT
POST ORDER
S. WITH WITH
BID
(FINAL)
1. Schedule of Vendor Documents
2. Confirmation of Technical Compliance
3. Guaranteed max. Power Consumption
4. Single line diagram
5. Electrical load data
6. Area classification
7. Block Diagram- FA & PA
8. Equipment layout
9. Cable layout
10. Sizing calculation
11. Cable schedule
12. Interconnection diagram
13. Electrical interface with owner
14. Technical details/Data sheets for major
equipment
15. Motor data sheet
16. GA and internal arrangement drawing for
panels
17. Schematic/Logic diagrams
18. Interconnection/Wiring diagrams
19. Bill Of Material
20. List of Mandatory Spares
21. List of recommended maintenance spares
22. Type Test certificates
23. Test certificates
24. Catalogues and brochures
25. Installation manual
26. Operation/maintenance manual
27. Inspection & Test Plan (ITP) -For review by
Inspection Dept.
28. Equipment storage procedure at site
29. GA and internal arrangement for VVVFD
Page 548 of 674

Document No.
FOR Rev. A
MV MOTOR
POST ORDER
S. WITH WITH
BID
(FINAL)
1. Schedule of Vendor Documents
2. Confirmation of Technical Compliance
3. Data Sheets (Duly filled-in)
4. Dimensional/Assembly Drawings : GA Drawing
For motors < 75kW
5. Dimensional/Assembly Drawings : GA Drawing
For motors >= 75kW
6. Dimensional/Assembly Drawings : Installation
Plan/Mounting Details
7. Dimensional/Assembly Drawings : Terminal
Box Arrangement
8. Dimensional/Assembly Drawings : Name Plate
Drawing
9. Performance Curves : Speed Torque Curves
10. Performance Curves : Speed-Current/Time
Curves
11. Performance Curves : Thermal Withstand
Curves (Hot & Cold)
12. Performance Curves : P.f. & Efficiency Curves
13. Inspection & Test Plan (ITP) -For review by
Inspection Dept.
14. Test Records
15. Type Test Certificates for similar equipment
16. List of Commissioning Spares
17. List of Maintenance Spares
18. List of Mandatory Spares
19. List of Special Tools & Tackles
20. Data Books/ Manuals : Installation Manual
21. Data Books/ Manuals : Operating/ Maintenance
Manual
22. Data Books/ Manuals : Catalogues/ Brochures
23. Equipment storage procedure at site
Notes :
1. "TICK" denotes applicability.
2. Post order, drawing / document review shall commence only after approval of Document Control Index (DCI).
3. All post order documents shall be submitted / approved through EIL eDMS portal.
Page 549 of 674

Document No.
FOR Rev. A
4. Final documentation shall be submitted in hard copy (Six prints) and soft ( two CDs/DVDs ) in addition to
submission through EIL eDMS.
5. All drawings & documents shall be submitted in A4 or A3 paper sizes. Documents in higher paper size shall
be submitted in exceptional circumstances or as indicated in the MR/Tender.
6. Post order- The schedule of drawing / data submission shall be mutually agreed between EIL & the bidder /
contractor / supplier during finalization of Document Control Index (DCI).
7. "@" indicates submission of documents to Inspection Agency.
8. Bill of Material shall form part of the respective drawing.
9. Also refer other department's VDR :-
10. Electrical
11. Instrumentation
12. Packaged Equipment
Page 550 of 674

Page 1 of 15
STANDARD SPECIFICATION FOR
L. V. INDUCTION MOTORS
DOCUMENT NO: 44NC-4600 : ESS 01A
PREVIOUS DOC. NO.: BSS - 05 - 101/2
Rev Issue Date Pages Rev Description Prepared Checked Approved

No. By By By
0 03 May 2010 15 Issued for Engineering VSL PPP RBD
Page 551 of 674

STANDARD SPECIFICATION : 44NC-4600: ESS 01A DATE : 03 May 2010
L. V. INDUCTION MOTORS PAGE : 2 OF 15
REVISION NO : 0
TABLE OF CONTENTS
1.0 SCOPE
2.0 STANDARDS
3.0 CLIMATIC CONDITIONS
4.0 ELECTRICAL SUPPLY SYSTEM
5.0 DESIGN FEATURES
6.0 SPECIAL TOOLS
8.0 PACKING AND DISPATCH
9.0 INFORMATION, DRAWINGS, LITERATURE SPARES
10.0 CERTIFICATION
11.0 SPARES
12.0 QUALITY ASSURANCE
13.0 DEVIATIONS
Page 552 of 674

REVISION NO : 0
1.0 SCOPE
1.1 This specification covers the Design, Manufacture, Testing and Supply of three phase
induction motors of the squirrel cage type.
1.2 This specification shall accompany Data Sheets, technical specification which will stipulate
specific requirements of motors. In case of any contradiction between various referred
standards/specifications/data sheets and statutory regulations, the following order of
precedence shall govern:
- Statutory regulations
- Data sheets
- Technical Specifications
- This Specification
- Codes & Standards
2.0 STANDARDS
2.1 Motors shall be manufactured in accordance with the latest Indian Standard Specification
current at the time of order, including amendments, and in particular following :
1 IS: 5 Colors for ready mixed paints & enamels
2 IS: 325 Three Phase Induction motors
3 IS: 1076 Preferred numbers

(Part 1, 2 & 3)
4 IS: 1231 Dimensions of three phase foot mounted induction motors
5 IS: 1271 Thermal evaluation & classification of electrical insulation
6 IS: 2071 Methods of high voltage testing

Part (1, 2 & 3)
7 IS: 2148 Electrical apparatus for explosive gas atmospheres flameproof enclosures d
8 IS: 2223 Dimensions of Flange mounted A..C. induction motors
9 IS: 2253 Designation for types of Construction and Mounting Arrangements of Rotating
Electrical Machines.
10 IS: 2254 Dimensions of vertical shaft motors for pumps
11 IS: 2968 Dimensions of Slide Rails for Electrical Motors.
12 IS: 4029 Guide for testing Three Phase induction Motors.
13 IS: 4691 Degree of Protection provided by enclosures for rotating Electrical Machinery
14 IS: 4722 Specification for rotating electrical machines
15 IS: 4728 Terminal Marking and direction of rotation for Rotating Electrical Machinery.
16 IS: 4889 Method of determination of efficiency of rotating Electrical Machines.
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17 IS: 5571 Guide for selection of electrical equipment for hazardous areas
18 IS: 5572 Classification of hazardous areas (other than mines) having flammable gases
and vapours for electrical installation
19 IS: 6362 Designation of Methods of Cooling for Rotating Electrical Machines.
20 IS: 6381 Electrical apparatus for explosive gas atmospheres increased safety e
21 IS: 7389 Electrical apparatus for explosive gas atmospheres pressurized enclosures p
22 IS: 7816 Guide for testing of insulation resistance of rotating machines.
23 IS: 8223 Dimensions and output series for electrical machines
24 IS: 8289 Specification for electrical equipment with type of protection n.
25 IS: 8789 Values of performance characteristics for 3-phase induction motor.
26 IS: 9628 Three phase induction motor with type of protection n
27 IS: 12065 Permissible limits of noise level for rotating electrical machines
28 IS: 12075 Mechanical vibration of rotating electrical machines with shaft heights 56 mm &
higher measurement, evaluation & limits of vibration severity
29 IS: 12615 Energy efficient induction motors three phase squirrel cage
30 IS:12802 Temp. rise measurement of rotating electrical machines
31 IS:12824 Type of duty class & rating assigned to rotating electrical machines
32 IS:13408 Code of practice for selection, installation & maintenance of the apparatus for
use in potentially explosive atmospheres
33 IS:13529 Guide on effects of unbalanced voltages on the performance of three phase

induction motors.
34 IS:13555 Guide for selection & application of three phase A. C. induction motors for
different types of driven equipments
35 IS:14222 Impulse voltage withstand levels for rotating electrical machines with form-wound
stator coils
36 IS:14568 Dimensions & output series for rotating electrical machines, frame numbers 355
to 1000 and flange numbers 1180 to 2360
2.2 In case of motors manufactured in accordance with other standards manufacturer or vendor
shall state the reference number and title of the standards adopted. Generally equivalent
standards by IEC/ BS/ VDE/ IEEE/ NEMA or equivalent standards shall be acceptable.
2.3 In case of imported motors, standards of the country of the origin shall be followed if these are
equivalent / stringent than the applicable Indian Standards.
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3.0 CLIMATIC CONDITIONS
3.1 Climatic conditions and other environmental conditions will be as specified in the Data
Sheets.
It should be however noted in general that the motors shall be suitable for use in tropical
climate with high humidity, heavy rainfall, and conducive to fungus growth and corrosion.
4.0 ELECTRICAL SUPPLY SYSTEM
4.1 Characteristics of electric supply system will be specified in Data Sheets.
4.2 Variations in electric supply, under which motor shall be operated continuously without any
adverse effects will be as follows, unless specified otherwise in the Data Sheets:
Voltage variation : + / - 10 %
Frequency Variation : +/-5%
Combined Voltage & Frequency Variation : + / - 10 %
Motors shall be designed to continue running through the following specific conditions against
their specified loads and to recover to normal conditions when the voltage is restored to
normal. This is applicable to HV motors only.
Induction motors: at zero voltage for 0.5 seconds, recovering instantaneously to at least 85%
normal volts.
5.0 DESIGN FEATURES
5.1 GENERAL
5.1.1 The offered equipment shall be brand new with state of the art technology and proven field
track record. No prototype equipment shall be offered.
5.1.2 Availability of spare parts and maintenance support services for the offered equipment shall
be ensured for at least for 15 years from the date of supply.
5.1.3 Vendor shall give a notice of at least one year to the end user of equipment before phasing
out of product/ spares to enable the end user for the placement of order for spares & services
5.1.4 All motors shall be continuous maximum rated unless otherwise specified in Data Sheet.
Intermittent rated motors shall conform to duty cycle specified in Data Sheet.
Unless otherwise specified, three phase squirrel cage induction motors of 2,4,6 & 8 poles for
all frame size up to 315L shall be energy efficient (eff1/ eff2 as specified in data sheet) having
output ratings as specified in IS 1231 for continuous duty (S1) operation at rated voltage and
frequency.
5.1.5 Motors shall be capable of giving rated output without reduction in the expected life span
when operated continuously with the variation in supply conditions as indicated in the data
sheet.
5.1.6 Motor body or frame shall be of close grained cast iron or of welded steel construction in case
of large motors. The design of the body shall ensure ruggedness and damping of vibration.
The rotor alongwith the fan and half coupling or other drive device (if fitted) shall be statically
and dynamically balanced.
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5.1.7 All parts of identical motors, such as rotors, bearings and end shields, etc. shall be fully
interchangeable with specific reference to rotor.
5.1.8 Design and construction of the motors shall be such as to facilitate inspection, cleaning,
maintenance and repairs.
5.1.9 Fans provided for fan-cooled motors shall preferably be of the non-directional type, with
protection against accidental contact. In case they are uni-directional, direction of rotation
shall be clearly indicated on the non-driving end of the motor.
5.1.10 All motors shall have single bare shaft extension with key way and key, except where noted
otherwise.
5.1.11 Fans for motors used in hazardous areas (Zone1 and 2) shall be manufactured from non-
sparking material and if non-metallic shall be painted with an electrically conducting paint, to
prevent accumulation of static charge.
5.1.12 Direction of airflow, in case of slip ring motors, shall be such that airflow will carry the carbon
dust away from the winding.
5.1.13 Air to water heat exchanger shall have double tube plates; spray baffles and drip trays with
siphon drains to prevent water reaching the windings.
5.1.14 Type of mounting required shall be as specified in Data Sheets.
5.1.15 All L. V. motors shall be Bi-directional. For 2 pole motors of frame size 280 and above the
direction of rotation may be unidirectional.
5.1.16 Normally, clockwise rotation is desired, when viewed from the driving (coupling) end. This is
applicable, when the terminals marked as per IS: 4728 are connected to the supply giving
terminal phase sequence corresponding to the alphabetical sequence of the terminal letters.
5.1.17 Counter-clockwise rotation of the motor shall be obtained by connecting the supply to
terminals so that the phase sequence corresponds to the reversed alphabetical sequence of
the terminal letters. Ample space shall be provided at the terminal box for interchanging any
two external leads for obtaining the reverse phase sequence.
5.2 ENCLOSURE
5.2.1 Enclosures for motors shall be as specified in Data Sheets. Degree of protection in
accordance with IS-4691 shall also be as per Data Sheet.
Motors for outdoor installation shall be of weatherproof construction (IPW 55) such that no
additional protection is required to be provided by the Purchaser. Motor casing shall be
provided with a suitable drain for removal of condensed moisture except in case of flameproof
motors.
5.2.2 Construction of enclosures for flameproof (Exd) motor and the terminal box shall conform to
IS 2148 and shall be suitable for the group of gasses specified in Data Sheet.
5.2.3 Construction of enclosures for increased safety (Exe) motors shall conform to the latest Indian
Standard Specification 6381 and shall be suitable for temperature class specified in Data
Sheet.
5.2.4 Vertical motors with downward shaft shall be provided with fully covering rain canopies.
Vertical motors with upward shaft e.g. on fin-fan coolers, shall be adequately protected, (such
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as cowls/canopies) against ingress of water into the enclosure or the bearing housing even
when standing still for long periods of time
5.2.5 All internal and external metallic parts which may come into contact with cooling air shall be of
corrosion resistant material or appropriately treated to resist the corrosive agents which may
be present in the atmosphere. Screws, nuts & bolts shall be hot dip galvanized or zinc
passivated to protect against corrosion.
5.2.6 Type of motors that require variable speed drive system shall be suitable for
variable speed range with temperature rise within limit and also shall be suitable for area
classification.
5.2.7 Flameproof Ex(d) motors operating on variable speed drive system shall have CMRI or
equivalent authority certifying the suitability of drive motor with VSDs.
5.2.8 Increased safety Ex(e) motor operating on variable speed drive system shall be type tested
as a unit in line with latest requirement of IEC (31J/47/FDIS).
5.3 BEARING & LUBRICATIONS
5.3.1 All motors shall have grease-lubricated ball and/or roller bearings or bearings of the sleeve
type. Vertical motors shall have special thrust bearings suitable for the load imposed by the
driven equipment.
5.3.2 All bearings shall be of reputed manufacture and of a type interchangeable with other makes
and types. Ball and roller bearings shall have an L10 life of 40, 000 hours at rated operating
conditions. (The L-10 rating life is the number of hours at constant speed that 90% of a group
of identical bearings will complete or exceed before the first evidence of failure). Unless
otherwise specified, the bearing shall be adequate to absorb axial thrust produced by the
motor itself or due to shaft expansion.
5.3.3 All bearings shall be provided with seals to prevent the ingress of dust, moisture and all other
harmful substances.
5.3.4 For large capacity motors, the bearing shall be of the pedestal oil ring lubricated, sleeve type,
fitted with liberally sized oil reservoir and level indicator. Sleeve bearings shall be designed
with low bearing pressures and provided with drain plug. A thermometer with alarm and trip
contacts shall also be provided.
5.3.5 Grease lubricated bearings shall be packed with suitable grease before the motors are
dispatched. These shall be provided with nipples, and relief valves or plugs, suitable for on-
line greasing. Bearing shall be capable of grease injection from outside without removal of
covers with motors in the running conditions. The bearing boxes shall be provided with
necessary features to prevent loss of grease or entry of dust or moisture. Where grease
nipples are provided these shall be associated, where necessary, with appropriately located
relief devices, which ensure passage of grease through the bearing. Pre-lubricated sealed
bearings may be considered provided a full guarantee is given for 4 to 5 years of trouble-free
service without the necessary of re-lubrication.
5.3.6 In cases such as pumps for hot liquids where the driven machine operates at high
temperatures, bearings shall be cooled by a shaft mounted fan. This shall ensure efficient
ventilation of the bearing and disperse the heat transmitted from the driven object by
conduction or convection. For motors operating in hazardous areas, fans shall be of an anti-
static non-sparking material.
5.3.7 Wherever necessary, insulating pads between the bearing pedestals and bed plate shall be
provided to eliminate shaft circulating currents. An earth terminal shall be provided on the
drive and bearing pedestal.
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5.3.8 For unlocked shafts, the end clearance on the motor shall exceed the coupling end float.
Permissible limits of rotor movement shall be marked on the shaft.
5.3.9 The as built motor data sheets which shall be submitted by the supplier shall contain bearing
number for easy reference.
5.4 PHASE CONNECTION
5.4.1 The windings shall be connected in delta. However, for motors rated 2.2KW and below, star
connection may be accepted.
5.4.2 If star-delta starting is required, this will be specified in the data sheet and the motor windings
shall be fully insulated for delta connection.
5.5 TERMINAL BOX
5.5.1 The terminal box shall be robust construction and large enough to facilitate easy connection
of the cables. The terminal box shall be with necessary clearances, creepage distances
between live parts and between live parts to earth considering air insulation and without any
compound filling. Terminal box cover shall be provided with handles to facilitate easy removal.
5.5.2 Terminal boxes shall be cast iron or of welded steel construction with screwed conduit entries.
The size of the terminal boxes, conduit entries and terminals shall be suitable for termination
and connection of specified type and size of cables. Adequate space shall be provided for
termination of aluminium conductor cables. The terminals shall be complete with two flat
washers, one lockwasher and nut to make them secure and vibration-proof.
5.5.3 Numbers of terminals shall be as given below :
SCR Motors upto & including 7.5 KW - 3 Nos.

SCR Motors above 7.5 KW - 6 nos.
Slip ring motors - 6 nos.
5.5.4 Terminal boxes for power cables shall be located on right hand side when viewed from the
driving end or on top. The terminal boxes shall be rotatable in steps of 90 without disturbing
the motor winding connections to the terminal block.
Caution nameplates on flameproof or increased safety motor terminal boxes shall be as per
IS 2148 or IS 6381 respectively.
5.5.5 The terminal box shall be capable of withstanding internal short circuit condition without
danger to the personnel or plant from the emission of hot gases or flames due to excessive
distortion or damage to the terminal enclosure.
5.5.6 An adequately sized earth terminal shall be provided in the motor terminal box for termination
of the fourth core of specified cables.
5.5.7 Identification of Terminals

Motor terminals as well as anti-condensation heater and temperature detector terminals shall
be clearly identified as per IS 4728. A motor connection diagram shall also be affixed inside
the terminal box on the cover.
5.5.8 Separate auxiliary terminal boxes shall be provided for anti-condensation heaters and
temperature detectors. Caution nameplates with inscription "Caution-Live Heater / Detector
Terminals" shall be provided on auxiliary terminal boxes for heater and detector terminal
boxes.
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5.6 STARTING CHARACTERISTICS
5.6.1 Unless otherwise specified, motors shall be designed for direct-on-line starting. Motors shall
be designed for re-acceleration under full load after a momentary loss of voltage with the
residual voltage being 100% out of phase.
5.6.2 All motors shall be suitable for starting under specified load conditions with 85% of the rated
voltage at the terminals.
5.6.3 Minimum locked rotor thermal withstand time at rated voltage shall be 10 seconds under cold
condition and 8 seconds under hot condition. The hot thermal withstand time at 100% voltage
shall be atleast 5 seconds more than the starting time at 80% voltage.
5.6.4 Unless otherwise agreed, the starting time of the motor shall be less than the hot thermal
withstand time of the motor (time tE in case of increased safety motors) to facilitate application
of conventional bimetal relays or thermal release against locked rotor and overload
conditions.
5.6.5 All motors shall be capable of atleast two starts in quick succession after the motor windings
have attained their maximum permissible temperature. If a more onerous duty is required, the
same shall be indicated in the Data Sheet.
5.6.6 Motors shall be designed to allow the minimum number of consecutive starts
indicated below:
Condition Min. no. of consecutive starts
No. of hourly starts uniformly distributed, starting from 4

final steady working temp.
With initial temp. of the motor as ambient temp. (cold)

3
With initial temp. of the motor as full load operating 2

temp. (hot)
5.6.7 Starting current of squirrel cage motor with full voltage starting shall normally not exceed
600% of the full load current with tolerance specified in IS 325.
5.6.8 Starting torque of Squirrel cage induction motors started on full voltage shall generally not be
less than 200% of the full load torque. Cases, where higher starting torque is required, will be
indicated in Data Sheets. Pull out torque (breakdown) of motors shall not be less than 200%
of the full load torque. In case of motors driving equipment with pulsating loads (e.g.
reciprocating compressors) the minimum value of pull out torque at 75% of the rated voltage
shall be more than the peak value the pulsating torque. Unless otherwise agreed, the pull out
torque shall not exceed 300% of the rated load torque.
5.6.9 Starting torque and minimum torque of the motor shall be compatible with the speed torque
curve of the driven equipment under specified operating condition. For heavy-duty drives such
as blowers, fans, etc. high starting torque (min.150%) motors shall be provided.
5.6.10 In case of L.V. Motors driving high inertia equipment, the manufacturer shall provide
calculations for acceleration time, torque speed curves for motor and current time curves.
Necessary Data for the driven equipment such as torque-speed curves, moment of inertia
etc., shall be furnished by others for this purpose.
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In case of reciprocating compressor or similar equipment, the stator current pulsations shall
be given by the manufacturer. In all cases, manufacturer shall ensure that the starting current
withstand time of the motors shall be higher than the calculated starting time.
5.6.11 The manufacturer shall also furnish time tE for Exe and Ex n motors.
5.7 INSULATION AND WINDINGS
5.7.1 L.V. motors shall have class 'B' insulation unless Data Sheet specify another class of
insulation.
5.7.2 The windings shall be tropicalized. Winding of motors shall be treated or impregnated with
suitable varnishes to render them non-hygroscopic and resistant to dirt and oil. Windings shall
also be treated to make them resistant to acidic / alkaline vapours when the atmosphere is
specified as corrosive.
5.7.3 In case of SPDP motors, used for outdoor installation, or in case of vertical hollow shaft pump
motors, end turns of windings shall be treated with epoxy based varnishes for weather
resistance. Suitable baffle shall be provided to avoid direct splashing of water on the
windings.
5.7.4 All insulating materials used in the construction of motors shall be non-hygroscopic. Coils
shall be made of copper.
5.7.5 Windings shall be adequately braced to prevent any relative movement during operating and
in this respect, particular care shall be taken for the stator windings of direct-on-line starting
squirrel cage motors. Insulation shall be provided between coils of different phases, which lie
together. Core laminations must be capable of withstanding burnout for rewind at 4000C
without damage or loosening.
5.7.6 In case of motors driving equipment with pulsating loads, special attention shall be paid to the
joints of rotor bars and end rings to avoid premature failures due to induced fatigue stresses.
5.7.7 Insulation and impregnation of windings shall be carried out in a manner which will facilitate
easy removal and replacement of coils. All coils shall be adequately supported to prevent
movement under shock or short circuit stresses, or shocks due to electro-dynamic braking
with phase reversal.
5.7.8 Joints shall be kept to a minimum, where joints are made, conductors shall be tinned to
prevent oxidation, rivetted and soldered or brazed.
5.7.9 All joints shall be supported adequately to relieve them from mechanical strain. Insulation
level of the joints shall not be less than for the motor windings.
5.7.10 Leads from motor windings to the terminal box shall be adequately supported throughout and
shall be kept away from sharp edges to prevent abrasion. Openings in the motor frame
through which the leads are brought out shall be sealed to isolate the terminal box from the
motor.
5.8 TEMPERATURE RISE
5.8.1 The temperature rise of motors for all types of enclosures when tested in accordance with IS
325 shall not exceed the limits specified therein, corresponding to the class of insulation used
and on the basis of normal conditions of service stipulated in Data Sheets.
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5.8.2 Motor shall be suitable for continuous running, without exceeding temperature limits when the
motor terminal voltage drops to 85% of the motor rated voltage, for 5 minutes, commencing
from hot condition.
5.9 COOLING SYSTEM
All motors shall be self-ventilated, fan cooled. Fans shall be corrosion resistant or
appropriately protected. They shall be suitable for motor rotation in either direction without
affecting the performance of the motor. If this is not possible for large outputs, it shall be
possible to reverse the fan without affecting the balancing of the motor.
5.10 ROTORS
5.10.1 All rotors shall be free from excessive inherent axial thrust. End play of rotor shall be kept to a
minimum, unless Data Sheets specify the end-float required.
5.10.2 The rotor shall be dynamically balanced to provide a low vibration level and long service life
for the bearings. The accepted values of peak to peak vibration amplitudes for a motor at
rated voltage and speed on a machined surface bedplate with the motor leveled and with a
half-key or coupling fitted shall not exceed those given in IS: 12075. Die cast aluminum rotors
for motors in hazardous areas may be accepted provided the same are type tested and
approved by competent authorities.
5.11 EMBEDDED TEMPERATURE DETECTORS
5.11.1 Embedded temperature detecting sensors may be provided when specifically asked for.
5.11.2 Adequate precaution shall be taken to ensure that detector leads shall not be charged
accidentally to motor potential. Film type arrestors will be fitted at detector terminals in
terminal boxes to prevent danger to detecting equipment and personnel.
5.11.3 All motors operating on VSDs shall have embedded temperature detectors / thermistors for
winding with thermistor relay which will trip the motor in case the temperature of winding
exceeds the permissible limits. For temperature detectors / thermistors 2/3 logic shall be
provided for tripping.
5.12 ANTI-CONDENSATION
5.12.1 Anti-condensation heaters shall be provided when specifically asked for. Heaters shall
normally be suitable for 250 volts, Single Phase, A.C. supply, designed for continuous
operation unless otherwise specified in Data Sheet. Heaters shall be metal encased with a
low surface temperature. In addition, a removable, threaded, plug shall be provided to remove
condensed moisture.
5.12.2 Motors meant for humid location such as cooling tower fans, sump pump motors etc. shall be
provided with space heaters irrespective of the motor rating in motor data sheet. The heaters
shall be permanently ON when the motor is not in service.
5.12.3 For motors to be installed in a hazardous atmosphere (Zone-1 or zone-2) such heaters shall
be confirm to the provisions of applicable IS and temperature classifications defined in the
data sheet.
5.12.4 The heater leads shall be brought out to a separate terminal box of the same specification
and grade of protection as the main power terminal box.
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5.12.5 A warning label with indelible red inscription shall be provided on the motor to indicate that the
power line and the heater supply shall be isolated before carrying out any work on the motor.
5.13 LIFTING HOOK
All motors shall be provided with lifting hooks or eye bolts.
5.14 EARTHING TERMINALS
5.14.1 Two earthing terminals comprising terminal studs, two plain washers, one spring washer shall
be provided preferably on diagonally opposite sides of the frame.
5.14.2 All accessories used shall be hot dip galvanised.
5.15 PAINTING
5.15.1 Before despatch from the motor manufacturer's works, all motors shall have all bright parts
coated with anti-rusting compound.
5.15.2 All motors shall be painted in an approve manner using two priming coats, one undercoat and
one finish coat to the Purchaser's Painting Specification, and shall have all surface throughly
cleaned and degreased prior to painting.
5.15.3 The Purchaser's Painting Specification will be issued to the Vendor when orders are placed.
The final colour shall be to the Purchaser's requirements.
5.16 RATING PLATES, LABELS & MARKING
5.16.1 Rating plates shall be provided on all motors. These rating plates together with any labels
giving necessary instructions, shall be of a design so that corrosion will not cause obliteration.
5.16.2 The Purchaser's Motor reference and bearing numbers and other details shall be marked on
an auxiliary stainless steel nameplate if called for in Data Sheets. Rating plates/name plates
shall be fixed to an easily visible, non-removable part of the frame. Rating plates shall give
the necessary information as specified in the applicable standards. Additional nameplate shall
be provided to indicate the service and tag no. of each motor.
5.16.3 For motors to be used in explosive gas atmospheres, indication plate shall have information
such as, the type of construction and the explosion grade and ignition temperature class of
gas.
5.16.4 Motor terminals shall be clearly and permanently marked with reference letters in accordance
with the applicable Indian Standards/IEC.
5.16.5 A non-corrosive connection diagram plate shall be fixed to the motors having special windings
or tappings, such as multi-speed motors.
5.16.6 Uni-directional motors shall have their direction of rotation clearly marked by means of an
arrow.
5.17 VIBRATIONS
Limits of viberations shall be in accordance with IS-12075. The velocity of motor vibration
shall not exceed the value specified in the IS-12075 when measured on the bearing housings
of motors in the horizontal, vertical & axial directions operated with no-load at rated voltage
and rated frequency.
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5.18 NOISE LEVEL
The mean sound pressure level of motors shall not exceed 85 dBA at 1 meter, measured in
accordance with IS-12065 or relevant IEC standard.
5.19 CRITICAL SPEEDS
The first actual critical speed of stiff rotors shall not be lower than 125% of the synchronous
speed. For flexible rotors this shall be between 60% and 80% of the synchronous speed; the
second actual critical speed shall be above 125% of the synchronous speed.
5.20 BEDPLATES & SOLEPLATES
When slide rails, bedplates or soleplates are supplied alongwith motor, the holding down bolts
for the motor shall also be supplied. All embedded parts shall be supplied and shims of SS
304 shall be used.
6.0 SPECIAL TOOLS
A set of any special tools necessary for maintaining the whole of the requirement supplied
shall be provided.
7.1 Test Certificates shall be furnished for all motors indicated in the Data Sheets.
7.2 Routine tests as per IS 4722 shall be carried out on all motors. Type tests shall be carried out
on L.V. Motors, when specifically called for. In case of identical motors, type tests may be
carried out on the first of each rating and speed.
7.3 The manufacturer shall periodically carry out the following type tests as per applicable Indian
Standards for all the frame sizes & ratings of the motors:
a) Full load test and measurement of voltage, current, power & slip
b) Measurement of starting torque, starting current, full load torque & pull out torque
c) Measurement of efficiency & pf at 100%, 75% & 50% load
d) Temperature rise test
e) Momentary overload test
f) Measurement of noise level test
g) Measurement of vibration
h) Over speed test
The above tests shall be witnessed and approved by reputed inspection agencies. The
manufacturer shall maintain the test records and submit to the Owners inspector at the time
of final inspection & testing. In no case the test records shall be more than 5 years old.
In special cases where the type tests are asked to be carried out, these shall be witnessed by
the Owners inspector.
The manufacturer shall carry out routine tests as per applicable Indian Standards. Routine
tests not limited to the following shall form part of the acceptance testing:
a) General visual checks, name plate details, mounting, terminal box location
and cable gland sizes
b) Measurement of shaft height dimensions
c) Measurement of clearances in the terminal boxes
d) Verification of type of terminals (For Ex-e & Ex-n motors)
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e) Verification of direction of rotation

f) Measurement of winding resistance
g) Insulation resistance test ( before & after high voltage test)
h) High voltage test
i) No load test & measurement of voltage, speed, current & power inputs
j) Locked rotor test at reduced voltage & measurement of voltage, current &
power input
k) Reduced voltage staring & running
l) Tests on Ex-d enclosures as per IS
7.4 The Purchaser reserves the right to witness all tests and the Purchaser shall be given ten
working days notice of all tests being carried out.
7.5 All apparatus, instruments etc. required for tests shall be provided by the manufacture and
shall have been checked and tested for accuracy during the twelve months prior to the test.
Calibration certificates for all indicating meters and instruments used for testing shall be
furnished at the time of inspection.
7.6 A certificate issued by the relevant authorities shall be provided for each Ex-d or Ex-e certified
motor.
The manufacturer shall submit the following certificates for verification to the Owners
Inspector:
(a) Test certificate for the degree of protection of enclosure
(b) Test certificates issued by the recognized independent test house for hazardous area
motors
(c) Approval certificates issued by Statutory Authorities for Ex-d motors
BIS license & marking requirement as required by Statutory Authorities for Ex-d
motors
7.7 Thought the motors shall be accepted on the basis of the satisfactory result of the testing at
shop, it shall not absolve the Vendor from liability regarding the proper functioning of the
motors coupled to the driven equipment at site.
8.0 PACKING AND DISPATCH
All the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for transportation by ship/ rail
or trailer. The equipment shall be wrapped in polythene sheets before being placed in crates/
cases to prevent the damage to finish. Crates/ cases shall have skid bottom for handling.
Special notations such as Fragile, This side up. Centre of gravity, Weight, Owners
particulars, PO no etc shall be clearly marked on the package together with other details as
per purchase order.
The equipment may be stored in outdoors for long periods before installation. The packing
shall be completely suitable for outdoor storage in areas with heavy rains/ high ambient
temperature, unless otherwise agreed.
9.0 INFORMATION, DRAWINGS, LITERATURES
9.1 Vendor to furnish these as per Vendor Document Requirements attached with the
specification. The drawings shall generally include the following :
Data Sheet - Duly filled data sheet
GA drawings - Fully dimensioned, indicating foundation
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details, number and size of cable entries, frame

sizes etc.
Terminal Box Drawing - Fully dimensioned, including arrangement of
Terminals & auxiliaries
Performance
Characterstics - As specified in data sheet
Terminal Wiring Diagram
Calculation for cost effectiveness for energy efficient motors
10 CERTIFICATION
The motors and associated equipment shall have test certificates issued by recognized
independent test house (CMRI/ BASEEFA/ LCIE/ UL/ FM or equivalent). All indigenous
motors shall confirm to the Indian standards and shall be certified by Indian testing agencies.
All motors (indigenous & imported) shall also have valid statutory approvals as applicable for
the specified location. All indigenous flameproof motors shall have valid BIS license &
marking as required by statutory authorities.
11 SPARES
The Vendor shall provide with his quotation, separate priced list of recommended
commissioning and operating spares.
12 QUALITY ASSURANCE
12.1 Quality Assurance shall follow the requirements of Jacobs QA documents.
12.2 Quality Assurance will commence at the enquiry stage and follow through to completion and
acceptance, thus ensuring total conformity to Purchaser's requirements.
13 DEVIATIONS
13.1 Deviations from specification must be stated separately in writing at the quotation stage.
13.2 In the absence of such a statement, it will be assumed that the requirements of the
specification are met without exception.
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Page 1 of 8
MEDIUM AND HIGH VOLTAGE HEAVY DUTY CABLES
DOCUMENT NO: 44NC-4600 : ESS 008
By By By
Page 566 of 674

STANDARD SPECIFICATION : 44NC-4600: ESS 008 DATE : 03 May 2010
MEDIUM AND HIGH VOLTAGE HEAVY DUTY CABLES PAGE : 2 OF 8
REVISION NO : 0
TABLE OF CONTENTS
1.0 SCOPE
2.0 STANDARDS
3.0 SERVICE CONDITIONS
4.0 GENERAL CONSTRUCTION
5.0 TYPE DESIGNATION (FOR PVC INSULATED CABLES)
6.0 GENERAL
7.0 TESTING AND INSPECTION
8.0 INFORMATION AND TEST CERTIFICATES
10.0 DEVIATIONS
11.0 ATTACHMENTS / APPENDICES : NONE
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REVISION NO : 0
1.0 SCOPE
1.1 This specification covers design, manufacture, testing and supply of Medium Voltage PVC
Cables and High Voltage XLPE Cables.
1.2 This specification shall accompany data Sheets, technical specification which will stipulate
specific requirements of Medium and High Voltage Heavy Duty Cables. In case of any
contradiction between various referred standards/specifications/data sheets and statutory
regulations, the following order of precedence shall govern:
- Statutory regulations
- Technical Specifications
- This Specification
- Codes & Standards
2.0 STANDARDS
2.1 The cables shall conform to latest edition of the relevant Indian Standard Specifications with
amendment upto the date of issue of Enquiry, particularly the following Standards :-
IS 613 : Copper rods and bars for electrical purposes
IS 1554 : PVC insulated (heavy duty) electric cables for working voltages
(Part 1) upto and including 1100 Volts
IS 1554 : PVC insulated (heavy duty) electric cables for working voltages
(Part 2) from 3.3kV upto & including 11kV
IS 1885 : Electro Technical Vocabulary Electrical cables

(Part 32)
IS 2633 : Methods for testing uniformity of coating of zinc coated articles
IS 3961 : Recommended current ratings for cables : Part 2 PVC insulated

(Part 2) and PVC sheathed heavy duty cables
IS 3975 : Mild Steel wire, formed wires and tapes for armouring of cables
IS 5831 : Specification for PVC insulation and sheath of electric cables
IS 7098 : Cross - linked polyethylene insulated PVC sheathed cables for

(Part 1) working voltages upto and including 1100 V.
IS 7098 : Cross - linked polyethylene insulated PVC sheathed cables for

(Part 2) working voltages from 3.3 kV upto and including 33 kV
IS 7098 : Cross - linked polyethylene insulated thermoplastic sheathed

(Part 3) cables for working voltages from 66 kV upto and including 220 kV
IS 8130 : Conductors for insulated electric cables and flexible cords
IS 10418 : Drums for Electrical Cables
IS 10462 : Fictitious calculation method for determination of dimensions of

(Part 1) protective coverings of cables
IS 10810 : Methods of test for cables : Mass of zinc coating on steel armour
(Part 41)
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REVISION NO : 0
IS 10810 : Methods of test for cables : Oxygen Index test

(Part 58)
IS 10810 : Methods of test for cables : Flame Retardant test

(Part 61)
IS 10810 : Methods of test for cables : Flame Retardant test for bunched
(Part 62) cables
IEC 230 : Impulse tests on cables and their accessories
IEC 811 : Test methods for insulating and sheathing materials of electric
cables
IEC 840 : Tests for power cables with extruded insulation for rated voltages
above 30KV upto 150KV
IEC 60332 : Test on electric cables under fire conditions
IEC 60540 & : Test methods for insulation and sheaths of electric cables
IEC 60540 A
ASTM D2863 : Standard method for test for flammability of plastics using oxygen
index method
IECAS-61-402 : Thermoplastic insulated wire & cable for transmission & distribution
NEMA-WC5 of electrical energy
IECAS-66-524 : Cross linked thermosetting poly ethylene insulated wire & cable for
NEMA-WC7 transmission & distribution of electrical energy
2.2 In case of medium and high voltage heavy duty cables manufactured in accordance with
other standards, manufacturer or vendor shall state the reference number and title of the
standards adopted. Generally IEC/ BS/ VDE/ IEEE/ NEMA or equivalent standards shall be
acceptable.
2.3 In case of imported medium and high voltage heavy duty cables, standards of the country of
the origin shall be followed if these are equivalent / stringent than the applicable Indian
Standards.
2.4 Medium and high voltage medium voltage heavy duty cables details shall be as specified in
the Technical Specification enclosed with this specification. Manufacturer shall furnish all the
information asked in the enquiry along with the quotation.

Cables shall be suitable for installation as follows:
Above ground in open air locations (trays ducts) in tropical, humid and corrosive atmosphere
prevalent in refineries/petrochemical plants with severe weathering and exposure to solar
radiation.
Directly buried in underground trenches, conduits with uncontrolled back-fill and possibility of
flooding by water and chemicals.
Laid underground in RCC lined cable trenches with possibility of flooding by water.
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REVISION NO : 0
3.0 GENERAL CONSTRUCTION
All power and control cables for use on medium/high voltage shall be heavy duty type,
aluminium / copper conductor, PVC / XLPE insulated, inner sheathed, armoured and overall
PVC sheathed as described below.
4.1 PVC INSULATED CABLES (MEDIUM VOLTAGE)
4.1.1 Conductor
The conductor shall be made from high purity aluminium of grade H4 or shall be of annealed
high conductivity copper of sizes as indicated in the enclosed "Specific Requirements" and
conforming to IS 8130. The conductors of nominal area 10 sq.mm and less shall be circular.
Conductors above 10 sq.mm may be circular or sector shaped.
4.1.2 Insulation
The core insulation shall be of PVC and applied over conductor by extrusion. The PVC
compound shall conform to type A of IS 5831. The core identification shall be as per IS 1554
Part 1. The insulation shall have uniform thickness throughout its length. The average
thickness of insulation and tolerance on the same shall be as per IS 1554 Part 1.
4.1.3 Inner Sheath
For all cables having two or more cores, inner sheath shall be applied over laid cores either
by extrusion or by wrapping, as indicated in enclosed "Specific Requirements". The inner
sheath shall be applied as circular as possible and to fit closely on the laid up cores so that it
can be removed without damage to the insulation.
The inner sheath shall be of PVC compound and shall not be harder than PVC used for
insulation. This shall conform to requirement of type ST-I of IS 5831.
4.1.4 Armouring
Armouring shall be applied over inner sheath, where specified and shall be of galvanised
steel as per IS 3975. The armour shall be applied as closely as possible with left hand
direction of lay. For cables having diameter over the inner sheath less than 13 mm, the
armour shall be of galvanised round steel wires. Where the calculated diameter over the inner
sheath is greater than 13 mm, the armour shall consists of either galvanised round steel wires
or galvanised steel strips. The dimension and resistance of armour shall be as per IS 1554
Part 1.
4.1.5 Outer Sheath
The outer sheath of the cable shall be applied by extrusion and shall be of black colour PVC
compound conforming to requirements of type ST-1 compound of IS 5831. The thickness of
outer PVC sheath and its tolerance shall be as per IS 1554 (Part 1). To protect the cable
against rodent and termite attack, suitable chemicals shall be added into the PVC compound
of the outer sheath.
4.2 XLPE INSULATED CABLES (HIGH VOLTAGE) :
4.2.1 Conductors
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REVISION NO : 0
The conductors shall be made from H4 grade aluminium wires. These shall be stranded and
compacted circular in shape up to 35 sq.mm size cables. The conductors of three core cables
having their nominal cross section 50 sq.mm and above shall be either circular or sector
shaped. The conductor and its construction shall conform to IS 8130 and IS 7098 (Part 2).
4.2.2 Insulation
The insulation shall be chemically cross-linked polythylene conforming to the physical,

electrical and ageing properties as required by IS 7098 (Part 2). Only natural colour
compounds shall be used for insulation of cables. It shall be free from voids and shall
withstand all mechanical as well as thermal stresses under steady state and transient
operating conditions.
4.2.3 All cables rated above 4.3/4.3 KV shall be provided with screening. This shall consist of
conductor screening as well as insulation screening.
1 Conductor Screening
Conductor screening shall be non-metallic and shall consist of either semi-conducting
tape or extruded semi-conducting compound.
2 Insulating screening shall be in two parts, first non-metallic semi-conducting part and
second metallic part. Non-metallic part shall be applied directly over insulation of
each core and shall consist of tapped or extruded semi-conducting compound. On
top of this, metallic screening of non-magnetic tap or braid or concentric serving of
wire shall be applied.
4.2.4 Inner Sheath
In cables having three cores, the individual core shall be laid up with suitable non-
hygroscopic fillers and then applied with common covering of PVC or thermoplastic material
by extrusion or tapping such that circulating of cable is maintained. The sheath shall conform
to requirements of type ST-2 compound of IS 5831. The thickness of sheath shall be as per
IS 7098 (Part 21).
4.2.5 Armouring and Outer Sheath
The Armouring and outer sheath of XLPE cables shall be generally in line with Clause 4.1.4
and 4.1.5 , respectively, as described above. However, size and tolerance for XLPE cable
shall be as per IS 7098 (Part 21), except for outer sheath to be of type ST-2 as per IS 5831.
5.0 TYPE DESIGNATION (For PVC insulated cables)
1 AYWY : Aluminium conductor, PVC insulated, PVC sheathed round steel

wire armoured with overall PVC sheathed.
2 AYFY : Same as in '1' above, except that flat steel strip armoured in place of
round steel wire
3 YWY : Same as in '1' above, except that copper conductor in place of

aluminium conductor
4 YFY : Same as in '2' above, except that copper conductor in place of

aluminium conductor
5 AYY : Same as in '1' above but without armour
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REVISION NO : 0
6 YY : Same as in '3' above but without armour
6.0 GENERAL
6.1 Cables shall be supplied in accordance with the enclosed "Specific Requirements". Cable
lengths indicated therein are tentative and actual requirements will be indicated to the
Supplier at the time of order placement. Quoted unit rate shall be applied for actual length
required without any price variation for change in length.
6.2 Cables less than standard drum length shall be supplied in one length.
6.3 Each type and size of cables ordered shall be supplied in separate non-returnable wooden
drum of robust construction covered with wooden planks all round as per IS 10418. Each
cable drum shall be clearly marked with cable size, type, length of cable, total weight,
direction of drum rotation etc. as per IS 1554.
6.4 Both ends of every cable piece shall be adequately sealed and protected against damage
and ingress of moisture.
6.5 A tolerance of plus or minus 5% maximum shall be permissible for each drum unless
specifically agreed. Short/non-standard length of cable shall not be accepted.
6.6 Following information shall be embossed at every one (1) meter for full length of cable.
- Manufacturer's identification mark
- Standard mark of Bureau of Indian Standard with applicable specification
number
- Sequential marking of cable length in meter
- Cable size
7.1 After completion of manufacturing of cables and prior to despatch, cable shall be subjected to
routine tests, acceptance test and type test (if indicated in "Specific Requirements") in
accordance with latest edition of relevant Indian Standard Specification at manufacturer's
works.
7.2 Purchaser/Consultants reserve the right to inspect cables during process of manufacture in
all its stages as well as after manufacture to witness tests. Final acceptance of materials shall
be subject to satisfactory inspection and testing at manufacturer's works.
8.0 INFORMATION AND TEST CERTIFICATES
Information and test certificates shall be furnished by the Vendor as per the Vendor
Document Requirement enclosed and given below.
8.1 Copy of certification mark license obtained from Bureau of Indian Standards.
8.2 Full constructional data giving details of conductor, insulation, sheath, armour etc.
8.3 Current ratings in air as well as ground under normal condition of installation at an ambient
temperature of 40C. (Also indicate - (a) Normal conditions, (b) Maximum conductor
temperature when it is carrying its rated current, and (c) Maximum conductor temperature
during short circuit );
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REVISION NO : 0
8.4 Rating factors for different methods of installation with reference to ambient/ground
temperature, grouping, variation in depth of laying in ground, thermal resistivity of soil etc.;
8.5 Colour scheme for core identification;
8.6 Insulation resistance at 20C per K.M.;
8.7 Conductor resistance at 20C;
8.8 Values of inductance and capacitance per km.;
8.9 Overload capacity giving values of current and duration;
8.9 Short circuit capacity giving values of current and duration;
8.10 Weight in kg. per km.;
8.11 Standard drum lengths for each size of cable;
8.1 Quality Assurance shall follow the requirements of Jacobs. Q.A. Documents, as applicable.
8.2 Q.A. involvement will commence at Enquiry and follow through to completion and accep-
tance, thus ensuring total conformity to Purchaser's requirements.
10.0 DEVIATIONS
9.1 Deviation from Specifications must be stated in writing at the quotation stage. In the absence
of such a statement, it will be assumed that the requirements of the Specifications are met
without exception.
Page 573 of 674

Page 1 of 33
ELECTRICAL INSTALLATION
By By By
Page 574 of 674

ELECTRICAL INSTALLATION PAGE : 2 OF 33
REVISION NO : 0
TABLE OF CONTENTS
1.0 GENERAL 3
2.0 DESIGN 3
3.0 EQUIPMENT & MATERIALS 5
4.0 CIVIL WORK 7
5.0 OUTDOOR SWITCHGEAR INSTALLATION 8
6.0 INSTALLATION OF TRANSFORMERS 8
7.0 INSTALLATION OF EHV, HV & MV SWITCHGEAR & MOTOR CONTROL CENTRES 9
8.0 INSTALLATION OF BUSDUCT 10
9.0 INSTALLATION OF BATTERIES 10
10.0 INSTALLATION OF NEUTRAL EARTHING RESISTOR 10
11.0 INSTALLATION OF POWER & LIGHTING DISTRIBUTION BOARD 10
12.0 MOTORS 11
13.0 CABLE INSTALLATION 11
14.0 LIGHTING INSTALLATION 15
15.0 EARTHING & LIGHTNING PROTECTION 19
16.0 ELECTRICAL INSTALLATION IN HAZARDOUS AREAS 21
17.0 STEEL WORK 22

18.0 INSPECTION, TESTS & COMMISSIONING OF ELECTRICAL EQPT. 22
AND INSTALLATION
19.0 INSTRUMENT & TOOLS 26
20.0 LABOUR, SUPERVISION, COORDINATION & PROGRESS, LICENCE, 27
STATUTORY APPROVAL
21.0 QUALITY ASSURANCE - QUALITY CONTROL 27
22.0 ACCEPTANCE OF INSTALLATION 28
23.0 ATTACHMENTS / APPENDICES : 28

23.1 APPENDIX I - LIST OF CODES, STANDARDS & STATUTORY 28
REGULATIONS
23.2 APPENDIX II 30
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REVISION NO : 0
1.0 GENERAL
1.1 SCOPE
This specification covers the technical requirements for equipment, materials and
installation methods, testing and commissioning of electrical system which will generally
include the following:
i) E.H.V & H.V. Outdoor Switchyards
ii) Power & distribution Transformers
iii) E.H.V., H.V. & M.V. Switchgear
iv) Motor Control Centres
v) Power distribution Boards/Power Control Centres
vi) Lighting Installation, including Lighting Distribution Boards, Lighting Fittings &
Socket Outlets.
vii) Wiring for Power, Control, Lighting & Instrumentation
viii) Earthing & bonding of Electrical Equipment, Anti-static Earthing & Lightning
Protection
ix) Emergency Power Generating Equipment
x) Batteries & Associated Equipment.
xi) Communication Systems
xii) Fire Alarm System
1.2 CODES, STANDARDS AND STATUTORY REGULATIONS

Appendix I to this Specification lists the codes, standards and statutory regulations to be
used. This list is not exhaustive and in general, all equipment materials as well as
design and construction shall be in accordance with the latest issues of Indian and/or
Relevant Standards currently in force.
1.3 RELATED DOCUMENTS

This specification is to be read in conjunction with the other contract Documents that will
include General Conditions of Contract, Special Conditions of Contract.
2.0 DESIGN
2.1 EQUIPMENT AND MATERIALS
Equipment of a major or specific nature, such as Transformers, Switchgear, Motor
Control Centres, Motors, Starting & Control Gear, Generators, Batteries, Rectifiers,
communication Equipment, Fire & Plant Alarm System etc. shall be provided by the
Contractor. Equipments supplied by the Contractor shall conform to the
Purchaser's/Owner's 'Particular Specifications' for such equipment. These specifications
may also be detailed in the Contract Documents. Materials not specifically described
shall be of the best quality, complying with applicable codes, standards or current
engineering practice. Selection of equipment and materials shall also be based on the
technical details, performance figures and recommendations given by the manufacturer
and site condition.
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REVISION NO : 0
2.2 ALTERNATIVE EQUIPMENT, MATERIALS OR METHODS

Where the Contractor wishes to use alternative equipment, materials or methods to
those specified, the approval of the Purchaser/PMC shall be sought at the time of
tendering, and shall not be assumed unless specifically confirmed by the
Purchaser/PMC, in writing.
2.3 INSTALLATION DOCUMENTS
The Contractor shall carry out, all electrical installation design including the following:
i) Single Line Diagram for Power and Lighting distribution, Earthing System,
Communication System.
ii) Schematic & Control wiring Diagrams for Circuit Breakers, Motor Control and
other Electrical Controls, including Fire Alarm and Plant Alarm Systems.
iii) Location of items of electrical equipment, including Switchgears, Transformers,
Generating Set(s), Control Batteries, Motor Control Centres, Power & Lighting
Distribution Boards, Motors, Control Stations, Lighting Fittings, Socket Outlets,
Switches, Instruments, Instrument/Control panels, Communication Fire & Plant
Alarm Systems, etc.
iv) Main routes for distribution of power, control, lighting and instrumentation
cabling, earthing system, with size and construction details, of associated
trenches, ducts, overhead cable trays, floor / wall cut-outs etc.
v) Cable Schedule, giving type and sizes of cables, respective termination points,
approximate route length, etc. for all power, control and instrument cables and
for main lighting cables.
vi) Sub-circuiting of distribution boards for power, lighting, socket outlet supplies,
process instrumentation and control.
vii) Layouts of earthing system showing earth electrodes, main earth loops or
earthing system, details of construction and earth connections to equipment, for
both equipment and static earthing systems.
viii) Layout and constructional details for lightning protection system, showing
protected zones.
ix) The classification and extent of hazardous areas.
x) Typical installation details for Power, Lighting and earthing.
xi) Material take-off Schedule (Bill of Materials).
xii) Basis of Design & Design Calculations.
The contractor shall carry out design in accordance with Purchaser's Design Standards
Listed in Appendix 1. Installation design other than described above shall be in
accordance with this specification and/or as detailed in the Project Documents. Work
not expressly described shall be in accordance with applicable Codes or Standards
detailed in Appendix 1.
2.4 APPROVAL OF DRAWINGS
2.4.1 All design calculations & drawings prepared by the Contractor shall be submitted to the
Engineer / Purchaser / PMC for comments / approval, before they are finalised. The
number of copies to be furnished by the Contractor shall be as indicated in the Contract
Documents.
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REVISION NO : 0
2.4.2 The Contractor shall be responsible for obtaining approvals of drawings from Statutory
Authorities or Electrical Power Supply Authority as required, when such drawings are in
his scope of work and required to be prepared by him.
3.0 EQUIPMENT AND MATERIALS

3.1 GENERAL
3.1.1 All equipment and materials supplied by the Contractor shall be suitable in all respects for
the type of environment in which these are to be used. Nature of special conditions of
environment, and the extent of areas affected are specified elsewhere.
3.1.2 All equipment shall be of robust construction. The enclosures of equipment installed
indoors shall be dust & damp proof. Equipments installed outdoors shall have weather
proof enclosures.
However, dust & damp proof equipment with a weather protecting canopy may be
accepted in special cases, subject to the approval of the Purchaser / Consultant's
Engineer.
3.1.3 For equipment installed outdoors, particular attention should be paid to the following:
i) Fixing holes shall not be provided through the enclosure or casing of any
component. External mounting lugs with fixing holes shall be provided.
ii) Removable covers and cable entries at the top of the equipment shall be avoided as
far as possible. Where this is not practicable, suitable means (which
shall be to the approval of the Purchaser / Consultant's Engineer) shall be adopted
to prevent the ingress of water through the covers or cable entries.
iii) Gaskets shall be secured to the main parts of the enclosure, in such a way, that
they need not be detached during normal installation & maintenance. Gasket
material shall be non-deteriorating and shall not deform or set with age. Where
hinged doors are provided, the door fastners shall be designed to ensure uniform
pressure at all points on the gasket. When the door is closed.
3.1.4 Equipment used in hazardous areas shall be certified by a competent authority as suitable
for use in such areas. The enclosures and other requirements shall be in accordance with
the standards & codes listed in Appendix 1.
3.1.5 All equipment & materials supplied by the contractor shall be to the approval of the
Purchaser / Consultant's Engineer regarding its quality, conformity with specifications and
standards and suitability for site conditions.
3.1.6 The Contractor shall furnish required number of copies of test certificates from
manufacturers or statutory authorities for major equipment as well as equipment suitable
for hazardous areas, supplied by him.
3.2 CABLE AND CONDUIT ENTRIES
Tapped entries shall be provided on equipments, for conduits and cables
If tapped entries cannot be provided on the enclosure, conduit or cable glands terminated
at the enclosure shall be effectively bonded to the same by means of an earthing or
bonding washer (e.g. serrated star washer or equal).
3.3 EARTHING TERMINALS / EARTH BUS
All metal work of the enclosures and non-current carrying metallic parts of the equipment
shall be effectively bonded to one another and connected to two external earth terminals
provided on the enclosure. In equipments, such as Motor Control Centres or Switch-
boards on earth bus running along the entire length of the board should be provided in
place of earth terminals, to which the bonding of internal components shall be carried out,
Page 578 of 674

REVISION NO : 0
the earth bus in turn shall be connected to the main earthing system by 2 separate and
distinct connections.
3.4 EQUIPMENT AND MATERIALS SUPPLIED BY THE CONTRACTOR
The equipment and materials being supplied by the Contractor will be detailed in the
Project Documents. All other equipment and materials required for the complete electrical
installation shall be supplied by the Contractor.
3.5 CABLES
3.5.1 The types of cables used in the installations shall generally be as given below. If any other
special types of cables are required to be used, details of the types will be given
elsewhere.
3.5.1a Paper insulated, lead or lead alloy sheathed armoured or unarmoured, jute served or PVC
sheathed cables of 32, 22 or 11 KV grades, with aluminium conductors.
3.5.1b XLPE insulated screened or unscreened armoured or unarmoured, PVC sheathed cables
of 3.3 KV, 6.6 KV, 11KV, 22KV, 33KV grade with aluminium conductor.
3.5.1c PVC insulated with PVC / rubber inner sheath armoured unarmoured and with overall
PVC sheath with aluminium or copper conductors.
3.5.1d PVC insulated screened or unscreened, armoured or unarmoured PVC outer sheathed
cables of 3.3KV, 6.6KV grade with aluminium conductor.
3.5.1e Muticore flexible cables, with stranded copper conductors, rubber / PVC insulated, with or
without pliable armour and with an overall PVC / Rubber Sheath.
3.5.1f Single core PVC insulated cables with copper / aluminium conductors.
3.5.1g Mineral insulated aluminium conductor cables. Type designation: ALPYRO.
3.5.1h Telephone & communication Cables - Twisted pairs, armoured or unarmoured shielded
cables or coaxial cables.
3.5.1I Special cables - Details of which will be given in specific cases.
3.5.2 Minimum Sizes of Conductors.
No cable having copper conductors of less than 1.5 mm or aluminium conductors of less
than 35 mm shall be used, except special types of cable specifically detailed elsewhere.
3.5.3. CABLE TERMINATIONS AND CABLE JOINTS
3.5.3.1 HV XLPE and PVC armoured cables, shall be terminated or jointed by means of cold
setting epoxy based cast resin jointing system or heat shrinkable or cold setting kit. the
ingredients used shall be of best quality, which will give the joint, excellent mechanical
and electrical properties, resistance to aging & tropical climatic conditions. Plastic moulds
shall be used for casting the joints.
3.5.3.2 Heavy duty PVC cables, up to 1.1 KV grade (armoured & unarmoured) shall be
terminated by means of a compression type cable gland. In hazardous areas or for
outdoor installation, cable glands with two seals, one on outer sheath and one on the
inner sheath, shall be used. In safe and indoor areas, cable glands, with only one seal on
outer sheath may be used. In case of glands for armoured cables, armour earthing cone
or washers shall be incorporated in the gland.
3.5.3.3 Universal type cable glands as per cable manufacturer's design shall be used for Mineral
insulated Cables.
3.5.3.4 Glands used in Division 1 hazardous areas shall be of approved flameproof type.
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3.6 CONDUITS AND CONDUIT ACCESSORIES
Heavy gauge, screwed, rigid steel / PVC conduits shall comply with IS 9537. Steel
conduit may be black enamelled or galvanised as specified elsewhere. PVC conduit
may be black or grey as specified elsewhere.
All conduit fittings and accessories shall be of cast iron / malleable iron / PVC, provided
with screwed entries, and of robust construction. Only large round junction boxes (min.
dia. 80mm) shall be used in the installation. Large round and adaptable rectangular
junction boxes, shall have external fixing lugs. Two external and internal terminals
complete with hardware shall be provided on the steel junction boxes. Terminal blocks
of adequate rating & number shall be provided in the junction boxes for looping.
Inspection type fittings such as bends, elbows and tees shall not be used, unless
specifically called for or approved by the Engineer.
All conduits and accessories shall be black enamelled or galvanised or PVC as
specified elsewhere.
3.7 STRUCTURAL STEEL
All structural steel such as channels, angles, flats, plates, etc. used in the installation
shall be new and of best quality, conforming to relevant Indian Standards.
3.8 CARE OF EQUIPMENT AND MATERIALS
3.8.1 Storage and Care Prior to Erection
The contractor shall be entirely responsible for the safe storage and care of equipment
and materials he supplies for the contract.
Equipment and materials supplied by the Contractor will be held in the Contractors
stores.
During the storage period the Engineer may instruct the Contractor to submit reports
upon the condition of such equipment or materials, to carry out maintenance on
equipment in accordance with manufacturer's instructions or to attend to such points as
giving motors a part turn to alter the position of bearings and insulation resistance tests
on motor winding.
The Contractor shall be responsible for the care and maintenance of all electrical
equipment, whether supplied and/or erected by him, after installation is completed and
until the Certificate of Acceptance of Electrical Installation is signed by the Purchaser.
The Contractor shall ensure that the proper enclosure of equipment is maintained at all
times and that access doors or covers are opened only when necessary to work upon
the equipment. All unused cable or conduit entries shall be effectively sealed.
4.0 CIVIL WORK

4.1 GENERAL
All major Civil work such as foundation for electrical equipment, sub-stations or switch
room buildings shall be carried out by the Contractor. Minor civil works such as
grouting of equipment foundation bolts, breaking and remaking of floor walls, etc. shall
also be carried out by the Contractor.
Excavation & backfilling of trenches for directly buried cables, earth electrodes,
installation of street lighting poles (including concrete foundation for poles) shall be in
Contractor's scope of work. Provisions of Hume pipes for road crossings shall also be
in the scope of Contractor's work.
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REVISION NO : 0
5.0 OUTDOOR SWITCHGEAR INSTALLATION

5.1 GENERAL
The installation work for outdoor switchyards shall generally consist of installation of
outdoor equipment, such as air-break switches, lightning arresters, circuit breakers,
current & potential transformers and overhead bus work. Installation of transformers is
covered by Section 6.
5.2 STEEL WORK
All steel work shall be painted in an approved manner as described in Section 13 and
hardware used may be hot dip galvanised.
5.3 INSTALLATION & COMMISSIONING
5.3.1 Requirements of Indian Electricity Rules shall be strictly observed.
5.3.2 Various types of equipment shall be installed in accordance with drawings and / or
manufacturers instructions and good engineering practice. Particular attention shall be
paid to lubrication of moving parts & bearings, alignment tightness of all connections
(mechanical and electrical ) and wiring.
5.3.3 Overhead bus work shall be of copper or aluminium or A.C.S.R. conductors. Suitable
terminal clamps or connectors shall be provided, except where these are provided on
the equipment. Where dissimilar material are joined. The materials of connectors shall
be suitable for preventing bimetallic corrosion. The connectors shall be vibration-proof
and their design shall allow thermal expansion of conductors. Alternatively, expansion
joints shall be used.
5.3.4 Complete installation shall be tested for its intended satisfactory operation.
6.0 INSTALLATION OF TRANSFORMERS

6.1 GENERAL
This section shall apply to the installation of Power and Distribution Transformers. Small
transformers for special purposes, such as instrument supplies, low voltage supply, etc.
are excluded.
6.2 INSTALLATION, TESTING & COMMISSIONING.
6.2.1 The transformer shall be installed in accordance with IS 10028 - 'CODE OF PRACTICE
FOR INSTALLATION & MAINTENANCE OF TRANSFORMERS'.
6.2.2 The transformers shall be moved to its location and shall be correctly positioned on its
base.
All parts of the transformers, which are supplied loose, such as conservator, radiator
banks, buchholz relays, dial thermometers, bushings, etc. shall be fitted onto the
transformer.
Transformer oil supplied in drums shall be filled into the transformer after duly testing /
filtering, up to the correct level required.
6.2.3 In case of large transformers, the tanks may be nitrogen filled. In such cases, the
correct procedure as per manufacturer's instructions should be followed for oil filling.
6.2.4 Wiring of devices such as buchholz relay, dial thermometers, etc. shall be carried out up
to the marshalling box.
6.2.5 The transformer shall be dried out by one of the methods specified in IS 10028. Drying
out with centrifugal or vacuum type filters will, however, be preferred. The Contractor
shall carry out the process of drying out without interruption and shall maintain a sheet
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indicating time, oil temperature and insulation resistance.
6.2.6 After complete drying out of the transformer, oil samples shall be collected by the
Contractor and shall be tested for dielectric strength as specified in IS 335 .
6.2.7 All devices such as buchholz relays, dial type thermometer and their alarm and trip
contacts shall be checked for satisfactory operations.
6.2.8 All tests specified in Appendix 'C' of IS 10028 shall be carried out by the Contractor (as
applicable to the particular installation in consultation with the Engineer).
7.0 INSTALLATION OF EHV, HV & MV SWITCHGEAR & MOTOR CONTROL CENTRES

7.1 GENERAL
This section covers Switchgear & Motor Control Centres of indoor as well as outdoor
type. The term switchgear used throughout shall include Motor Control Centres also.
7.2 PRELIMINARY INSPECTION
The Contractor shall carry out a preliminary inspection of the equipment to ensure that
the switchgear to be installed is in a satisfactory condition.
7.3 INSTALLATION
The Contractor shall place the switchgear correctly on the bases or foundation prepared
for the same. If the switchgear consists of a switchboard with number of panels bolted
together, he will place all sections of the switchboard correctly, align them and bolt the
sections together to form one continuous switchboard. The switchgear shall then be
secured to the foundation by means of nuts and bolts or foundation bolts grouted in the
base. The Contractor shall also make inter-section bus / wiring connections.
The Contractor shall clean all parts of the switchgear, including HV bushings (with
carbon tetrachloride), plug & socket contacts, auxiliary switches, etc. Conducting
petroleum jelly shall be applied to all electrical contact surfaces.
The Contractor shall lubricate all moving parts of the Circuit Breaker mechanism with
recommended lubricants, and ensure satisfactory mechanical operation. Alignment of
draw out type circuit breakers or switches shall be checked, for horizontal and/or
vertical movements and its correctness shall be ensured. Operation of all mechanical
interlocks shall also be checked.
In case of oil circuit breakers, the Contractor shall fill, clean and test transformer oil in
the circuit breakers, collect oil samples and test the same as per IS 335.
The Contractor shall generally check all internal wiring of the switchgear for its accuracy
as per Vendor's wiring diagram. Satisfactory operation of all controls and protection
circuits, relays, meters & electrical interlocks shall also be checked. Relay settings and
adjustments, if any, shall also be carried out by the Contractor.
The Contractor shall test the insulation resistance of main power circuits, bus bars, P.T.
primary windings, etc. of HV & EHV switchgear with a high voltage megger (minimum
2,500 volts). The insulation resistance of MV switchgear and motor control centres as
well as control and auxiliary wiring of HV & EHV switchgear may be tested with a
500 megger.
The Contractor may also have to carry out high voltage tests on the switchgear, if
indicated elsewhere..
The Contractor shall also carry out Primary and Secondary injection test and check the
calibration of relays and meters wherever required.
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8.0 INSTALLATION OF BUSDUCT

The bus duct as per relevant drawings will be supplied in parts and all the parts shall be
assembled and the bus bar connections shall be made at site. The insulators in bus ducts
shall be inspected for any possible damage during transit and the defective ones shall be
replaced. The insulators shall be cleaned. Contact surface of bus bars, bus bar bolts and
nuts shall be thoroughly cleaned. Petroleum jelly shall then be applied and bolted
connection made. The bus duct enclosure shall be checked for earth continuity and then
earthed at two places. The bus duct shall be properly supported between switchgear and
transformer. The opening in the wall where the bus duct enters the switchgear room shall
be completely sealed to avoid rain water entry. Expansion joints, flexible connections etc.
shall be properly connected. The bus duct levelling shall be checked with spirit level and
pendulum weight.
9.0 INSTALLATION OF BATTERIES

Battery shall be erected on stands and insulators supplied by the manufacturer of the
batteries. Electrolyte shall be filled as per manufacturers instructions. Inter row
connections shall be made with the leads supplied by the manufacturer. Charging and
discharging shall be carried out as per manufacturers instructions. Lamp bank load for
discharge test shall be provided by the contractor and battery capacity shall be rechecked.
10.0 INSTALLATION OF NEUTRAL EARTHING RESISTOR

The neutral earthing resistor shall be inspected for any damage to the resistor grid and other
components. The resistor shall be levelled and installed. All covers etc. shall be checked for
tightness to ensure that the enclosure of the resistor is dust, vermin and weatherproof.
Earthing conductors shall be taken from the outer end terminal of the resistor for connection
to earth electrodes and to the main grid.
11.0 INSTALLATION OF POWER & LIGHTING DISTRIBUTION BOARD

11.1 GENERAL
This section shall apply generally to Power & Lighting Distribution Boards, which may
comprise switch-fuse units, isolators, fused distribution boards, distribution boards with
miniature circuit breakers, circuit switchboxes etc.
11.2 PRELIMINARY INSPECTION
The contractor shall carry out a preliminary inspection of the equipment before installation
to ensure that the equipment is in a satisfactory condition.
11.3 INSTALLATION & COMMISSIONING
The installation of factory built distribution boards shall be carried out generally in the same
manner as for M.V. Switchboards of Motor Control Centres.
In case of wall / structure mounted distribution boards, the Contractor shall fabricate and
install the structural steel framework suitable for mounting the various distribution boards.
The Contractor may have to prepare drawing showing the proposed general arrangement,
of the structural frame which shall be to the approval of the Engineer. The fabrication and
installation of the framework shall be recommended only after the approval of drawing.
Various items for the distribution board shall be mounted in accordance with the approved
drawings.
After completion of the installation of distribution boards, internal / interconnecting wiring
shall be checked for correctness. Insulation resistance of wiring and equipment shall be
tested with a 500 Volts megger. Operations of all equipments shall be checked for correct
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functioning.
12.0 MOTORS
12.1 GENERAL
Motor shall be installed along with the driven equipment.
12.2 COMMISSIONING OF MOTORS
The Contractor shall check all the motors installed, carry out the tests required and
commission the motors. The work will include the following:
a. Check rotor for free movement.
b. Check end play in bearings.
c. Check for mechanical defects, if any, by visual inspection.
d. Inspect bearings to ensure they are greased.
e. For D.C. or slip ring induction motors, check commutators, slip rings, brushes,
brush holders and springs, brush lifting gear, etc. for satisfactory condition.
f. Check direction of rotation for correctness and reconnect the leads, if necessary.
g. Check conduit entries on terminal boxes, block unused entries.
h. Carry out insulation test with an appropriate megger.
13.0 CABLE INSTALLATION

13.1 GENERAL
This section covers installation, termination and connection of various types of single-core
or multicore cables (Ref. Sec.3.5).
13.2 INSTALLATION OF CABLES
13.2.1 Cable routes and mode of installation shall generally be as shown in the relevant
construction drawings. When these are not indicated on the drawings, the Contractor shall
determine the same and get them approved from the Engineer before commencing the
work.
For multiple runs of cables, separation between individual cables shall be provided, when
so indicated, to meet the following conditions.
i) Spacing between loaded cables (power) to suit the rating factors applied in the cable
installation design.
ii) Separation between cables for high voltage service and medium or low voltage service.
iii) Separation between certain types of cables for instrument service and other cables.
iv) Separation between duplicate feeders run along the same route, to prevent damage to
one feeder when the other feeder becomes faulty.
13.2.2 Identification tags indicating cable designation, shall be affixed to each cable at ends and at
an interval not exceeding 15 meters or at the location where cables change direction or
elevation. Cable tags shall be made of stainless steel or any other non-corroding material
suitable for site and installation conditions. Cable designation shall be embossed in the
tags.
13.2.3 Mode of Installation
Modes of installation of cables shall generally be as given below:
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i) Directly buried in the ground.
ii) Installed in built-up trenches in ground, floors, etc.
iii) On cable trays run overhead along pipe/cable racks, or supported on structures,
masonry etc.
iv) Cables run along structural steelwork or masonry, supported by suitable saddles, cleats,
hangers, etc.
13.2.4 Directly Buried Cables
Trenches shall be excavated along the routes indicated in the relevant drawings and / or
approved by the Engineer. They shall be straight and excavated uniformly to a depth shown
on the relevant drawings or approved by the Engineer.
After excavation, the floor of the trenches shall be firmed and a bedding of sifted soil or
clean sand with a well distributed grain size shall be prepared. The bedding shall be well
compacted to density of 1,750 kg / cubic meter. The thickness of the compacted bedding
shall not be less than 75mm.
Proper equipment, such as stands for supporting cable drums and rollers for drawing
cables shall be used for laying cables in trenches. Cables shall be laid without kinks and
utmost care shall be taken in handling them.
After laying the cables, they shall be covered with sifted soil or clean sand well compacted,
up to 150 mm above the top of cables. The cables shall be covered by interlocking cable
tiles extending at least 50 mm beyond the cables on both sides. Alternative methods, such
as use of bricks for cable protection or coloured concrete screen, as specified elsewhere.
After placing of cable tiles, the trenches shall be backfilled completely with riddled soil.
Large stones shall not be backfilled. The backfill shall be well rammed and compacted.
At road crossings or at specified locations, cables shall be laid in hume pipes or
prefabricated cable ducts, or any other type of pipes specified elsewhere. After drawing the
cables, the ends of pipes or ducts shall be sealed adequately with wooden plugs or any
other approved means, to prevent ingress of soil or dirt into the pipes and ducts.
When directly buried cables enter the buildings, the openings made in walls shall also be
adequately sealed to prevent ingress of soil or sub--soil water into the building. Bituminous
or suitable type of PVC compound shall be used for this purpose.
Approved type of cable markers shall be fixed along the cable routes at a distance not
exceeding 15 meters along straight routes, and also where cable loops or cable joints are
located. The position of cable markers and cable identification tags shall coincide.
When cables are laid in multiple tiers, space between individual tier shall be filled and
compacted with sifted soil or sand. Spacing between tiers shall be as specified elsewhere.
Protective cable tiles above the topmost tier only.
13.2.5 Cables in Built-up Trenches
Cables run in trenches shall unless otherwise specified, be installed in sand, in layers.
Separators of non-combustible materials shall be provided, where necessary to ensure
adequate segregation between cables.
Each layer of cables shall be laid on a compacted and consolidated bed of clean sand
having well distributed grain sizes (silver sand). Each layer of cables shall be covered by a
well compacted clean sand up to 75 mm above the top of cables. Next layer of cables will
be laid on this sand bed. On completion of laying of cables, the whole trench shall be
completely sand filled and well compacted. The trenches shall then be covered by any one
of the following methods as specified elsewhere.
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Built-up trenches for cables may be provided in outdoor plant areas, buildings, switch
rooms,
a) Fitted with RCC covers (preferably coloured red) and sealed.
b) Screened over with red coloured lean concrete to finished payment level.
c) Fitted with removable steel chequered plate, covers, generally in sub-stations,
switch-rooms, control rooms and similar indoor locations.
d) Fitted with specially designed covers at road crossings or similar locations
subjected to heavy traffic.
Cables emerging from trenches for final runs to items of equipment shall be protected by
steel pipes up to a height of 200 mm above the finished floor/pavement level. Pipes shall
be fixed onto the trench wall and where they pass through the trench cover, shall be
sealed with bitumastic compound.
All openings in trenches for ducts, cable entry into buildings, etc. shall be sealed
adequately with bitumastic compound or lean concrete.
The trenches in non-hazardous indoor areas, such as control rooms, switch rooms, etc.,
need not be sand filled. Cables may be supported in trenches by means of hangers, cleats,
cable trays, etc.
13.2.6 Cables on Walls, Structures or Cable Trays
Cables shall be run on walls, structure or laid on cable trays, as required. Only approved
type of cable supports or fixings such as cleats, saddles, hangers or straps shall be used.
13.2.6.a Cables Fixed to the Walls or Steelwork
Cables shall be secured by means of saddle bars and saddles. Minimum clear spacing
between walls or steelwork and cables shall be 6mm ( "). The type of saddles used shall
be as shown in the relevant drawings or subject to the approval of the Engineer.
13.2.6.b Cables Supported on Cable Trays
Cables shall be secured to the cable trays by means of single fixing type of saddles or
adjustable cable saddles, made of approved material, when run on horizontal or vertical
cable trays.
13.2.6.c Spacing of Cable Supports
Maximum horizontal & vertical spacing of cable supports shall not exceed 750 mm (30") &
500 mm (20") respectively. When cables are run on cable trays, they shall be securely
supported on each rung of the cable tray.
13.2.7 Cable Trays
Cable trays shall be one of the following types or as specified elsewhere:
i) Site fabricated ladder type cable trays from M.S. Channels, angles, flats as per
cable tray details depending on the weight of cables required to be supported on
cable trays and maximum cable tray supporting distance. The construction of
these cable trays shall be all welded type.
ii) Shop fabricated, heavy pattern, perforated, steel cable trays, galvanised or
painted as specified elsewhere. The cable trays shall be in standard length
sections and shop fabricated bends or tees shall be used. Individual sections
shall be securely bolted together.
iii) Shop fabricated PVC / FRP cable trays.
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Cable trays supports and tray design shall be based on the loading of cable trays.
Generally, the design, shall be such that cable trays supports spacing will be 2 meters or
more.
13.2.8 Single Core Cables
Single core Cables comprising one 3 phase circuit shall be run throughout in trefoil
formation. Cables spacers made of hardwood blocks or any other suitable non-magnetic
material shall be used for supporting the cables. Type and material of clamps shall be to
the approval of the Engineer.
Single core cables shall not be run directly buried in ground unless they are installed in a
protected area, not accessible to unauthorised persons and suitable mechanical protection
is provided. When more than one cable is in parallel per phase, care should be taken to
ensure that all such cables have equal lengths. When single core cables are run in trefoil
formation, for long distances, cables shall be transposed at regular intervals.
13.3 TERMINATION & CONNECTION OF CABLES
13.3.1 High Voltage PVC / XLPE Armoured Cables
H.V. XLPE / PVC armoured cables shall be terminated or jointed by means of cold setting
epoxy based cast resin jointing system or heat shrinkable or push on type cold setting kit.
In case of cable terminations at equipment, dust sealing glands may be used where cables
enter the enclosure, even though the termination is made with cast resin. Particular care
shall be taken to ensure proper bond between the cable armour and earthing system. The
earthing clamp and the earth conductor shall be of adequate size to ensure sufficient earth
return current in the event of a fault. for HV cables, a stress cone shall be made for proper
distribution of dielectric stress.
13.3.2 Heavy Duty LT PVC / XLPE Cables
Heavy duty LT PVC / XLPE Cables, armoured or unarmoured shall be terminated with
compression type cable glands.
When armoured cables are used, the armour shall be prepared in a manner suitable for the
type of cable glands. Armour shall be securely clamped & bonded to the body of the gland.
Armour shall be properly cleaned and petroleum conducting jelly applied to the armour as
well as clamping surfaces. When specifically called for and in hazardous areas, cable
glands shall be further sealed with cold setting PVC compound.
When cable glands are fixed onto a sheet metal enclosure, with a slip hole, a bonding /
earthing washer and a heavy check - out shall be used to ensure effective bonding of the
cable gland with the enclosure.
In corrosive areas, glands shall be coated with corrosion inhibiting varnish lacquer after
installation and covered with PVC hoods, if specifically called for.
13.3.3 Mineral Insulated Metal Sheathed Cables
These cables shall be terminated with the appropriate glands and in a manner
recommended by the manufacturers.
13.3.4 Prevention of Strain at Terminations
Special attention shall be given to ensure that the cable is adequately supported so that
there is no strain on the termination or connection of conductors
Particularly when cables are terminated at equipments, which are subject to vibrations,
strain relief clamps shall be provided where the support for the cable is derived from the
equipment so as to prevent relative displacement of the support with respect to the
termination.
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In case of small sized PVC cables or mineral insulated cables a loop may be formed
adjacent to the termination. This will also allow for slight movement of the equipment.
13.3.5 Connection of Cable Cores / Conductors
13.3.5.a All cable cores or conductors shall be connected to the equipment terminals be means of
approved type of connectors. Conductors of small sizes may be directly connected to
equipment terminals, without using special connectors. The sizes of directly connected
conductors will depend on the type of terminals provided. Connections of larger cables or
cables connected to motors shall be made, generally with crimping type cable lugs, unless
best quality, approved type, mechanical connectors are used. Solid conductor of small size
cable shall be connected by forming loop and Ross Cutney.
13.3.5.b Conductors shall be thoroughly cleaned and smeared with conducting petroleum jelly
before they are connected directly or with mechanical connectors, particularly when bi-
metallic connections, such as aluminium and copper or brass are made. Materials used for
mechanical connectors shall also be of suitable type when bi-metallic connections are
involved.
Mechanical connectors or equipment terminals shall be of pressure clamp type (not
pinching type), when aluminium conductors are to be connected. However, if stranded
aluminium conductors have to be made to pinching type terminals, the conductors shall be
soldered solid before connection.
13.3.5.c Core identification ferrules or coloured PVC adhesive tapes shall be provided for all
multicore cables at the point of connection. Generally, red, yellow & blue coloured tapes
may be used for identification of cores in power circuits. Ferrules or numbered tapes shall
be used for identification of control cable cores.
13.3.5.d Jointing & Soldering of Aluminium Conductors
Most of the cables used will be with aluminium conductors, and the contractor shall
exercise care for joining and soldering aluminium cables. The contractor shall ensure that
this work will be carried out by competent persons having a thorough knowledge and
experience of aluminium soldering work in electrical trade and preferably, having a
certificate from cable manufacturers.
The Contractor shall use special soldering materials & accessories such as fluxes, special
wiping cloth, cleaning tongs, special laddies & solder pot with thermometer, which are
essential for joining. The work shall be carried out strictly in accordance with approved
codes of practice for aluminium conductor soldering.
All materials used shall be of approved type. Petroleum conducting jelly or equivalent
corrosion inhibiting compound shall be copiously used after finishing the above work, to
prevent corrosion and its after effects
14.0 LIGHTING INSTALLATION
14.1 GENERAL
The lighting fixtures in the plant shall be fed from lighting panel. All outdoor lighting shall
be group controlled from control stations or through synchronous timer or photocell.
Lighting wiring between panel and lighting fixtures shall be done with PVC insulated
3 core (phase, neutral and earth) copper conductor armoured cable for hazardous areas.
Wiring in the building shall be done by means of 3 core copper conductor, PVC insulated,
armoured cables, or PVC insulated copper conductor wires in conduit / Metsec
channel as specified elsewhere. All joints of conductors in Switchboards / JBs, fittings
shall be made only by means of approved mechanical connectors (nylon / PVC
connectors), Bare twist joints shall be permitted any where in the wiring system.
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14.1.1 The electrical contractor shall determine, with approval of Engineer-in-charge or his
authorised representative, the exact locations of each fixture in order to avoid interference
with piping or other mechanical equipment and also with a view to obtain as much uniform
illumination as practicable and to avoid objectionable shadow. Conduits shall be laid out
by the contractor to suit field conditions as per directions of the Engineer-in-Charge.
14.1.2 On walkway, platforms and other outdoor area, lighting fixtures shall be located nearer to
landing of stairs or ladders, gauges, flow meters, panel boards and other equipment to
provide proper illumination.
14.1.3 The minimum height of any lighting fixture shall be preferably not less than 2.5 meters
above the floor level.
14.1.4 All outdoor cable terminations to junction boxes, panels etc. shall be preferably through
bottom or side entry. Top entries for cables shall be avoided to avoid water entry. All
cable glands for outdoor terminations shall be double compression type and the gland
shall be covered with PVC or rubber boot shroud. All unused cable entries shall be
plugged with suitable blanking plugs.
14.1.5 Mounting height of equipment shall be as under :-
Top of Witch Box : 1200 mm from FFL (Finished floor level)
Top of Lighting / Power Panel : 1800 mm from FFL
5/15 Amp. Receptacle : 300 mm from FFL unless otherwise specified
(1200 mm for process areas).
Lighting fixture : As indicated in layout drawing.
Exhaust fan : In the cut out provided / As indicated in Layout
Drawing.
14.1.6 Fixtures shall be firmly supported from the structures. Support clamps etc. may be bolted
or welded to the existing steel work or metal inserts. In case of concrete structures, where
metal inserts are not available, fixtures shall be suspended from Concrete surfaces with
the help of anchor fasteners. In such cases special care shall be taken to see that
anchoring is firm. In places where ceiling fans are provided, lighting fixtures shall be
suspended below the level of fan to avoid shadow of fan falling on ground.
14.1.7 Circuit cables shall be cleared in a group to structure by using galvanised strip clamps or
run in cable trays wherever trays are available. Spacers and cleats shall be of required
size to accommodate the cables. All hardware shall be galvanised or zinc passivated.
Underground lighting cables (in paved areas) shall be taken in suitable G.I. sleeves buried
at a minimum depth of 300 mm from FFL. GI pipe sleeves shall be extended to 300 mm
above FFL. Exact termination / layout of G.I. pipes ( for protection of cables ) shall be
decided at site as per site convenience.)
14.1.8 Wiring for all socket outlet shall be done with 3 cores of equal sizes of wire for phase,
neutral and earth. The terminals of switch sockets shall be suitable to receive the size of
wire specified elsewhere.
14.1.9 All lighting fixtures shall be provided with terminal block with required terminals suitable for
connection of 2.5 sq. mm conductor size or higher as specified elsewhere.
14.1.10 The cable shall be straightened after unwinding it from the drum. All cables be clamped /
laid in straight run without any sag and kink.
14.1.11 For location where fan points are shown, fan hooks with junction box shall be provided
during concreting. Where fan hooks and J.Bs. are provided separately JB shall be located
within a distance of 300 mm from hook for mounting of ceiling rose.
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14.1.12 Industrial type plug sockets with appropriate rating of MCB or rating as per job
specification shall be provided at a height of 500 mm from FFL for window AC units.
Socket outlets plugs in Sub-station, DG shed, workshop maintenance shop etc. shall be of
industrial metal clad type.
14.1.13 Wiring for exhaust fans shall be terminated in receptacles as specified elsewhere and
the connection from receptacle to the exhaust fan shall be by means of a flexible cord
equivalent in size to the main run of wires. Switch for exhaust fan shall be located in
a separate switch board along with other switches.
14.2 CONDUIT INSTALLATION
14.2.1 Surface Conduit Installation
When conduits for exposed or concealed wiring are installed on surface, the complete
routing shall be marked on the surfaces. The installation shall be carried out only after
approval of the routing by the Engineer. Conduit installation shall be carried out accurately
and neatly, with conduit runs truly vertical or horizontal. Conduits shall be threaded to close
tolerances and burr removed from the ends after threading. All screwed connections shall
ensure that at least five threads are engaged and electrical continuity maintained.
Conduits shall be supported with saddles at a spacing of 1200mm max. for conduits up to
1" size and 180mm maximum for larger sizes. Saddles shall also be provided at both ends
of fittings, equipment, devices, junction boxes, bends or offsets, within 200mm max.
Minimum clearance between conduit and surface shall be 6mm. Saddles shall be of cast /
malleable iron, cast aluminium or any other approved material, and galvanised painted or
cadmium plated.
14.2.2 Embedded Conduit Installation
Conduit installation may be embedded in RCC structures or brick work.
The installation in RCC structures shall be carried out after the form work and
reinforcement work is complete, but before concreting . Concreting, which will be done only
after completion of the conduit installation and its approval by the Engineer. Conduits laid
in concrete all have minimum 50mm cover up to the finished surface and shall preferably
be laid behind the reinforcement. Conduits shall be securely led to prevent their movement
during concreting.
Installation in brickwork will require chases to be made in brickwork, sufficiently deep to
provide adequate cover for the conduits. Conduits shall be securely fixed to the brickwork
and chases made good.
In this type of conduit installation, a galvanised fish wire shall be drawn in conduits.
All embedded accessories such as junction boxes, switchboxes, etc. shall be mounted
such that they will flush with the finished surfaces including plaster. All joints in the
installation shall be tight and covers properly gasketted and fixed to prevent ingress of
concrete slurry, water or dust.
14.3 Conduit Wiring
Conduit wiring shall generally be carried out with single core PVC insulated cables / wires.
If any other type of cables is to be used, the same will be indicated in the Contract
Documents.
The Conduit installation shall be complete in all respects before the cables are drawn in
conduits. All conduit runs shall be thoroughly cleaned of dust, moisture, etc. by blowing
compressed air or by any other suitable means. An approved lubricating compound (such
as soap stone powder, lux flakes or talc) shall be applied to the insulated cables before
they are drawn in conduits. The cables shall be neatly bunched together to prevent kinks or
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twisting.
14.4 POINT WIRING
Each point wiring shall comprise the following:
Supply and installation of " /1" / 1" heavy duty M.S. / PVC conduits with MS / PVC
accessories such as 90 bends, inspection Tees etc. as required - supply and pulling of 2
nos. 3/22 PVC insulated stranded copper single core wires of 440V grade and one number
14 SWG copper wire outside conduit for earthing. It shall also include supply and
installation of multi-way large round junction boxes with Dome / Flat covers and four way,
15A terminal block. For suspending of fluorescent lighting fitting, dome cover junction box
shall be used.
Supply, Fabrication and Fixing of hardware such as clamp, Saddles Bolts, Nuts,
Framework, etc. as required. 14 gauge bare copper earthing wire shall be run within
conduits for earthing of fittings, junction boxes, switch / single phase socket outlet
enclosures.
Earthing shall be done at single point.
Wiring from LDB to lighting fittings exhaust fans single phase outlets, shall be carried out
with 3/22, YY cables through " /1" / 1" heavy duty M.S / PVC conduits.
Junction boxes shall be fixed on brackets, fabricated from 25 x 3 mm MS flat. Such
brackets shall be fixed to the ceiling / wall by means of anchor bolts / nylon raw plugs and
screws. Each equipment such as lighting fittings, switches, junction boxes, socket outlets,
exhaust fans etc. shall be earthed internally by the third core of the 3 x 2.5 mm YWY cable
used.
14.5 MEASUREMENT OF POINT WIRING
Wiring from D.B's / switchboard to the first lighting fitting through the circuit switch shall be
considered as one point. Wiring from the first fitting to the next fitting in the same circuit
shall be considered as half point. Wiring to the exhaust fan shall be considered as one
point. For measurement of switch socket point wiring, wiring from D.B. / switchboard upto
first socket outlet through ckt. switch shall be considered as one point. Subsequent wiring
to next socket outlet shall be considered as half point, supply and installation of light fitting,
fans, exhaust fans, socket outlets shall be covered under separate item rate.
If a separate circuit is tapped from the same lighting circuit, it shall be treated as half point.
If a socket is located very near to a Distribution Board, it will be considered as half point.
Otherwise this shall be considered as an independent point.
Quoted rate of point wiring is applicable for any length of conduit emanating from LDB to
first fitting and for subsequent points also.
14.6 HAZARDOUS AREA INSTALLATION

14.6.1 Wiring in hazardous area shall be done by using minimum 2.5 mm2 copper conductor
armoured cable. Circuit wiring feeding hazardous areas shall be controlled by two pole
switches / MCBs ( for phase as well as neutral isolation).
14.6.2 Correct type of lighting equipment (fixtures and JBs) with regard to enclosure protection
as specified elsewhere, shall be installed for the areas classified as Zone 1, Zone 2 etc.
14.6.3 The terminations in the junction boxes and the lighting fittings shall be done avoiding
possibility of loose connections due to vibrations. After the terminations are made the
cover of the junction boxes and the lighting fittings shall be closed properly with all bolts
and hardware in correct position, retaining its explosion and weather protections. In
fixtures having double cable entries, both the entries shall be used for looping in and
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looping out connection, thus minimising the use of a separate junction box. Wherever
separate control gear boxes (C.G. box) are provided looping in and looping out
connections shall be through CG box, thus avoiding the use of an additional junction box.
All unused cable entries shall be sealed with suitable plugs.
14.6.4 Cable glands for terminating cable on flameproof equipment shall be of double
compression FLP type. Any material / equipment specified to be supplied by contractor for
installation in hazardous areas, shall be tested by CMRI and duly approved by C.C.E
Nagpur.
14.7 BUILDING LIGHTING
14.7.1 The type of wiring system shall comprise surface / concealed conduit system or cable
wiring as specified elsewhere.
14.7.2 Mounting details of fixtures shall be indicated on the drawings.
14.7.3 Wiring in areas above false ceiling shall be done in Surface Conduit (25 mm dia GI
conduit) suitably clamped to the true ceiling. Vertical drops from true ceiling for panels,
switches, receptacles etc. shall be taken in 25 mm dia PVC conduit concealed in walls up
to switch boards / panels. Lighting fixtures shall be supported from true ceiling. Exact
location of fixtures shall be finalised in co-ordination with air-conditioning duct diffuser
layout, panels layout and false ceiling grid layout. To facilitate easy maintenance Looping
back system of wiring shall be followed throughout. Accordingly supply tappings and other
interconnections including those for earthing are made only at fixture connector blocks or
at switch boards. Required number of junction boxes shall be used at intervals for wire
pulling and inspection.
14.8 STREET LIGHTING
14.8.1 Street lighting poles to be located on road side shall be installed at a minimum distance of
300 mm from the edge of the walkway of the road. Size of wires from marshalling box up
to fixture shall be 1.5 mm2 / 2.5 mm2, copper conductor PVC insulated.
14.8.2 Each pole shall be earthed at two points by connecting to the plant earth grid as shown on
Installation standards.
14.8.3 Street lighting fixture shall be mounted on steel tubular poles as per standard drawings.
The foundation for the street lighting poles will be made by electrical contractor. Street
lighting poles shall be supplied with a base plate.
14.9 MAST LIGHTING
14.9.1 The lattice structure masts shall be installed on concrete foundations with the base plate
bolted on to the anchor bolts. The lattice structure shall be painted with a coat of primer
and two coats of aluminium paint, the second coat to be given just before handing over to
the owner. The masts shall be numbered as per drawings. The masts shall be connected
to the plant earth grid at two points.
14.9.2 The main feeder up to the distribution board of lighting mast shall be through PVC
insulated armoured cable of size as specified elsewhere. Wiring from Distribution Board to
each flood light fixture shall be by means of a 3-core 2.5 sq mm, copper conductor PVC
insulated armoured cable. All the cables shall be neatly clamped to the structure at
intervals not exceeding 25 cms.
15.0 EARTHING AND LIGHTNING PROTECTION

15.1 GENERAL
This Section covers installation of earthing system for electrical equipment, static earthing
and for lightning protection. Installation of earthing system for electrical equipment and
static earthing shall be carried out in accordance with IS 3043 - 'CODE OF PRACTICE
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FOR EARTHING' and IS 7689 - GUIDE FOR CONTROL OF UNDESIRABLE STATIC
ELECTRICITY respectively. Earthing system for lightning protection shall be in
accordance with IS 2309 - 'CODE OF PRACTICE FOR THE PROTECTION OF
BUILDINGS AND ALLIED STRUCTURES AGAINST LIGHTNING'.
Generally, a common earthing system shall be provided for equipment earthing and static
earthing. The earthing system for lightning protection shall be separate and may be
interconnected with the former, unless otherwise specified elsewhere.
15.2 EARTH ELECTRODES
Earth electrodes shall generally consist of copper or G.I. plates buried in ground or copper
coated steel rods or cast-iron pipes driven in ground. The type of electrodes shall be as
specified elsewhere. The method of installation of earth electrode shall be in accordance
with the drawings or in accordance with IS 3043, when the drawings are not furnished.
15.3 MAIN EARTH CONDUCTORS
Main earth conductors shall be copper or G.I flats or stranded copper / aluminium
conductors with or without PVC sheath as specified elsewhere. They shall be connected,
at one end, to the earth electrode and to the earth bus or test - link at the other end. All
connections below ground shall be made by bolting or riveting and brazing or welding.
Sizes of main earth conductors shall be as specified elsewhere. All connections to the test
- link or earth bus shall be securely bolted. Contact surfaces shall be tinned and suitably
protected with Petroleum Conducting Jelly to prevent corrosion. All connections below
ground shall be protected as per IS 3043.
15.4 EARTH SYSTEM AND EQUIPMENT BONDING

Main Earth Loops or Earthing Ring Mains shall originate from the earth bus or test links.
Equipments shall be connected to the main earth loops by means of earth conductors.
All electrical equipment viz. transformers, switchgear, motor control centres, motors,
control stations, switches lighting fittings and other electrical apparatus shall be connected
to the main earth loop by means of two separate and distinct, external earth conductors.
The material, type and size of the earth conductors will be as shown in the drawings or as
specified elsewhere.
Two earth terminals will, generally, be provided on most of the electrical equipment.
However, if these are not provided, the Contractor shall provide the same, by drilling and
tapping the equipment suitably and supply necessary hardware.
The entire conduit installation, cable sheaths and cable armour shall also be bonded to
earth at both ends. It must be ensured that the conduit installations maintain electrical
continuity throughout its entire length. Conduits shall be effectively bonded together at
each joint, such as couplings, junction boxes, draw boxes or any other accessories and
equipments. Where conduits and screwed cable glands are terminated at equipment
enclosures with slip-holes, earthing / bonding washer (e.g. star - washer) shall be used to
maintain electrical continuity.
All earth connections with solid or stranded conductors shall be made by means of
soldered / crimping cable lugs. Connections with copper or G.I. flats shall be directly
bolted type. All hardware used shall be galvanised steel, brass or passivated to prevent
corrosion. Spring washer or lock washers shall be used to make all connections secure
and vibration
Earth connections from transformer neutrals and lightning arresters shall be taken as
directly as possible to the earth buses or test links. Main earth conductors from earth bus
or test - link to the Earth Electrode shall be coated with bitumastic.
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15.5 LIGHTNING PROTECTION
Lightning protection system shall generally comprise lightning finals (air terminals), roof
conductors, down conductors, test links and earth electrodes. The number, types,
materials and sizes shall be in accordance with the drawings or as specified elsewhere.
Air terminals shall be mounted on top of buildings or structures as shown in the drawings.
All air terminals shall be inter-connected with roof conductors, chimneys, vent, pipes, hand
rails or any other metallic projection above the roofs shall also be bonded to the roof
conductors. Down conductors from air terminals or from roof conductors shall be routed as
directly as possible to the test links on earth buses, with minimum bends.
All provisions regarding connections of conductors for equipment earthing system shall
also apply to lightning protection system. In corrosive atmospheres, lightning finials or air
terminals shall be covered by plumbing metal for corrosion protection.
16.0 ELECTRICAL INSTALLATION IN HAZARDOUS AREAS

16.1 GENERAL
Electrical installation in hazardous areas as defined in I.S. 5571 shall be carried out with
utmost care and special precautions shall be taken to ensure operational safety.
All personnel, especially supervisory staff, working on such installations shall be fully
conversant with the applicable National Standards and Codes of Practice and shall have
previous experience of such work.
16.2 EQUIPMENT & MATERIALS
Electrical equipment and materials used in the installation shall conform to the relevant
Standards and shall be certified (by a competent authority) suitable for use in Division 1 or
Division 2 hazardous areas, as the case may be.
No modifications shall be made in any certified equipment or material used in the
installation which will impair its effectiveness and invalidate the certificate.
All certified equipments shall be inspected before their use for any damaged or
deteriorated condition which will render the equipment unsafe. Such equipments shall not
be used in the installation.
When any equipment is dismantled for the purpose of installation, care shall be taken to
prevent damage to vulnerable parts such as screw threads, conduit threads, machined
surfaces, etc. If the equipment is to remain dismantled for a prolonged period, machined
surfaces, screw threads, etc. shall be protected against corrosion by means of grease, oil,
petroleum jelly or any suitable corrosion inhibiter. These shall, however, be cleaned
thoroughly before re-assembly.
All hardware used for mounting shall be hot dip galvanised or plated to prevent corrosion.
All bolted connections shall be made secure and vibration proof by means of locknuts,
lock washers, etc.
16.3 WIRING
All wiring in Division 1 hazardous areas shall be carried out with armoured cables or with
PVC insulated wires laid in solid drawn seamless conduits. In Division 2 areas, ERW
conduit may be used.
Termination of cables shall be made with certified or approved cable glands or cable end
boxes. Cable glands and boxes shall be effectively sealed. All conductors connections
shall be made with soldered / crimping cable lugs, or approved mechanical connectors. It
must be ensured that all connections shall be made secure and vibration-proof, by means
of locknuts, lock-washers, etc. Prevention of strain at terminations is of utmost
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importance.
16.4 EARTHING
All provisions of Section 12 for earthing apply with much greater force regarding effective
bonding of electrical equipment, cable armour, conduit installation, process equipments
and process piping (requiring static earthing) to the earthing system.
Special attention shall be paid to the following:
a) Adequate support for earth conductors throughout for protection against breakage.
b) Secure and vibration proof earth connections, protected suitably against corrosion.
c) Continuity of conduit installation or process piping when static earthing is required, by
means of conduit bonds.
16.5 MISCELLANEOUS
All opening between hazardous and non-hazardous areas for cable and conduits shall be
properly sealed by approved means. In case of conduit wiring, conduit stopper boxes shall
be used in conduit runs at the junction of hazardous and non-hazardous areas or at
terminations of conduit runs at any equipment such as motors, starters, push buttons, etc.
Stopper boxes at the junction of hazardous and non-hazardous areas, shall be located at
the boundary between the 2 areas.
17.0 STEEL WORK

17.1 All steel work carried out by the Contractor for equipment and cable supports such as
cable trays, brackets, hangers, saddles, etc. shall be of the best workmanship. Only
certified welders shall be employed for welding. All bolted connections shall be made
secure and vibration proof by means of spring washers or lock washers or lock nuts.
Fixing or grouting of steel-work in floor, ceilings or walls shall be carried out with
approved foundation bolts or fasteners.
17.2 Finished steel work shall be thoroughly cleaned by wire-brushing or sand blasting etc.
All scales and rust shall be removed. The steelwork shall be then painted with 2 coats of
approved primer such as red oxide or red lead and shall be finished with 2 further coats
of approved paint.
17.3 When atmospheric conditions are highly corrosive, chemical works type paints may be
specified. In such cases, special primers and paints shall be used for adequate
protection from corrosion.
18.0 INSPECTION, TESTS & COMMISSIONING OF ELECTRICAL EQUIPMENT

AND INSTALLATION
18.1 GENERAL
This Section covers the requirements of inspection & tests to be carried out on
equipment and installation as well as commissioning of electrical installation. Inspection
and tests shall be carried out jointly by the Contractor in presence of Engineer and / or
Owner.
18.2 INSPECTION
Inspection shall be carried out to ensure that the complete installation is carried out in
accordance with drawings and complies with the requirements laid down by Indian
Electricity Rules, Regulations for the Electrical Equipment of Building by Insurance
Association of India (Fire Section), Indian Standard Specifications & Codes of Practice,
Electrical Inspector, Explosive inspector and any other statutory regulations and
competent authorities. The complete installation shall be subject to the approval of any
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or all of the competent authorities and the Owner / Engineer.
18.3 DETAILS OF TESTS
The tests specified below shall be carried out on the electrical equipment and
installation before commissioning the same. The tests shall be performed by or under
the direct supervision of a competent person, qualified to carry out the tests. All tests
shall be carried out in the presence of the Authorised Representative of the Owner
and/or the Engineer, unless this stipulation is waived in writing.
The installation shall not be accepted by the Owner unless it has been approved by the
competent authorities, and the authorised representative of the Owner and/or the
Engineer.
All test results shall be recorded on prescribed 'ELECTRICAL TEST REPORTS' duly
signed by the person conducting the test and by the authorised representative of the
Owner and/or the Engineer, if tests are witnessed.
In case the installation is found to be not in conformity with the requirements or the test
results indicate defective materials or workmanship, the same will have to be rectified to
the complete satisfaction of the Owner / Engineer and tested again.
18.3.1 POWER & DISTRIBUTION TRANSFORMERS
a) Check HV & LV cable terminations, ground connections, fittings and accessories,
oil level and oil leaks at various joints. Check breather, thermometers & buchholz
relay for proper functioning and operation. Check junction boxes, marshalling
box, etc. for correct wiring.
b) Oil Test
c) Dielectric test as per Clause 7.11 of IS 10028. The oil shall withstand at least 40
KV with a gap of 4mm.
d) Insulation Resistance Test
e) This may be carried out on new transformer without drying out the transformer,
provided the transformer has not been idle or stored for a long period.
Otherwise, this test shall be carried out during drying out of transformers.
Insulation resistance test shall be carried out between primary & secondary to
ground as well as between primary and secondary. Windings not under test shall
be grounded during the test.
f) A megger rated 1000 volts or higher shall be used for the test.
g) Check operation of automatic tap changer and its control panels (local and
remote), for correct functioning, if provided.
h) Check operation of forced cooling system complete with its control panel for
correct functioning, if provided.
i) Polarity & Phasing Out Test
j) Check external connection of the transformer in accordance with diagram of
connections and phase sequence (anti - clockwise).
k) Polarity & Connections of Instrument Transformers
l) Check for correctness of CT & PT connections provided with transformer. Check
electrical continuity of secondary circuits with ELV tester.
m) Adjust spacing of arcing horns / rod gaps, if provided.
18.3.2 EHV, HV & MV SWITCHGEAR
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a) Check proper mechanical operation of circuit breakers including alignment of
trolleys in case of draw - out type circuits breakers, smooth operation of all
mechanical parts, lubrication, mechanical interlocks etc.
b) Check contact alignment and wipe, proper sequence of closing and opening of
main and arcing contacts.
c) Oil test for transformers, in case of oil circuit breakers.
d) Check electrical relays, instruments & controls for correct wiring
e) Insulation test on busbars - phase to phase and phase to ground. This test will be
carried out with circuit breakers in service position, but contacts remaining open.
f) Insulation test on relays & control wiring including current and potential
transformers and wiring of CT & PT secondaries.
g) Insulation test on circuit breakers in withdrawn position - phase to phase and
phase to ground with contacts closed.
h) Adjust correct settings of relays and/or direct acting trips - as specified
elsewhere.
i) Operation Test
Energise only control circuits and carry out closing and tripping operations (where AC
supply derived from main supply is used for operation, the switch-gear bus may be
energised). Check operations of electrical interlocks. Check tripping of circuit breakers
by manual operations of protective relay contacts. Check operations of mechanical
closing and tripping devices. Check lockout conditions for closing of circuit breakers by
simulating the required conditions. Check control, indications, sequence interlocks and
alarms.
a) Polarity and connections of instrument transformers - Check for correctness of
CT & PT connections provided. Check electrical continuity of secondary with ELV
tester.
b) Adjust spacing of arcing horns / rod gaps, if provided.
c) Check operation of instruments, meters, relays and tripping of circuit breakers by
primary / secondary injections as specified elsewhere.
d) Check continuity of power circuits and earth continuity of all non current metallic
parts with a low voltage (6 volts or less) continuity tester.
e) Carry out HV test on power and control circuits, if specifically called for.
18.3.3 MOTOR CONTROL CENTRES, SWITCHGEARS, POWER CONTROL CENTRES
(POWER DISTRIBUTION BOARDS ), UPS, V / F PANEL, ETC.
a) Check equipment, internal wiring, smooth mechanical operation, interlocks, etc.
b) Check continuity of power circuits and earth continuity of all non-current carrying
metallic parts with a low voltage continuity tester.
c) Insulation test for power & control circuits between phases, between phases and
neutral and between phase / neutral and ground.
d) Check operation by energising control circuits (without energising power circuits)
for correct functioning. Simulate external controls and interlocks for the same.
Note chatter or humming of Contactor and rectify, if necessary.
e) Check fuse ratings and adjust relay settings (overload, single phasing preventers
etc.) in accordance with load ratings.
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f) Carry out HV test on power & control circuits, if specifically called for in Contract
Documents.
g) Polarity and connections of instrument transformers - check for correctness of CT
& PT connections provided. Check electrical continuity of secondary circuits with
ELV tester.
18.3.4 MOTORS & ROTATING EQUIPMENT
a) Check equipment for free movement of rotor, and play, lubrication, and for any
other mechanical defects.
b) Check commutators, slip rings, brushes, brush-holders etc. for satisfactory
conditions.
c) Insulation test of motors - between winding and ground. Use 500 volts megger
for M.V. motors and 1000 volts megger for HV motors.
d) Check electrical continuity with ELV tester.
e) No load running of motor noting down no load current and voltages in all three
phases.
18.3.5 CABLES
a) Insulation Test - between each phase and neutral and between each phase /
neutral and ground (Ref. APPENDIX - II).
b) D.C. High Voltage Test on HV cables in accordance with the relevant Indian
Standards and Code of Practice. This test shall be carried out on cables installed
in final positions, and all joints and terminations have been made. The cables,
however, may not be connected to the equipment, so that the equipment may not
be subjected to the test voltage (Ref. Appendix-II)
c) In case of lighting wiring, insulation test shall be carried out on lighting feeders
with branch circuits open. Branch circuits shall be tested separately with lamp
holders, plug receptacles and lighting fittings in position, but without lamps. In
case of lighting circuits with lamp ballasts and glow starters insulation resistance
may be measured between phase and ground only.
d) In case of directly buried cables, insulation resistance of cables shall be
measured before and after the back-filling.
e) Test all receptacles for correct phase sequence.
18.3.6 EARTHING SYSTEM
a) Measure earth resistance of each electrode separately. If a number of earth
electrodes are interconnected with one another, combined earth resistance shall
also be measured. The earth resistance of each electrode and/or a group of
electrodes shall not exceed the values specified elsewhere.
b) Carry out line earth loop impedance test. The loop comprises the line conductor
from the point of fault, back to the supply transformer, the path through
transformer winding, the earthed neutral point of the transformer and path from
that point to the point of fault through the earthing system.
c) Continuity test for earth continuity conductors with ELV tester.
18.3.7 RELAY & CONTROL PANELS, ALARMS PANELS & MISCELLANEOUS EQUIPMENT
a) Carry out insulation test on all power and control circuits.
b) Check all equipment for satisfactory operation and correct wiring.
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18.3.8 BATTERY
a) Visual inspection of all components.
b) Capacity test as per I.S.
18.3.9 BATTERY CHARGER
a) Connection checking
b) Measurement of voltage regulation
c) Insulation test
d) Functional check of auxiliary devices
e) Alternating current measurement at no load and rated load
19.0 INSTRUMENT AND TOOLS

19.1 GENERAL
This section covers the instruments, tools & plant which will normally be required to
carry out the electrical installation including testing & commissioning and which shall be
made available as and when required by the contractor. Meters used for tests shall be
of proven accuracy and to the satisfaction of the engineer.
19.2 TOOLS & PLANT
Hand Tools
Screw drivers, pliers, cutters, spanners, hacksaw, hammers, rawl punches, etc.
Power driven Tools & Equipment
Drilling, grinding, cutting machines, hammers, arc welding set, oxy-acetylene welding
and cutting set and welding accessories.
19.3 INSTRUMENTS
a) Instruments to be always available at Site.
i) Insulation resistance tester (Megger) rated 500 volts
ii) Multi-meter of a reputed make
iii) Clip-on ammeter / voltmeter (tong tester)
iv) Phase sequence indicator
v) Extra low voltage continuity tester (6 volts or less)
b) Instruments to be made available as and when required.
i) Insulation resistance tester, (Megger) rated 500V / 1000V / 2500V, 5000V.
ii) Earth resistance tester with all accessories
iii) Transformer oil testing set
iv) High Voltage testing set
v) Relay testing equipment
vi) Centrifugal or vacuum type oil filtering unit.
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20.0 LABOUR, SUPERVISION, COORDINATION & PROGRESS, LICENCE,
STATUTORY APPROVAL
20.1 SUPERVISORY LICENCE
The contractor shall possess a valid contractor's licence for the state in which site is
located and shall ensure its validity during the duration of the contract. The contractor
shall furnish authenticated copies of certificates to the purchaser for himself and his
workmen before commencement of work.
20.2 LABOUR
The Contractor shall employ adequate skilled and unskilled labour to complete all work
according to programme of work. Skilled workers shall possess the minimum
qualifications stipulated by statutory or competent authorities.
20.3 SUPERVISION
The Contractor shall employ adequate number of supervisors to control the labour force
and to carry out the work as per schedule. Supervisory staff shall also possess the
minimum qualifications stipulated by statutory and competent authorities.
20.4 CO-ORDINATION
The Contractor shall coordinate his work with that of other agencies, so that the work
can proceed smoothly and without hindrance to all concerned.
20.5 PROGRESS
The Contractor shall submit periodic Progress Reports to the engineer. The period of
report shall be determined by the Engineer. The Progress Report shall indicate planned
progress as per programme and physical progress. the format in which the reports are
to be submitted shall be decided by the Engineer.
20.6 STATUTORY APPROVAL
The Contractor shall be totally responsible for obtaining statutory approval from the
electrical inspector or any other statutory authority for the entire installation carried out
by him unless otherwise specified and agreed. Necessary test reports shall be
submitted by him to electrical inspector. This will be an integral part of the contract and
shall not be paid for separately.
21.0 QUALITY ASSURANCE - QUALITY CONTROL

21.1 Quality Assurance (Q.A.) shall follow the requirements of the Purchaser's Q.A.
documentation applicable to the equipment and/or systems being installed.
21.2 Q.A. involvement will commence at the instigation of the project and follow through to
final acceptance of each and every system and item of equipment, thus ensuring total
conformity to the Purchaser's requirements.
21.3 The Contractor shall provide the necessary 'Test Sheets' for recording the results of his
electrical acceptance tests.
The full set of forms shall be submitted to the Engineer for his approval prior to the
implementation of the acceptance testing programme.
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21.4 The tests which the Contractor must perform, as a minimum requirement, shall be those
described in clause 15.0 of this specification in the order indicated and shall be made in
accordance with the equipment and / or systems Standards and Regulations quoted by
the Engineer in the Contract Documents and any tests required by the particular
equipment / system manufacturer.
21.5 Test values acceptable to the Engineer shall be those laid down in the indicated
standards and specifications by the Engineer, together with any values quoted in the
Contract Documents. Any discrepancy in the acceptable test values discovered by the
Contractor shall be resolved by the Engineer, whose interpretation shall be final. No
equipment shall be set to work unless tests on its associated circuits have been found
satisfactory.
22.0 ACCEPTANCE OF INSTALLATION

On completion of the work the Engineer, together with a representative of the Purchaser
and the Contractor, will carry out an Inspection of the Installation. The Engineer will
issue a completed copy of the Purchaser's Acceptance of Electrical Installation to the
contractor as confirmation that the work has been accepted, subject to any matters
noted on the form being attended to.
23.0 ATTACHMENTS / APPENDICES:
23.1 APPENDIX I -LIST OF CODES, STANDARDS & STATUTORY
REGULATIONS
23.2 APPENDIX II
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23.1 APPENDIX I - LIST OF CODES, STANDARDS & STATUTORY

REGULATIONS (Refer Section 1.2)
IS 732 : Code of Practice for Electrical Wiring Installations.
IS 1646 : Code of Practice for Fire Safety of Buildings (General)
Electrical Installation.
IS 3043 : Code of Practice for Earthing.
IS 2309 : Code of Practice for the Protection of Buildings & Allied
Structures against Lightning.
IS 7689 : Guide for control of undesirable static electricity.
IS 10028 Part 1 to 3 : Code of Practice for Selection, Installation & Maintenance
of Transformers.
IS 900 : Code of Practice for Installation & Maintenance of
Induction Motors.
IS 1255 : Code of Practice for Installation and Maintenance of
Power cables upto and including 33 KV rating.
IS 10118 Parts 1 to 4 : Code of Practice for Selection, Installation and
Maintenance of Switch gear and Control gear.
IS 5571 : Guide for Selection of Electrical Equipment for Hazardous
Areas.
IS 5572 : Classification of Hazardous Areas(other than mines)
having flammable gases and vapours for Electrical
Installation.
IS 5216 Parts 1 & 2 : Guide for Safety Procedure & Practice in Electrical work.
IS 5479 : Solders for Jointing Aluminium and Aluminium Alloys.
IS 335 : New Insulating oils
IS 9537 Parts 1 to 4 : Conduits for electrical Installation
- Regulations for the Electrical Equipment of Buildings -
The Institution of Electrical Engineers.
- Indian Electricity Rules
- Fire Insurance Regulations
- Factory Act & Regulations
- National Building Code ( ISI Publication)
- National Electrical Code ( ISI Publication)
- Tariff Advisory Committee regulation
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23.2 APPENDIX II
1.0 TESTING AND ELECTRICAL MEASUREMENTS OF CABLE INSTALLATIONS
1.1 INSULATION RESISTANCE TEST ON NEWLY INSTALLED CABLES BEFORE
JOINTING
All new cables should be tested for insulation resistance before jointing. After satisfactory
results are obtained cable jointing and termination work should commence. It should be
noted here that insulation resistance test gives only approximate insulation resistance and
the test is meant to reveal gross insulation fault(s). A fairly low insulation resistance
reading compared to the values obtained at factory testing should not be a cause of worry
since the insulation resistance varies greatly with parameters such as length and
temperature. This is particularly more pronounced in the case of PVC cables. The voltage
rating of the insulation resistance tester for cables of different voltage grades should be
chosen from the following table:
Voltage Grade of Cable Voltage Rating of IR Tester
1.1 kV 500 V
3.3 kV 1000 V
6.6 kV 1000 V
11 kV 1000 V
22 kV 2.5 kV ( see Note)

33 kV 2.5 kV ( see Note)
NOTE - For long feeders, motorized insulation resistance tester should be used.
1.1.1 More accurate insulation resistance values can be measured only by a portable resistance
measuring bridge.
1.2 TEST RESULT OF COMPLETED CABLE INSTALLATION
The test of completed installation may be carried out and entered into record book for
comparison purposes during service life of cable installation and during fault location.
1.2.1 Insulation Resistance
Insulation resistance is measured by a suitable bridge. In non-screened cables, the
insulation resistance of each core is measured against all the other cores and armour /
metal sheath connected to earth. With screened construction the insulation of each core is
measured against all the other cores and the metal screen connected to earth.
1.2.2 Conductor Resistance (dc)
1.2.2a The resistance of conductor is measured by a suitable bridge. For this purpose conductors
at other end are looped together with connecting bond of at least same effective electrical
cross - section as conductor. The contact resistance is kept to a minimum by proper
clamped or bolted connections. With properly installed and jointed cables, values thus
measured and corrected to 20C, are in general agreement with values given in test
certificates.
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1.2.2b The measured loop resistance is converted to ohms per km per conductor as :
R
Rt = ------
2L
Where
R = measured loop resistance in ohms at temperature, tC;
Rt = measured resistance per conductor at tC in ohms; and
L = length of cable (not the loop) in km.
The ambient temperature at the time of measurement to be recorded and the

conductor resistance to be corrected to 20C by the following formula:
Rt
R20 = ----------------- ohm/km at 20C.
(1+a) (t-20)
Where
R20 = conductor resistance at 20C in ohm / km,
t = ambient temperature during measurement (in
C)
and
a = temperature coefficient of resistance
(3.93 x 10.3 ohms / C for aluminium).
1.2.3 Capacitance
1.2.3.1 For unscreened cables, capacitance is measured for one conductor against others and
metal sheath / armour connected to earth. In case of screened cable it is measured
between conductor and screen. Capacitance bridge is used for this purpose. The
measurement may be carried in case of cables above 11 KV; alternatively values given
in test certificate are considered sufficient.
1.2.4 High Voltage Test
1.2.4a Cables after jointing and terminating are subjected to dc high voltage test. The
recommended values of test voltages are given in Table 6. The leakage current shall
also be measured and recorded for future reference.
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TABLE 6 DC TEST VOLTAGES AFTER INSTALLATION ( BEFORE

COMMISSIONING)
RATED TEST VOLTAGE BETWEEN DURATION
VOLTAGE
OF CABLE
U./ U Any Conductor and Conductor to Conductor
Metallic Sheath / (For Unscreened
Screen / Armour Cables)
KV KV KV Minutes
(1) (2) (3) (4)
0.65/1.1 3 3 5
1.9 / 3.3 5 9 5
3.3 / 3.3 9 9 5
3.8 / 6.6 10.5 18 5
6.6 / 6.6 18 18 5
6.35 / 11 18 30 5
11/11 30 30 5
12.7 / 22 37.5 - 5
19 / 33 60 - 5
1.2.4b Generally dc test should be preferred as test equipment required is compact, easily
portable and power requirements are low.
1.2.4c The cable cores must be discharged on completion of dc high voltage test and cable
should be kept earthed until it is put into service.
1.2.4d DC test voltage for old cables is 1.5 times voltage or less depending on the age of
cables, repair work or nature of jointing work carried out, etc. In any case, the test
voltage should not be less than the rated voltage. Test voltage in these cases should be
determined by the Engineer - in - charge of the work.
1.2.4e It may be noted that frequent high voltage tests on cable installations should not be
carried out. This test should be carried only when essential. During the high voltage
test, all other electrical equipment related to the cable installation, such as switches,
instrument transformers, bus bars, etc., must be earthed and adequate clearance
should be maintained from the other equipment and framework to prevent flashovers.
1.2.4f In each test, the metallic sheath / screen / armour should be connected, to earth.
2.0 CABLE INSTALLATION PLAN
2.1 On completion of laying, terminating and jointing of the cables, a plan should be
prepared, which should contain the following details of the installation:
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REVISION NO : 0
a) Types of cables, cross - section area, rated voltage. Details of construction,
cable number and drum number;
b) Year and month of laying;
c) Actual length between joint - to - joint or ends;
d) Location of cables and joints in relation to certain fixed reference points, for
example, buildings, hydrant, boundary stones, etc;
e) Name of the jointer who carried the jointing work;
f) Date of making joint; and
g) Results of original electrical measurements and testing on cable installation
2.2 All subsequent changes in the cable plan should also be entered.
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Page 1 of 11
ELECTRICAL CONTENT OF PACKAGE UNIT
By By By
Page 607 of 674

ELECTRICAL CONTENT OF PACKAGE UNIT PAGE : 2 OF 11
REVISION NO : 0
TABLE OF CONTENTS
1.0 SCOPE 2
2.0 DESIGN 3
3.0 SPECIFICATIONS 3
4.0 RESPONSIBILITIES 3
5.0 GENERAL REQUIREMENTS 5
7.0 MOTORS 9
8.0 PROTECTIVE GUARDS 9
9.0 RATING PLATES 9
10.0 CABLES 9
11.0 CABLE GLANDS 9
12.0 LOCAL PUSH BUTTON STATION 9
13.0 INSTALLATION 10
14.0 MAINTENANCE AND TOOLS 10
15.0 SPARES 10
16.0 DRAWINGS AND DATA 10
17.0 QUALITY ASSURANCE 10
18.0 INSPECTION & TESTING 10
19.0 DEVIATIONS 11
1.0 SCOPE
This specification covers the minimum technical requirements for the Design, manufacture,
supply and commissioning of the electrical content of a Package Unit.
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REVISION NO : 0
The definition of a package unit for the purpose of this specification is as follows:
Individual items of equipment mounted on one or more skid bases, which operate together
to deliver a particular product or perform a particular function.
2.0 DESIGN
Electrical equipment and material shall be in accordance with the specifications in
paragraph 3, and the following information: -
2.1 SUPPLY VOLTAGE
Voltage: Volts Phase
Wire: Hz Fault level
Neutral Grounding Solid/Resistance/Unearthed
Variation: Voltage : 10 %
Frequency: : 3%
Combined : 10 %
2.2 CONTROL VOLTAGE: 110V/240V 10%, Single phase, 50 3% Hz.
If the supply voltage is other than the control voltage specified, Vendor shall provide a
suitably rated control transformer with switch and fuse to derive the specified control
voltage.
2.3 POWER SUPPLY
The Contractor shall derive the electric power supply required for the incoming switchgear.
All other scope of supply shall be as per clause 4.0 - "Responsibility".
As specified elsewhere
2.4.1 Installation : a) Indoor / outdoor
b) Hazardous / non-hazardous area
c) Classification
Zone: As applicable
Gas group: As applicable
Temp. Class: As applicable
3.0 SPECIFICATIONS
Unless otherwise specified material and equipment shall be in accordance with the brief
specification here under.
4.0 RESPONSIBILITIES
The responsibility for design, supply of material and documentation within the packaged unit
shall be as marked in the appropriate box mentioned below:
Vendor Purchaser PMC Remarks

A) Design / Engineering
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1) Rating of all materials & equipment

2) Single line diagram
3) Control & Schematic wiring diagram
4) Power layout of battery limit plant with
MTO
5) Earthing layout drawing with MTO for
battery limit plant
6) Cable Schedule
7) Interconnection diagram/schedule
8) Motor list
9) MTO Schedule
B) Supply of Materials
1) Motors/MCC/Distribution board
2) Starter panels
3) Control panel
4) Local push button stations
5) Cables
a) From MCC to Motors
b) MCC to Control Panels
c) From Control Panel to field devices
6) Earthing material as per earthing Drawings
7) Cable trays/cable rack & accessories for
battery limit plant / area
8) Junction boxes
9) Installation materials
10) Commissioning spares & maintenance
spares for two years
C) Documentation as per Vendor Document
Requirements
1) Maintenance Instructions
2) Operation Instructions
3) Test certificates
4) Installation drawings
D) Installation of complete electrical system
under the scope
E) Commissioning
4.1 All testing equipment shall be arranged by the Contractor. Contractor shall furnish the test
result so obtained in the form of test certificate.
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4.2 Contractor shall assist owner to get the electrical installation approved by Electrical
Inspector.
4.3 All design / engineering documents produced by the Vendor shall be submitted to JH&G /
Owner for their comments & approval.

The materials and equipment shall be suitable for the service conditions, ambient
temperatures, humidity, altitude, environment, etc. specified in cl. 2.4.
5.2 SYSTEM
5.2.1 The electrical system voltage, frequency and tolerance shall be as stated in clause 2.0.
5.2.2 All materials and equipment shall be capable of operation continuously and without
adverse effect or injurious overheating, under all specified conditions of operation,
including variations in the system voltage, frequency or combined voltage and frequency of
the nominal rating as stated in clause 2.0.
5.3 EQUIPMENT FOR HAZARDOUS AREA
5.3.1 All equipment for installation in hazardous areas shall comply with the stated specifications
and standards and shall be certified, by a recognised Authorising Body, for use in the
declared hazard.
5.3.2 The Vendor giving details of the equipment shall provide a schedule of hazardous area
equipment including: equipment identification, description, catalogue number, equipment
classification, temperature class, certifying authority and certificate number.
6.0 BASIS OF DESIGN

6.1 GENERAL
6.1.1 All equipment shall be designed to facilitate inspection, cleaning and maintenance with due
care to safety in operation and personnel protection.
6.1.2 All equipment shall run without undue vibration and within the noise specification.
6.1.3 All equipment shall be designed to prevent the risk of accidental short-circuit or open
circuit.
6.1.4 All materials shall be new and of suitable quality.
6.1.5 Electrical windings and apparatus subject to dust and moisture shall be suitable for the
working conditions without distorting or deterioration, or the setting up of undue strain in
any part that would affect the efficiency and reliability of the package unit.
6.1.6 Connections and all wiring shall be so arranged and/or protected to prevent them from
being damaged. Connections shall terminate at terminals of correct rating and size for the
circuit and conductors.
6.2 ENCLOSURES
6.2.1 All components shall be contained within enclosures suitable for the specified conditions of
installation and operation. Enclosures shall have a recognised enclosure to IP
designation.
6.2.2 There shall be no fixing holes through the enclosures.
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REVISION NO : 0
6.2.3 Gaskets shall be secured to the main parts of the components in such a way that they
cannot be detached or mislaid during normal installation and maintenance.
6.2.4 Removable covers on the top of enclosures shall be so constructed as to ensure the
water-tightness of the enclosure.
6.3 GENERAL ARRANGEMENT OF CONTROL EQUIPMENT/MCC
6.3.1 Motor starters, relays and controls shall be grouped together and located into a composite
enclosure if deemed practical. Otherwise separate Motor Control Centre and control panel
shall be considered. MCC shall be as per requirement.
6.3.2 Motors of less than 0.18 KW and single phase may be switched direct. Over-load
protection will not be required, but shall be protected by a suitably rated HRC fuse or
miniature circuit breaker.
6.3.3 Motors of 0.18 KW and above shall be controlled by a starter which shall be complete with
suitable overload relays and HRC fuses for short-circuit protection.
6.3.4 Isolators and fused switches shall be suitably rated for duty and safe operation. Provision
shall be made for padlocking in the 'OFF' position. All line terminals or connections shall be
adequately shrouded. Where required for interlocking purposes, etc. auxiliary contacts
shall be fitted for isolation of other circuits.
6.3.5 Control circuits shall be connected phase to neutral unless specified otherwise, and phase
circuit protected by HRC fuses.
6.3.6 Start / Stop pushbuttons, selector switches and other control and indication devices shall
be fitted to ensure safe plant operation. Stop pushbuttons shall have 'stay put' facilities to
protect personnel and the equipment.
6.4 COMPONENTS AND WIRING
6.4.1 All live components shall be mounted so that they are insulated from the metalwork
forming the enclosure.
6.4.2 All internal wiring shall be arranged so that visual inspection and maintenance can be
carried out.
6.4.3 All internal wiring shall comply with the specification for type and colour coding and shall
be rated for the short circuit duty.
6.4.4 Not more than two conductors shall be connected to one terminal.
6.4.5 The ends of all wiring shall have an identification or reference number.
6.4.6 Wiring following a common route shall be clipped, loomed together, or run in trunking.
6.4.7 All wiring for external connections shall be brought out to individual terminals on an
accessible terminal block adjacent to the terminal point for external cables.
6.4.8 External cable entries shall be via either undrilled gland plates or ISO metric tapped
entries. The power and control cable connections shall be segregated from each other.
6.5 FUSES
6.5.2 All fuses shall be of the HRC cartridge type and shall be mounted in approved type carriers
with protection against contact with live parts.
6.5.3 All fuses shall be mounted in an easily accessible position but protected against misuse.
6.5.4 Each fuse or set of fuses shall have an identification or reference number.
6.6 TERMINALS
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6.6.1 Terminals shall be suitable for circuit duty and rating and each shall have an identification
or reference number. Common terminals shall have the same reference number.
6.6.2 Terminal studs shall be non-rotateable and not less than M5 size. Each stud shall be
complete with an effective arrangement of nuts and washers to enable continuous and
positive contact to be maintained.
6.6.3 Terminals of the 'pinch screw' type are not accepted.

6.6.4 Terminals, including earth terminals, shall not be used for any other purpose than for
conductor connections, e.g. they shall not be used for additional purpose of fixing
components or covers.
6.7 EARTHING AND BONDING
6.7.1 All non-current carrying metal work, which forms the package unit, shall be bonded for
earth continuity to the main skid base.
6.7.2 The minimum of two earth studs (M10) must be provided on the skid base, diagonally
opposite to each other, for connection to the main plant earth system.
6.7.3 Earthing and bonding shall generally be in accordance with Jacobs H&G Pvt. Ltd. standard
practice and as per IS 3043. The entire earthing system shall be of PVC insulated,
unarmoured, single core aluminium conductor cable.
6.7.4 Vendor shall bring his earthing system upto test link to be provided at the ground level from
where it will be connected to the Plant earthing system. All earth conductors shall be above
grade or in-built-up trenches.
6.8 CABLE TRAYS & CABLE INSTALLATION
6.8.1 Cable trays and structural required for laying of all power and control cables including
Purchaser's cable within the battery limit shall be provided by the Contractor. HV cables
will have to be suitably segregated from L.V. cables. All cables shall be laid in cable trays
above grade as far as possible. Where this is not feasible, cables shall be laid in built-up
trenches.
6.8.2 Cables in the trays shall be clamped at every 500mm interval in horizontal run and at every
300mm interval in vertical run.
6.8.3 All power connections shall be made with soldered cable lugs for conductor size upto
10mm. For higher sizes crimping type aluminium lugs shall be used. Control connections
may be done directly.
6.9 TYPE OF COMPONENTS
Component Type
1) Circuit Breaker : Air break manually operated draw-out type without
(Incomer) releases. Unless specified otherwise. Rating - 125%
of feeder rating.
2) Switch (Incomer) : Triple Pole, heavy duty, quick make and break
confirming to IS 13947- Part 3. Rating - 125% of
feeder rating.
3) Switches : Triple pole, motor duty, quick make and quick break
(Motor feeder) type. The rating of switch shall be suitable to make
and break the stalling current of motor. It should be
125% of motor full load current with minimum rating of
25A.
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REVISION NO : 0
(Power feeders) : Triple pole, heavy duty, quick make and break type.
Rating 125% of feeder rating.
4) Fuses : : HRC link.
1)Power
2)Control : HRC link.
5) Fuse base : Suitable for HRC link fuses. The rating of fuse base
shall be 120% rating of corresponding fuse link.
6) Contactor : Air break, Magnetic AC-3 duty conforming to IS
13947- Part 4. Rating 120% of motor full load current
with minimum rating 16A.
7) Overload relays : Thermal / overload relay having built-in phase failure
protection and manual reset facility.
Range 75% to 125% of feeder rating
8) Current transformer : Bar primary type having stud terminals for
connections on secondary side.
9) Push buttons : Test push button momentary type. Colour coding of
push buttons shall be as per Indian Standards
mounted within the motor feeder compartment.
10) Meters : All meters shall be digital type except voltmeter and
Ammeter, which shall be Analogue type.
11) Terminals: : Clamp / link type.
a)Power
b)Control : Clamp type.
12) Relay : Relays shall be Numerical type.
13) Control Transformer : With +2% taps and voltage regulation +4% at full
load. Earthed at one end of the secondary winding.
14) Auxiliary Contactors : Contacts shall be provided as per requirement.
15) Selector switch : Rotary type lockable at OFF position. Contact rated
for 10A at 110V AC.
16) Timer : Electronic type.
6.10 LABELS
6.10.1 All labels shall be non-corrodible and fixed with non-corrodible screws or bolts. Cubicles
and components shall be identified by labels.
6.10.2 Labels shall have black characters on a white background. Warning labels shall have white
characters on a red background.
6.11 PAINTING AND FINISHING
6.11.1 All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust,
grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace
of acid. The under surface shall be prepared by applying a coat of phosphate paint and
coat of yellow zinc chromate primer. The under surface shall be made free from all
imperfections before undertaking the finishing coat.
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REVISION NO : 0
6.11.2 After preparation of the under surface, the panels shall be powder coated with two coats of
epoxy based final paint. Colour shade of final paint shall be 632 as per IS: 5. The finished
panels shall be dried in stoving ovens in dust free atmosphere. Panel finish shall be free
from imperfections like pinholes, orange peels, runoff paint etc.
6.11.3 All unpainted steel parts shall be cadmium plated or suitably treated to prevent rust
formation. If these parts are moving elements then they shall be greased.
7.0 MOTORS
7.1 All motors shall comply with the Standard Specifications and shall be suitably rated for all
duty conditions. The selected enclosure type and materials shall be suitable for the
environmental conditions.
7.2 Motors below 0.37 KW shall be single phase, all others shall be 3-phase. Motor rated
above 160 KW shall be high voltage motors. Make of motors shall be that of other motors
of the plant as per owner's choice.
7.3 Motors shall be 'direct on line' started, unless motor duty conditions impose alternative
starting.
8.0 PROTECTIVE GUARDS

All guards necessary to afford protection to personnel from electrical apparatus and
moving parts shall be to the appropriate Standard (or other recognised National or
International Standards) and meet the requirements of the Factories Acts or other
relevant regulations and requirements of the locality in which the equipment is installed.
The guards shall be capable of being removed without disturbing adjacent equipment.
9.0 RATING PLATES

Rating plates, together with other instruction plates, shall be affixed to equipment and
shall be of an approved non-corrodible material, stamped or engraved to maintain
legibility.
10.0 CABLES
All power cables shall be 1100/650V grade PVC insulated, G.I. wire/flat armoured, PVC
sheathed overall heavy-duty cables conforming to IS 1554 (Part-1). Power cables up to
25mm size will be of copper conductor while those of size above 25mm will be of
aluminium conductor. Cable for system voltage 3.3 KV and above shall be of XLPE
insulated of suitable voltage grade conforming to IS: 7098 (Part 1 & 2). All control cables
shall be 1100/650 V grade PVC insulated G.I. wire armoured PVC sheathed overall
copper conductor cables conforming to IS 1554 (Part 1). Minimum size of control cables
shall be 1.5 mm.
11.0 CABLE GLANDS

All cable glands shall be of double compression type nickel-plated brass.
12.0 LOCAL PUSH BUTTON STATION

All local push button stations enclosure shall be of cast aluminium alloy weatherproof
suitable for outdoor installation. Stop push button shall be of stay put type with mushroom
knob. GE make ODC type control switches shall be provided for H.V. Motors.
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REVISION NO : 0
13.0 INSTALLATION
All equipment shall be installed conforming to good engineering practice in general and
particularly conforming to Indian Electricity Rules, Indian Standard Codes of Practices
and Statutory rules applicable in the area. Adequate clean & clear space shall be
provided around all electrical equipment for easy operation and maintenance.
14.0 MAINTENANCE AND TOOLS

14.1 All equipment shall be arranged to facilitate ease of maintenance.
14.2 The electrical equipment within the Process Plant that may require special tools and
spanners for operation and/or maintenance shall be provided by the equipment
Manufacturer.
14.3 The special tools etc, shall be accommodated in a suitable container with locking
facilities.
15.0 SPARES
15.1 Separate priced lists of recommended operation and maintenance spares shall be
provided by each electrical equipment manufacturer.
16.0 DRAWINGS AND DATA

17.0 Drawings and data in accordance with the requirements of paragraph 4 and Vendor
Document Requirement attached elsewhere.

17.1 Quality Assurance shall follow the requirements of Jacobs Q.A. documents as applicable
to the packaged unit concerned.
17.2 Q.A. involvement will commence at the bid stage and follow through to equipment accep-
tance, thus ensuring total conformity to Purchaser requirements.

18.1 Test certificates for type and routine tests carried out on individual items and equipment,
as a whole shall be provided. Tests shall be as those listed in the relevant specifications,
and as a minimum shall be those listed in the relevant Indian Standard Specifications (or
I.E.C. equivalents).
18.2 The Purchaser reserves the right to witness tests at the Manufacturer's works / test
facilities as laid down in the relevant Vendor Quality Plans. The witness tests, as a
minimum, shall consist of:
Routine tests on components / equipment.
Operational tests (electrical and mechanical).
Type tests where specified.
18.3 The Manufacturer shall give two weeks notice of tests prior to commencement.
18.4 The Purchaser reserves the right to inspect equipment at the Manufacturer's works prior
to despatch to prove compliance with specifications
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REVISION NO : 0
19.0 DEVIATIONS
19.1 Deviations from specification must be stated in writing at the bid stage.
19.2 In the absence of such a statement, it will be assumed that requirements of the
specification are met without exception.
Page 617 of 674

Page 1 of 15
AC VARIABLE SPEED DRIVE SYSTEM
By By By
Page 618 of 674

AC VARIABLE SPEED DRIVE SYSTEM PAGE : 2 OF 15
REVISION NO : 0
TABLE OF CONTENTS
1.0 SCOPE 2
3.0 DETAILS OF DESIGN 3
4.0 CUBICLE DESIGN AND CONSTRUCTION 7
5.0 DETAILS OF COMPONENTS 8
6.0 DETAILS OF PROTECTION, CONTROL, METERING AND INDICATION / 9
ANNUNCIATION
7.0 PAINTING 12
8.0 DRAWINGS & DATA 12
9.0 SPARES 13
10.0 TESTS & INSPECTION 13
11.0 SITE TESTING AND COMMISSIONING 14
13.0 DEVIATIONS 15
1.0 SCOPE
1.1 This specification covers design, Manufacture, testing at works and supply of AC variable
Page 619 of 674

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speed drive system, consisting of Squirrel cage induction motor, converter, DC link reactor,
converter supply transformer, switch fuse on incoming side, bypass contactor with BMR,
Harmonic filter circuits along with associated auxiliaries and local operating panel.
2.0 BASIS OF DESIGN

2.1 The equipment shall conform to this specification, the latest issue of the relevant Indian
standard specifications or the equivalent specification of the country of origin or IEC
specifications including amendments and addenda. Some of the relevant standards are
listed below :
IS 325 : Three phase induction motors
IS 2026 : Standards for transformers.
IS-3700: : Essential ratings and characteristic of semi-conductor devices.
IS-3715 : Letter symbols for semi-conducting devices
IS: 4411 : Code of designation of semi-conducting devices.
IS-5001 : Guide for preparation of drawings for semiconductor devices.
IS-5469 : Code of practice for the use of semiconductor junction devices
IS-7132 : Guide for testing of Synchronous machines.
IS: 13947 : Low voltage switchgear and control gear: General rules.
IEC-297 : Dimensions of panels and racks.
IEC-326 : General requirements and measuring methods for printed wiring
boards
IEC-352 : Solder-less wrapped connection.
IEEE-444 : Protection standards for converter
IEEE-519 : Harmonic control & reactive compensation of static power
converters
DIN-41488 : Electrical Engg. dimensions of cubbies.
IS-4237 General requirement of swgr. & control gear for voltage not
exceeding 1000V.
IS-325 : Three phase Induction motors.
3.0 DETAILS OF DESIGN

3.1 The system offered shall be energy efficient, provide very high reliability, high power factor,
low harmonic distortion, low vibration and wear and noise. It shall be easy to install with
minimum time and expense and no special tools shall be required for routine maintenance.
3.2 The system shall be suitable for the load characteristics and the operational duty of the
driven equipment It shall be capable of withstanding the thermal and dynamic stresses and
the transient mechanical torque, resulting from short-circuit. Any damage resulting from
such a short circuit or internal fault shall be limited to the component concerned.
3.3 The system shall be either constant torque or constant power as dictated by the driven
equipment.
3.4 The system shall be suitable for continuous speed control of the motors in single drives
system and soft start feature shall be provided to reduce the disturbances in the electrical
system
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REVISION NO : 0
3.5 The drive motor shall be speed regulated to a speed corresponding to 4-20 mA or 0-10 V
reference signal. Upon complete loss of the user's speed reference signal, the drive shall
automatically run at constant speed as determined by the last speed reference available
prior to the loss of signal.
3.6 The power control regulator logic shall provide for acceleration / deceleration current limit
curve and shall be capable of field adjustments without shutting the system down.
3.7 The drive shall be able to accelerate the load over the full speed range of the speed torque
curves and with incoming line voltage variation of 10%.
3.8 The System shall be suitable for single quadrant operation and the range of speed
variation shall be with range 1:100 unless otherwise specified, with speed set accuracy of
1 % of rated maximum frequency and steady state regulation of 0.5% of rated
frequency.
3.9 Unless otherwise specified, output voltage regulation shall be within 2% under steady
state condition from no load to full load and 10% under transient condition of 50% step
load change with recovery time of 100ms. The total harmonic content of the voltage at
inverter output shall not exceed 3% rms of the fundamental
3.10 The frequency regulation shall be 0.05% of rated maximum frequency under steady state
and 0.5% during transient condition
3.11 The system shall be suitable for operation on a supply system with a short circuit rating as
calculated based on the converter transformer.
3.12 The system shall be designed to supply 150% of the rated controller current for one
minute. If the motor load exceeds 150%, the drive shall automatically reduce the frequency
and voltage to the motor to guard against overload. If load demands exceeds 150% current
for more than 1 minute, the drive shall shut down to prevent motor over heating.
3.13 During the continuous operation, the system shall be capable of developing sufficient
torque under all load conditions to respond to a 20% alteration in set point within a time
limit of 5-120 seconds.
The integrator action of the set point alteration shall be independently adjustable for both
an upward and a downward alteration.
3.14 The power supply system shall provide precise adjustable (active and reactive) power to
the motor started on line. It shall operate on constant V/F supply with required voltage
boost capability in low frequency mode of operation. Short time voltage dips upto 80% of
nominal shall not cause the control system to stop functioning.
3.15 The system shall be equipped with an automatic restart facility which will restart the system
in the case of voltage dip over 20% or power interruptions for less than 4 seconds with
recovery of the voltage to 95%. The drive shall have the facility to block the automatic
restart.
3.16 The system shall be suitable for no. Of starts as per JH&G specification for induction
motors.
3.17 The power controller shall be regulated to always start the motor in the forward direction.
Logic shall be provided to prevent the motor from being started in the reverse direction.
3.18 It shall be possible to vary the speed of the drive either manually or in auto mode. In
manual mode also, motor operated potentiometer shall be provided as a speed set point
device. The potentiometer shall be adjustable from local and remote by means of
raise/lower push buttons. Auto/manual selection shall be from VSD panel unless otherwise
specified. Necessary equipment required for interfacing shall also be provided.
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REVISION NO : 0
3.19 The system shall have provision to control and monitor through the control panel/operator
console (PLC/DCS). Control and monitoring through PLC/DCS can be done in 2 ways:
a) Hardwired signals such as 4 to 20 mA and dry contacts or
b) Serial link (using protocols such as mudbugs, profibus etc)
The required provision for the interface with the system including the details of
communication module and data transfer facility, I/O details shall be furnished. The drive
shall support a standard open protocol for this communication.
3.20 Redundant ventilating fans per channel shall be provided and system shall be shut down in
case of ventilating system failure.
3.21 Maximum noise level from the complete drive system at 1 meter distance, under rated load
with all normal cooling fans shall not exceed 75 dBA.
3.22 The starting, operating and stopping logic of the system shall produce potential free
contacts required for the closing and tripping commands to PCC / MCC.
3.23 Fault Diagnostic
Fault diagnostic and indication logic shall be built into the system to supervise the
operation and failure of the system. The information shall be retained for a period of
minimum 4 days after interruption of the power supply to the VSD.
3.24 Appropriate filters shall be provided to take care of long length of cables between VSD and
motors to take care of damage to motor insulation.
3.25 The responsibility for coordination of motor and inverter design with the load/speed
requirements will be as stated in data sheets. Vendor shall be responsible for this drive
coordination, in particular to following:
- To ensure that main drive motor and inverter are both adequately rated and sized
for the drive requirements stated and to recommend alternative configurations
where appropriate (like separate cooling fan, choice of frequency range etc.)
- To arrange where necessary for testing of motor with inverter unit to confirm
compliance with requirements of load, noise, vibration, temperature rise etc.
- To recommend any additional motor protection arrangements which may be
necessary to prevent motor winding damage.
3.26 MOTOR
The motor shall be designed, constructed and tested in accordance with the JH&G
standard specification for Induction Motors and Indian standard or equivalent applicable
International standards, in addition to the following requirements:
3.26.1 The motor shall be suitable for operation with a solid state power supply consisting of an
adjustable frequency inverter for speed control.
3.26.2 The motor shall be suitable for the current wave forms produced by the power supply
including the current harmonics generated by the wave form.
3.26.3 The motor shall be designed to operate continuously at any speed over the range (0-
100%) of rated speed or as specified in data sheet.
3.26.4 The temperature rise, taking into consideration the additional harmonic losses shall not
exceed the capabilities of the class rating of the insulation system and all the motors shall
be provided with class F insulation with temp. rise limited to 'B'.
3.26.5 Motors applied to line start or Transfer to the line applications shall be rated for line voltage
and frequency variation.
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REVISION NO : 0
3.26.6 The motor shall be constructed to withstand torque pulsation resulting from current
harmonics generated by the solid state power supply.
3.26.7 The motor shall be constructed such that in an emergency it can withstand, without
mechanical damage, 20% over speed above rated speed.
3.26.8 The motor shall be designed to conform to the noise level as per relevant standards.
3.27 POWER CONVERTER
3.27.1 The static power converter consists of a line side full power converter for operation as
phase controlled rectifier and a load side full power converter for operation as a phase
controlled inverter.
3.27.2 The rectifier and inverter shall be 12 pulses line and load communicated converters
3.27.3 The converter shall be co-ordinated with the isolation transformer if provided. The
converter shall be able to withstand a three phase short circuit current until interrupted by
normal breaker operation.
3.27.4 In case of circuit breaker controlled motors without any fuse, the inverter shall withstand
short circuit current till such time the fault current is interrupted by a circuit clearing
devices.
3.27.5 The thyristors shall have repetitive peak reverse blocking voltage margin at 250% of line
voltage.
3.27.6 All power converter thyristors design shall include co-ordination by peak voltage protecting
snuffer networks and di/dt and dv/dt networks so that converters can operate continuously
with one thyristor failed or shorted in each converter branch.
3.27.7 The current rating of the converter semiconductor components shall not be less than 120%
of the maximum current flowing through the elements at full load of the VSD over the entire
speed range. If parallel connection of semi conductors is applied, the above current rating
shall not be less than 140% of above values.
3.27.8 Filters for AC input and output shall be used. All capacitors in filter circuits shall be
provided with discharge circuits to ensure that all residual stored charge is reduced to less
than 50 V DC within 60 seconds after a loss of AC voltage.
3.27.9 The power converter circuit shall be designed so that motor can be powered at its full
name plate rating continuously without exceeding its rated temperature rise nor reducing
its service factor due to harmonic currents generated by the inverter operation.
3.27.10 The thyristor and associated heat sinks shall be assembled so that individual diode can be
replaced without requiring the use of any special tools.
3.27.11 The thyristor cooling system, if provided, shall be monitored and alarmed before any side
effect damage occurs to the power controller.
3.27.12 A logic shall be provided to restrict the no. of HOT/COLD start of the motor and having
bypass facility in case of emergency.
3.27.13 All the thyristors & diodes shall be protected with high speed semiconductor grade fuse. I2t
particulars of the power controller devices and the fuses shall be supplied along with the
calculations in support of the selection of fuses.
3.27.14 The inverter section may use transistor modules or GTO modules in place of thyristors.
3.27.15 Converter shall be cooled either by natural or forced air. The cooling system shall be fully
redundant and shall be consisting of two cooling units in parallel. In case of failure, an
automatic change-over on the standby mode shall be made. All air ducting, heat
exchanger, insulators, pumps etc. shall be included in contractor's scope.
Page 623 of 674

REVISION NO : 0
3.28 DC LINK REACTOR
3.28.1 Smoothing reactors for the DC link shall be designed to sufficiently de-couple the rectifier
and inverter portion of the converter and to limit fault currents in this circuit.
3.28.2 The reactor shall be air-cooled / oil-cooled type for indoor and outdoor installation
respectively.
3.28.3 Air filled weatherproof terminal boxes shall be provided for termination of the cables.
3.28.4 The outdoor oil filled reactor shall have features and protective devices as required for
converter transformer.
3.28.5 The indoor reactor shall be housed in a panel and shall have redundant fans. Fan shall be
monitored and alarmed if one fan fails, and shut down the drive system if both fans fail.
3.28.6 Converter reactor shall be suitable for operation with the non-sinusoidal current wave
shapes and DC components under all operational conditions of the system without
exceeding its temperature.
3.29 HARMONIC FILTERS
3.29.1 Harmonic filters shall be provided at the supply side of the drive system on the maximum
allowable levels of current and voltage distortion as stated below:
3.29.1.1 Current harmonics
Based on short circuit capacity of the system, the percentage of the 5th, 7th, 11th, 13th, 17th,
19th, 23rd and 25th harmonic in the line current shall be limited to maximum 3%, 3%, 10%,
8%, 1%, 1%, 5% and 5% respectively.
3.29.1.2 Voltage Harmonics
Based on the minimum short circuit capacity of the supply system, the percentage of the
5th, 7th, 11th, 13th, 17th harmonic in the line voltage shall be limited to maximum 5%, 4%,
3%, 2.2% and 1.2% respectively.
3.30 LOCAL OPERATING PANEL (LOP)
3.30.1 The LOP shall be in cast metal or sheet steel housing and shall conform to Indian or
international standard.
3.30.2 It shall be provided with flameproof enclosure if it is to be installed in hazardous area.
3.30.3 Minimum control and indication shall be as specified elsewhere
3.30.4 Cable entry to the LOP shall be from bottom and shall be provided with double
compression weatherproof or flameproof cable glands as required.
3.30.5 One no. earthing terminal shall be provided.
3.30.6 Nameplates indicating the equipment to be operated shall be provided on respective LOP.
4.0 CUBICLE DESIGN AND CONSTRUCTION

4.1 The converter and inverter section shall be suitably housed in sheet steel panels and shall
be fabricated with 2 mm thick cold rolled sheet steel and structural steel. The panel shall
be suitable for indoor installation if not otherwise specified. The panel shall be free
standing, dust and vermin proof and degree of protection IP-52 if not otherwise specified.
The maximum and minimum operating height of the switches shall be 1800 mm and 300
mm respectively.
Page 624 of 674

REVISION NO : 0
4.2 The cable entry shall be from the bottom of the panel and a removable bolted undrilled
gland plate shall be provided with compression type cable gland. Clamp type terminals
shall be used for connection of all wires upto 10 mm2 and terminal for higher sizes shall be
bolted type suitable for cable lugs.
4.3 Busbars shall be of aluminium and colour coded. All the live parts shall be shrouded to
ensure complete safety to personnel intending routine inspection by opening the panel
doors. All the equipment inside the panel and on the doors shall be provided with suitable
name plate. All wires shall be ferruled and terminals shall be properly numbered; min. 20%
spare terminal shall be provided.
4.4 All the fuses shall be fast acting semi-conducting type and mounted inside the panel. All
the power and control switches shall be mounted on the door operable externally. All the
instruments shall be switch board type, back connected, 72x72mm. Scale shall have red
mark indicating maximum permissible operating rating. Separate test terminals shall be
provided for measuring and testing of the equipment to check the performance.
4.5 Each panel shall be provided with illuminating lamp with switch and fuse. 5/15A, 240V
power socket with switch and fuse shall be provided. Each panel shall have space heater
with switch fuse and variable setting thermostat
4.6 All the non-metallic components / parts shall be connected to the main earth busbar
running at the bottom of the panel and min. 50 x 6mm Cu or equivalent AL busbar shall be
provided with provision for connection to plant earth grid.
4.7 All panels shall be same height so as to form a bank, which shall give good aesthetic
appearance.
4.8 All the control wiring shall preferably be enclosed in plastic channel. Each wire shall be
identified at both ends by self sticking wire marker tapes or PVC ferrules. Ferruling of wires
shall be as per relevant IS.
4.9 Power and control wiring inside the panel shall be done with PVC insulated copper
conductor. 1.5 mm2 size wire shall normally be used provided the control fuse rating is 10
Amps. or less and 2.5 mm2 size for control fuse rating above 16 A.
4.10 All thyristor modules and components shall be accessible from front of panel only. Modular
plug-in/draw-out assemblies for both the system control electronic equipment and power
electronic equipment shall be used. In case rear access being a must, it shall be indicated
clearly in the bid.
4.11 PCB construction shall be rigid and robust. Components shall be wave soldered to the
PCBs. Each component on the board must be clearly identified.
4.12 Suitable removable type hooks shall be provided for lifting the panel.
5.0 DETAILS OF COMPONENTS

5.1 The panel shall include suitable isolating device i.e. circuit breaker or MCCB or isolator for
main supply, contactors, diode (Converter)/ IGBT (Inverter) modules with protective
devices, reactors for suppressing commutating notches, control circuit, control
accessories, indication and annunciation, bypass contactor with BMR etc.
5.2 Main isolating device shall be electrically operated type with operating handle accessible
from outside the panel and lockable in 'off position.
5.3 All electronic components shall be of solid state type. All power diodes shall be of silicon
type with minimum VBO rating as 2.5 times the rated operating voltage.
5.4 The contactor shall be air break type with required no. of contacts for inter locking.
Page 625 of 674

REVISION NO : 0
5.5 Current transformer shall conform to accuracy class 1.0 & metering instrument shall
conform to relevant Indian Standards.
5.6 The fuses used for controller device protection shall be semi conductor type. Other fuses
shall be HRC type mounted inside the panel. All the switches shall be rotary type and fitted
on front of the panel.
5.7 All the electronic circuit cards shall be arranged in modular racks for easy replacement and
preferably 19 rack shall be used. Control power shall be indicated by LED's. Test point
shall be provided for testing the thyristor firing pulse in control circuit and at the thyristor
gate terminal.
5.8 Alarm annunciator may be solid state or electromechanical type. Visual indication shall be
provided using annunciation windows with white translucent facia of unbreakable acrylic
material. The accessories shall include flasher unit, solid state hooter, separate push
button for acknowledge accept, reset & test. These shall be mounted on the front.
5.9 Viewing windows shall be provided on the front of the panel door so that thyristor fault
indication can be viewed from the exterior of the panel without opening of doors.
6.0 DETAILS OF PROTECTION, CONTROL, METERING AND INDICATION /

ANNUNCIATION
6.1 The manufacturer shall provide all the system control, protection, alarm equipment and
metering for the entire drive system and its auxiliary equipment.
6.2 Automatic sequence control shall include start-up of cooling system, interlock checking,
automatic start and run-up of drive, planned and emergency shutdown. The same shall be
processed through microprocessor based system.
6.3 All Indications, controls, annunciation and metering shall be provided on front of the panel
only. Provision for remote control, annunciation, indication shall also be provided. Control
interface as required to operate the power controllers to and from the remote control shall
be provided.
6.4 Protection Requirement
The system offered shall incorporate adequate protection and alarms properly co-
ordinated by the Vendor for the drive control and for motor but not limited to the following:
6.4.1 Main Drive Motor and Supply Cables
a) Over-current (Through current control limiter) : Yes

b) Over-voltage (Through voltage control limiter and surge protection) : Yes
c) Short circuit (Through thyristor blocking) : Yes
d) Phase unbalance/single phasing : Yes
e) Loss of field : No
f) Field over current : No
g) Earth fault in the stator winding : No
h) Locked Rotor : Yes
i) Earth fault in supply cables : Yes
j) Phase reversal : Yes
k) Overspeed -105% / Under speed -95% : Yes
l) Underspeed : Yes
Page 626 of 674

REVISION NO : 0
m) Over temperature in stator (Through RTDs) : No
n) Insulation or component failure on rotor : No
(Through comparison of motor and exciter stator parameters)
o) Bearing temperature High/Low : No
p) Lube oil flow/pressure Low : No
q) Excessive vibrations : No
r) Line breaker tripped : No
e) And f) are required for synchronous motors
6.4.2 EXCITER
a) Earth fault in stator winding
b) Over-temperature in Stator
c) Bearing temperature High/Low
d) Lube oil flow Low
e) Excessive Vibration
6.4.3 CONVERTER TRANSFORMER / DC REACTOR
a) Short-Circuit
b) Over Current
c) Earth fault
d) Buchholz gas release
e) Buchholz sudden pressure
f) Differential
g) Oil Temperature high
h) Winding temperature high

i) PRV operated
a) To c) shall be provided in the HT panel. However differential protection shall be
provided by the Vendor with sending end CT required for differential in HT panel.
6.4.4 CONVERTER
a) Loss of incoming line voltage (U/V)
b) Transient voltage fluctuations
c) DC link over voltage
d) Loss of control voltage
e) Earth fault main circuit
f) Earth fault secondary circuit
g) High temperature inside enclosure
h) Failure of auxiliaries together with identification of the failed unit
i) Overcurrent
Page 627 of 674

REVISION NO : 0
j) Deviation from the set point
k) Cooling medium temperature high Not Applicable
l) Loss of one cooling system Not Applicable
m) Loss of cooling medium flow Not Applicable
n) Single device failure
o) Multiple device failure
6.5 Following minimum control is envisaged on front of the panel unless otherwise specified.
a) Start/stop
b) Speed control
c) Raise/lower
d) Forward/Reverse
e) Auto/Manual mode
f) Local/remote
g) Acknowledge/Accept/Test Push button for Annunciator.
h) Emergency stop
I) Trip remote breaker
j) Start/stop for by pass contactor
6.6 The system shall monitor the status of the following and provide indications.
a) Motor on
b) Motor off
c) Motor over speed
d) AC mains ON
e) Rectifier output 'ON
f) System ready to start
g) Motor zero speed
h) Remote breaker trip
6.7 In addition to fault Annunciation as per clause 6.4.4, following shall also be provided. Alarm
shall also be annunciated through solid state hooter. Display of five minimum most recent
faults shall also be provided.
a) Rectifier fuse failure
b) Main AC failure
c) Inverter fuse failure
d) Inverter overload
e) Inverter high temperature
f) No cooling of panel/motor
g) Motor failed to start
Page 628 of 674

REVISION NO : 0
i) Potential free contact for above and clause 6.4.1, shall be provided and wired up to
terminal block for owner's use.
6.8 The following metering shall be provided:
a) Input AC voltmeters
b) Input AC frequency meter
c) Input AC Ammeter
d) Output voltmeters
e) Output ammeter
f) Motor speed
g) Motor energy meter
h) DC Amps.
i) DC volts
Provision for remote metering shall be provided. Associated transducers shall be included
for that purpose.
6.9 Following control/metering shall be provided on local operating panel.
a) ON/OFF push button.
b) Speed Raise/Lower push button.
c) Emergency stop push button.
d) Local/remote selection indication.
e) Speed indicator
f) Ammeter
g) ON/OFF indication.
h) Drive ready to start indication
7.0 PAINTING
All metal surfaces shall be thoroughly cleaned and degreased to remove scale, rust,
grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace
of acid. The surface shall be prepared by applying a coat of phosphate paint and coat of
yellow zinc chromate primer. The surface shall be made free from all imperfections before
undertaking the finishing coat.
After preparation of the surfaces, the board shall be powder coated with two coats of
epoxy based final paint. Colour shade of final paint shall be as specified in datasheet. The
finished panels shall be dried in stoving ovens in dust free atmosphere. Panel finish shall
be free from imperfections like pinholes, orange peels, runoff paint etc.
All unpainted steel parts shall be cadmium plated or suitably treated to prevent rust

The CONTRACTOR shall submit the following drawings and data along with Purchase
Specification for OWNER/PMC approval/review.
a) Block diagram for the system.
Page 629 of 674

REVISION NO : 0
b) Single line diagram and control schematic showing equipment rating & interlocks.
c) GA drawing showing overall dimension with cut-out details for all equipment.
d) Technical particular
e) Torque/speed/current/power factor of the system.
f) Combined Type test certificate for the drive and motor.
g) Reference list of clients to whom such system has been supplied.
9.0 SPARES
The Bidder shall provide with his quotation separate priced list of recommended operation
and maintenance spares.
10.0 TESTS AND INSPECTION

After completion of all work at the manufacturer's works the Battery & Charger shall be
inspected and tests witnessed by the Purchaser's representative. However, stage
inspection may be carried out from time to time to check progress of work and
workmanship.
Routine test shall be carried out on entire system however; type test shall be performed on
at least one system of a group of identical systems to be supplied.
10.1 Routine Tests
Following tests shall be performed on the total system:
- No load tests
- Insulation test
- Functional test
- Visual inspection
10.1.1 No Load Tests
Following tests shall be performed on entire speed range
- Motor Noise Test/Radio frequency test
- Vibration severity measured at bearing housing.
10.1.2 Insulation Test
The insulation test shall be carried out as per relevant standards.
In case of DC test Voltage; AC test voltage shall be multiplied by Square root 2.
10.1.3 Functional Test
- Locked rotor test
- Test of speed protection at 95% of the minimum operational speed and 105% of the
maximum operational speed.
- Test the response time and adjustablity of ramp times within the operational speed
range.
- Test capability to restart the system and synchronize converter onto running motor
after a voltage interruption.
- Test of reference and remote control conditions.
Page 630 of 674

REVISION NO : 0
- Test of output frequency/voltage reduction initiated by motor current limitation.

- Test of 5% 'set-point - measured point deviation alarm.
- Component/aux. Failure
- Test of all protection, alarm and trip functions.
10.1.4 Visual Inspection
It involves checking of the various equipment/components fault diagnostic unit, Wiring,
Terminals, earthing ratings etc. in line with the approved drawings.
10.2 Type test
Following tests shall be performed.
10.2.1 Heat Run
The system is to run under the load and speed conditions at which the maximum
temperatures shall be reached. The unit is to run until the temperature of all components
have stabilised and continue for a minimum of 2 hours and current unbalance, motor
winding temperature rise, converter temperature rise, bearing temperature at maximum
speed and shaft vibration shall be measured.
10.2.2 Load Test
Measurement of overall efficiency, power factor, harmonic distortion in the current
(live/load side) at full and half load curve both at minimum operational speed of the total
unit and of the transformer, converter and motor individually.
- Noise test for all individual equipment
- 110% nominal current test for at least 10 minutes.
- Linearity between the set point signal and output.
10.2.3 Fault Condition Test
- Two phase short circuit at motor terminals at no-load condition upto max. rating of
1MW.
- Earth fault at the motor
- Single phasing of motor at full load
- Single phasing in the drive system supply at full load.
- Three phase interruption of the motor current at full load condition up to maximum
rating of 1 MW.
- Earth fault in the control supply system.
- Interruption/short circuit in the 4-20 mA control signals.
10.2.4 String test with driven equipment
Vendor shall provide all facilities such as power supply, testing instruments, and apparatus
required for carrying out the tests. Required copies of test certificates for all the tests
carried out along with copies of type test certificates and certificates from Sub-Vendor for
the components procured from them are to be submitted before despatch of VSD system.
11.0 SITE TESTING AND COMMISSIONING

Site testing and commissioning shall include atleast (but not limited to) following tests:
11.1 Operation of motor / converter panel over complete speed range (with load if available
Page 631 of 674

REVISION NO : 0
using local and remote control facilities.
11.2 Setting up and recording all on site adjustments.
11.3 Checking up operation of all front of panel indicators / alarms / lamps.
11.4 Recording any test point voltages (where fault diagnostic facilities are provided).
11.5 Checking operation of bypass system (if provided)

Quality Assurance shall follow the requirements of Jacobs Q.A. Documents as applicable.
Q.A. involvement will commence at bid stage and follow through to completion and accep-
tance, thus ensuring total conformity to Purchaser's requirements.
13.0 DEVIATIONS
Deviations from the Specifications must be stated in writing at the bid stage.
In absence of such a statement, it will be assumed that the requirements of the
Specifications are met without exception.
Page 632 of 674

Page 1 of 9
FLAME PROOF DISTRIBUTION PANEL, PLUGS,

SOCKETS, LAMPS AND LIGHTING FITTINGS
FOR HAZARDOUS LOCATIONS
By By By
0 09 April 2010 9 Issued for Engineering ASR PPP RBD
Page 633 of 674

STANDARD SPECIFICATION : 44NC-4600: ESS 067 DATE : 09 April 2010
FLAMEPROOF DISTRIBUTION PANEL, PLUGS, SOCKETS,
LAMPS AND LIGHT FITTINGS FOR HAZARDOUS LOCATIONS PAGE : 2 OF 9
REVISION NO : 0
TABLE OF CONTENTS
1.0 SCOPE 2
3.0 SERVICE CONDITIONS 3
4.0 DETAILS OF DESIGN 4
5.0 DRAWINGS AND DATA 8
6.0 TESTING AND INSPECTION 8
7.0 SPARES 8
9.0 DEVIATIONS 9
1.0 SCOPE
This specification covers design, construction, testing and supply of distribution boards,
Page 634 of 674

REVISION NO : 0
plugs, sockets, lamps and flameproof lighting fittings.
2.0 BASIS OF DESIGN

In general the equipment covered by this specification shall, unless otherwise specified,
conform to the latest edition of Indian Standards/ International Standards including
amendments and addenda but not limited to the following:
2.1 IS: 2148 Flameproof enclosure of Electrical Apparatus.
2.2 IS: 2147 Degree of protection provided by enclosure for low voltage switchgear
and control gear.
2.3 IS: 8828 Specifications for Miniature Air break circuit breakers for voltages not
exceeding 1000 volts.
2.4 IS: 4064 Air break disconnectors, air-break switch disconnectors & fuse
Part 1 combination units for voltage not exceeding 1000 V AC or 1200 V DC.
IS: 13346 General requirements for electrical apparatus for explosive gas
atmospheres.
IS: 13947 LV switchgear and control gear
IS: 5572 Part - I Classification of hazardous areas (other than mines) for electrical
installation Areas having flammable gases & vapours.
IEC: 79 Electrical apparatus for explosive gas atmosphere.
(Applicable
parts)
IEC: 309 Part-3 Plugs, socket outlet, connectors and appliance inlets for use in
explosive gas atmosphere
IS:5572 Classification of hazardous area (other than mines) for electrical
(Part 1) installation.
IS: 5571 Guide for selection of electrical equipment of hazardous areas.
IS: 8239 Classification of maximum surface temperature of electrical equipment
for use in explosive atmosphere.
IS: 6381 Construction and testing of electrical apparatus with type of protection
`e.
IS: 8289 Electrical equipment with type of protection `n.
IS: 2206 Flameproof electric lighting fittings (well glass and bulk head type,
fittings using glass tubes).
(Part 1 to 4)
IS: 8224 Electrical lighting fitting for division 2 areas.
IS: 1913 (Part 1) General and safety requirements for Luminaires.
IS:13408 Code of practice for the selection, installation and maintenance of
(Part 1) electrical apparatus for use in potentially explosive atmospheres (other
than mining application or explosive processing and manufacture).

The, distribution panel, plugs, sockets, lamps and flameproof lighting fittings shall be
designed to operate under the conditions as specified elsewhere.
Page 635 of 674

REVISION NO : 0
4.0 DETAILS OF DESIGN

4.1 FLAMEPROOF DISTRIBUTION PANEL
4.1.1 The enclosure shall be flame proof and suitable for indoor / out door installation as per
requirement. A canopy shall also be supplied, if panel is located in outdoor area. Panel
shall have external fixing lugs, and shall be suitable for mounting on vertical face such as
wall / column, or steel pedestal.
4.1.2 Panel shall comprise of one four-pole incoming isolating device, bus bars and required
number of outgoing feeder-isolating devices equally distributed over the phases. Each
outgoing shall have 2 pole isolation viz. Phase and neutral. The number of outgoing
feeders, and rating of both incomer and outgoing shall be as required.
4.1.3 Incomer, busbars, and outgoing feeder elements shall be housed in separate
compartments. The separation between the compartments should be such that no flame
propagation is allowed.
4.1.4 Incomer shall have mechanical ON / OFF indication and facility for pad locking the
operating handle in off position. An explosion proof cable gland for incoming cable shall be
provided, suitable for cable size required. Crimping type lugs shall be provided for
incoming cable.
4.1.5 Bus bars shall be made of high conductivity copper and supported by non-hydroscopic
insulators. Individual compartments shall have separate inspection covers secured by
screws / bolts requiring special tools for opening.
4.1.6 All outgoing circuit shall also have ON / OFF indicators.
4.1.7 Terminals shall be provided in an independent compartment for connection of outgoing
cables. Terminals should be anti-loosening type and suitable for 2.5 sq. mm-copper
conductor or of required size such that conductor is not damaged due to over tightening.
In addition to two terminals (phase and neutral) for each outgoing circuit having a three
core armoured cable, provision shall be made for connection of third core to be used for
earthing of the body internally.
4.1.8 Explosion proof cable glands shall be suitable for cable size required. Explosion proof
threaded plug to block unused outgoing cable entry shall be provided in numbers as
required. All cable entries (incoming and outgoing) shall be so designed, that no water
leaks in when panels are installed outdoor and if this cannot be met all the entries should
be necessarily pointing down.
4.1.9 Caution plates shall be provided on the inspection covers to avoid opening without
isolation. Nameplates shall be provided for each outgoing circuit, and for the complete
panel indicating panel number. All nameplates shall be fixed by screws and shall be made
of laminated plastic with white letters on black background.
4.1.10 The supply of the panel shall include the panel itself complete with all normal components
and devices required for full and proper operation of the equipment even though such
component of devices may not be stated in detail in this specification. Complete set of
special tools for opening / closing of enclosure bolts / screws (2 sets) shall be supplied with
these switchboards.
4.1.11 Approval certificates from CMRS and general arrangement drawings shall be furnished
with the bids.
Page 636 of 674

REVISION NO : 0
4.1.12 All the non-current carrying metallic parts of the panel shall be inherently bonded together.
Two 10 mm dia studs should be provided on the main housing for external earthing
connection. Earthing terminals for outgoing circuits should also be bonded to main
housing.
4.2 SOCKET OUTLETS AND PLUGS
4.2.1 Flameproof sockets shall be provided with a switch and a mechanical interlock so as to
break the electrical circuit before the plug is completely withdrawn and make the circuit
after the plug is fully inserted.
4.2.2 In order to prevent accidental removal of plug from socket, the engagement &
disengagement shall be by two separate and distinct movement & positions.
4.2.3 415 V, 63 A, three phase flameproof plug and socket meant for welding receptacle / any
other three phase auxiliary loads shall be provided with either 4 pins (3P+E) or 5 pins
(3P+N+E) as required.
4.2.4 4-pin socket shall be provided with 63 A, three-pole heavy-duty switch whereas 5-pin
socket shall be provided with four pole (TPN) heavy-duty switch.
4.2.5 Both 24 V and 240 V, 15 A single phase flameproof plug and socket shall be provided with
3 pins (2P+E).
4.2.6 Provision shall be made so that it shall not be possible to insert 24 V plug on to a 240 V
socket.
4.2.7 Each outlet shall be provided with either a spring loaded hinged cover, or with a cap
connected through metallic chain, to close the outlet when not in service.
4.2.8 All internal power wiring shall be done with 660 V grade PVC insulated copper wires of
suitable size.
4.2.9 Stud type terminals of suitable size shall be provided for all outgoing and incoming cables.
4.2.10 All sockets shall be suitable for two cable entries with looping facility and shall be provided
with two flameproof double compression brass cable glands and one flameproof brass-
sealing plug per socket to seal the unused cable entry.
4.2.11 24 V socket outlet unit shall be provided with built in 240 V / 24 V transformer. The
transformer shall be designed for 100 VA rating on continuous basis.
4.2.12 HRC fuses shall be provided on primary and secondary side of the transformer. The
transformer shall have an earthed screen between primary and secondary winding. The
socket outlet unit with built in transformer, switch, fuse, internal wiring shall be flameproof
as a complete assembly.
4.2.13 All units shall be provided with one internal & two external earthing terminals.
4.2.14 Scraping earth connection shall be provided between the plug and socket. Earth pin of
plug shall first engage with earth pin of switch socket.
4.2.15 The plug assembly shall be mechanically rugged, light and shall not unduly stress the
socket or its own pins when fitted on to the socket.
4.2.16 Each socket outlet unit shall have suitable mounting frame / bracket to facilitate installation
on vertical surface of wall / structure.
4.3 24 Volt HAND LAMPS
Page 637 of 674

REVISION NO : 0
4.3.1 The lamp holder of the hand lamp shall be suitable for 60 W, 24 V, 50 Hz lamp with ES
cap.
4.3.2 The metal casting of the hand lamp shall be corrosion resistant Aluminium alloy LM6.
4.3.3 Suitable handle for carrying hand lamp and a stand type guard suspension hook shall be
provided.
4.3.4 The well glass provided shall be clear, suitable for use under conditions involving
exceptional risk of mechanical damage. Mechanical strength of well glass shall satisfy
requirement of IS: 2206 (FOR TYPE a GLASS).
4.3.5 Hand lamp shall be provided with a galvanised steel wire protective cage having mesh
dimension not exceeding 50 mm.
4.3.6 Each hand lamp shall be supplied complete with 50 m length of 3 x 1.5 mm2 copper
conductor, PVC insulated, metal braided flexible cable duly terminated in the hand lamp
while the loose end shall be used for termination in 24 V plug.
4.4 Lighting fittings for Hazardous locations
4.4.1 Construction
4.4.1.1 All equipment shall be suitable for use in outdoor open locations and shall have IP-55
degree of protection.
4.4.1.2 The body of the lighting fixtures, control gearbox and junction boxes shall be cast
aluminium LM-6 alloy and shall be free from frictional sparking hazard. The temperature
rise of external surfaces shall be limited to applicable temperature class w.r.t. location of
fitting.
4.4.2 Lighting Fixtures
4.4.2.1 The construction of lighting fixtures shall be such that replacement of lamp or any normal
maintenance of fixture shall not affect their suitability for use in classified area.
4.4.2.2 Glass used for lighting fixture shall be clear suitable for use under conditions involving
exceptional risk of mechanical damage.
4.4.2.3 Well glass lighting fixture for Zone 2 classified area shall meet requirement IS 6381.
Mechanical strength of well glass shall satisfy requirement of IS 2206 (for type A glass) for
flameproof lighting fixtures and IS 6381 for Div. 2lighting fixtures. All well glass fixtures
shall be provided with a galvanised steel wire protective cage having mesh dimensions not
exceeding 50 mm.
4.4.2.4 Glass used for aviation and navigational lighting fixture shall be coloured in itself.
4.4.2.5 The fixing parts of the enclosure, which is to be opened for replacement of bulb, shall be so
fastened that they can be unfastened only with special tools. All fixtures shall carry a
special warning inscription in English Isolate supply elsewhere before opening.
4.4.2.6 All lighting fixtures which are not certified as flameproof construction but approved for use
in Zone-2 are shall have approved enclosed break lamp holder and complete enclosure
certified as having restricted breathing type construction. Lamp holder shall be screw type.
4.4.2.7 All lighting fixtures suitable for discharge lamps shall be provided with one ET threaded
entry and supplied with approved type double compression nickel-plated brass cable
gland.
Page 638 of 674

REVISION NO : 0
4.4.2.8 All lighting fixtures suitable for incandescent lamps shall be provided with two ET
threaded entry. Two entries shall be used for looping of circuit wherever required. The
fixtures shall be supplied with approved type two double compression nickel-plated brass
cable glands and one threaded plug for sealing unused entry.
4.4.2.9 The top of all well glass lighting fixtures shall be identically drilled/ threaded to facilitate the
installation on pole / column or ceiling.
All flood lighting fixtures shall be supplied with adjustable mounting arrangement both in
horizontal and vertical plane.
4.4.3 Control Gear Box
4.4.3.1 Lighting fixtures suitable for discharge lamps shall be provided with power factor correction
capacitor, choke starter, etc. housed in separate control gearbox. The choke shall be
copper wound. The complete control gear shall have power factor not less than 0.9. All
components shall be of approved make.
4.4.3.2 Control gearbox shall be provided with three ET threaded entry (incoming, supply to
lighting fixture and for looping to other fixture/ control gear box). The control gearbox shall
be supplied with approved type three double compression nickel-plated brass cable glands
and one threaded plug for sealing used entry.
4.4.3.3 Control gearbox shall be flameproof type.
4.4.4 Junction Boxes
The junction boxes shall be 3 way or 4-way type as required. All junction boxes for looping
of single-phase lighting circuits using cables up to 4 mm2 shall be minimum 100 mm dia
size. Each junction box shall be complete with requisite number of : ET threaded cable
entries and with approved type double compression nickel-plated brass cable glands and
one threaded plug for sealing unused cable entry.
4.4.5 Terminals & Wiring
4.4.5.1 All equipment shall be provided with sufficient number of terminals. More than 2 wires per
terminal shall not be permitted. If required, additional terminal with shorting link may be
used. Each terminal for external cable connection shall be suitable for termination of 4
mm2 copper conductor or as required using crimped type tinned copper lugs. All terminals
shall be of non-sparking, anti-loosening design such that they do not produce any are or
spark in normal operation.
4.4.5.2 Flexible wires used for internal wiring shall be minimum 1.5 mm2 copper conductor and
connections shall be done using crimped type tinned copper lugs.
4.4.5.3 Terminals shall be of approved make.
4.4.6 All equipment on single-phase supply shall be provided with an independent earth terminal
inside the enclosure for connecting the earth core of the cable and shall have facility for
looping.
4.4.7 All gaskets shall be of neoprene.
4.4.8 Three sets of special tools required for maintenance shall be supplied free of cost.
Page 639 of 674

REVISION NO : 0
4.5 CERTIFICATION
All offered equipment shall be of a type already tested by CMRI (Dhanbad) and approved
by CCE for use in specified gas group locations. BIS marking is mandatory. Equivalent
testing and certification of the country of origin may be acceptable for imported equipment.
Type test certificates for each type of offered equipment shall be furnished along with the
offer.
4.6 FINISHING & PAINTING
All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust,
grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any
trace of acid. The surface shall be prepared by applying a coat of phosphate paint and
coat of yellow zinc chromate primer. The surface shall be made free from all imperfections
before undertaking the finishing coat.
After preparation of the surface, the surfaces shall be powder coated with two coats of
epoxy based final paint . Colour shade of final paint shall be 632 as per IS:5. The finished
panels shall be dried in stoving ovens in dust free atmosphere. Panel finish shall be free
from imperfections like pinholes, orange peels, runoff paint etc.
All unpainted steel parts shall be cadmium plated or suitably treated to prevent rust

Drawings and Test Certificates as stipulated in Vendor Document Requirements enclosed
elsewhere shall be furnished.

6.1 The panel shall be tested in accordance with the relevant standards. The following tests
shall be conducted on all panels:
a) Insulation resistance with 500 V megger.
b) High potential test at 2 KV for 1 minute between phases and phase to earth.
Test certificates shall be furnished along with the equipment for the above.
6.2 CMRS test certificates along with CCE approval certificates as applicable shall be
furnished for each type of fixture. All equipment shall be routine tested as per
applicable Indian Standards.
6.3 During inspection, facility shall be provided for impact testing of random sample.
One well glass of each fixture type from each lot shall be tested for impart strength.
7.0 SPARES
The Bidder shall provide with his quotation, separate priced list of recommended operation
and maintenance spares.
Page 640 of 674

REVISION NO : 0

Quality Assurance shall follow the requirements of Jacobs Q.A. documents, as applicable.
Q.A. involvement will commence at bid stage and follow through to completion and
acceptance, thus ensuring total conformity to Purchasers requirements.
9.0 DEVIATIONS
Deviations from specification must be stated in writing at the bid stage.
In absence of such statement, it will be assumed that the requirements of the specification
are met without exception.
Page 641 of 674

APPENDIX - A
INDICATIVE INSPECTION & TEST PLAN**

PROJECT : 44NC-4600 : CPCL MANALI REFINERY, CHENNAI : RESID UPGRADATION SHEET 1 OF 2
PROJECT
EQUIPMENT / ITEM DESCRIPTION : LT MOTORS VENDOR :
P.O. NO. :
EQUIPMENT / ITEM TAG NO. :
TEST & INSPECTION AS PER : PR/PS NO.
(CODES & SPECIFICATIONS) : DRG. NO.
EQUIPMENT INSPECTION CODE : A
A 1 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY OWNER / PMC
C
T 2 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY THIRD PARTY
I INSPECTION AGENCY (TPIA) / STATUTORY AUTHORITY
V 3 WITNESS INSPECTION BY SUB VENDOR,VENDOR & LSTK CONTRACTOR
I
T 4 CERTIFICATES / DATA TO BE SUBMITTED BY LSTK CONTRACTOR /
Y VENDOR FOR APPROVAL / REVIEW BY TPI A / OWNER / PMC
1 A A R X DETAILED INSPECTION & TEST PLAN AFTER ISSUE OF PO/PR/PS

2 A R X INSPECTION & TEST PROCEDURES
3 R R X SUMMARY OF ALL SUPPLIMENTARY REQUIREMENTS AS SPECIFIED
IN THE ORDER /PS/PR
4 A X PACKING PROCEDURE / SHIPPING DRAWING OF COMPLETED
EQUIPMENT
5 H H W X ROUTINE TESTS CONSISTING OF:
- VISUAL & DIMENSIONAL CHECK INCLUDING ACCESSORIES &
NAME PLATE, TERMINAL BOX (MAIN & FOR SPACE HEATER),
BTD, RTD, COOLING, ROTATION, FRAME SIZE, EARTHING,
TERMININATION ETC.
- MEASUREMENT OF WINDING RESISTANCE
- NO LOAD TEST.MINIMUM 30 MINUTES RUNNING ON NO LOAD
- SHORT CIRCUIT TEST
- HV TEST
- IR TEST BEFORE AND AFTER HV TEST
- REDUCED VOLTAGE RUNNING TEST.-
6 H H W X TYPE TEST (WHEN SPECIFIED):
- LOAD RUN TEST (FOR SPEED-TORQUE CURVE)
- TEMPERATURE RISE TEST
- OVERSPEED TEST,
- VIBRATION TEST
- NOISE LEVEL TEST
7 R R X DOCUMENT REVIEW:
- TC FOR BOUGHT OUT COMPONENTS I.E. FOR COOLERS,
BEARINGS.
- TEST CERTIFICATES FOR SPECIFIED AREA CLASSIFICATION,
TYPE OF ENCLOSURE, INCREASED SAFETY ETC.
- CALCULATION OF TEMP.RISE, EFFICIENCY,PF, STARTING
TORQUE.STARTING CURRENT ACCELARATION TIME ETC.
8 H X SPARES & PACKING LIST CHECK. PACKING & LOADING OF
EQUIPMENT AS PER SHIPPING DRAWING.
Page 642 of 674

APPENDIX - A

PROJECT
EQUIPMENT / ITEM DESCRIPTION : LT MOTORS VENDOR :
P.O. NO. :
C
I
9 H H INSPECTION RELEASE CERTIFICATE
LEGENDS : H - HOLD, W - WITNESS, R - REVIEW, A APPROVAL, I - INFORMATION, X SUBMIT

PO PURCHASE ORDER, PR PURCHASE REQUISITION, PS PURCHASE SPECIFICATION
** NOTE : THIS IS AN INDICATIVE INSPECTION AND TEST PLAN IDENTIFYING SCOPE OF INSPECTION
/REVIEW OF DOCUMENTS AS A MINIMUM REQUIREMENT, DETAILED INSPECTION AND TEST PLAN
INDICATING ALL SPECIFIED REQUIREMENTS AFTER ISSUE OF PO / PR TO BE GENERATED BY
VENDOR AND SAME DULY APPROVED BY TPI A TO BE SUBMITTED TO OWNER/PMC FOR APPROVAL.
* TPI A TO CARRY OUT INSPECTION AT SUB-VENDORS WORKS.
OWNER/PMC RESERVES RIGHT TO WITNESS INSPECTION OF ANY ITEM AT ANY STAGE WHICH SHALL BE INDICATED ON QAP /
INSPECTION & TEST PLAN AT THE TIME OF APPROVAL AND SAME TO BE COVERED AS PART OF PURCHASE ORDER
CONDITION ISSUED BY CONTRACTOR.
Page 643 of 674

APPENDIX - A

PROJECT
EQUIPMENT/ITEM DESCRIPTION : MEDIUM & HIGH VENDOR :
VOLTAGE CABLES P.O. NO. :
C
I
1 H H X PRE-INSPECTION MEETING TO BE CONDUCTED AFTER ISSUE OF

PO/PR/PS. AGENDA TO BE PREPARED BY LSTK CONTRACTOR.
3 A R X INSPECTION & TEST PROCEDURES.
IN THE ORDER/PS/PR
EQUIPMENT
6 H H X ROUTINE TEST CONSIST OF :
VISUAL / GENERAL WORKMANSHIP, LENGTH & MARKING.
CONDUCTOR RESISTANCE TEST
HIGH VOLTAGE TEST
PARTIAL DISCHARGE TEST ( AS APPLICABLE)
ANYOTHER TEST AS PER PR/PS
7 H H W X ACCEPTANCE TEST
ANNEALING TEST ( FOR COPPER)
TENSILE TEST ( FOR ALUMINIUM)
WRAPPING TEST ( FOR ALUMINIUM)
TEST FOR THICKNESS OF INSULATION & SHEATH
T S & ELONGATION AT BREAK TEST FOR INSULATION & SHEATH
HOT SET TEST FOR INSULATION & SHEATH ( AS APPLICABLE)
PARTIAL DISCHARGE TEST ( FOR SCREENED CABLE ONLY)
HIGH VOLTAGE TEST ( AS APPLICABLE)
INSULATION RESISTANCE TEST (VOLUME RESISTIVITY)
TEST FOR FRLS/FR PROPERTIES ( AS APPLICABLE)
ANY OTHER TEST AS PER PR/PS
HIGH VOLTAGE TEST FOR 4 HOURS (HV CABLES)
- TEST FOR ANTI RODENT PROPERTIES
- VISUAL INSPECTION FOR FINISH ,LENGTH & MARKINGS
Page 644 of 674

APPENDIX - A

PROJECT
C
I
8 H H X TYPE TEST ( IF SPECIFIED)

ANNEALING TEST ( FOR COPPER)
TENSILE TEST ( FOR ALUMINIUM)
WRAPPING TEST ( FOR ALUMINIUM)
TEST ON ARMOURING WIRES / STRIPS
TEST FOR THICKNESS OF INSULATION AND SHEATH
TEST FOR INSULATION SUCH AS TENSILE STRENGTH &
ELONGATION AT BREAK, AGEING IN AIR OVEN TEST, HOT TEST,
SHRINKAGE TEST, WATER ABSORPTION TEST.
TEST FOR OUTER SHEATH SUCHAS TENSILE STRENGTH AND
ELONGATION AT BREAK, AGEING IN AIR OVEN, SHRINKAGE
TEST, HOT DEFORMATION, BLEEDING AND BLOOMING TEST.
PARTIAL DISCHARGE TEST (AS APPLICABLE)
BENDING TEST
DI - ELECTRIC POWER FACTOR TEST AS A FUNCTION OF
VOLTAGE AND TEMPERATURE
INSULATION RESISTANCE TEST ( VOLUME RESISTIVITY)
HEATING CYCLE TEST
IMPULSE WITH STAND TEST
TEST FOR FRLS/FR PROPERTIES.
HIGH VOLTAGE TEST ( AS APPLICABLE)
ANY OTHER TEST AS PER PR/PS
9 R R X REVIEW OF DOCUMENTS
TEST CERTIFICATE FOR BOUGHT OUT ITEM
CALIBRATION REPORT OF INSTRUMENT
10 H X SPARES & PACKINIG LIST CHECK. PACKING & LOADING OF
Page 645 of 674

APPENDIX - A

PROJECT
C
I
LEGENDS : H HOLD, W - WITNESS, R - REVIEW, A APPROVAL, I INFORMATION, X SUBMIT

OWNER/PMC RESERVES RIGHT TO WITNESS INSPECTION OF ANY ITEM AT ANY STAGE WHICH SHALL BE INDICATED ON QAP /
INSPECTION & TEST PLAN AT THE TIME OF APPROVAL AND SAME TO BE COVERED AS PART OF PURCHASE ORDER
CONDITION ISSUED BY CONTRACTOR
Page 646 of 674

APPENDIX - A

PROJECT
EQUIPMENT / ITEM DESCRIPTION : AC/DC DRIVES VENDOR :
P.O. NO. :
C
I
1 H H X PRE-INSPECTION MEETING TO BE CONDUCTED AFTER ISSUE OF

PO/PR/PS. AGENDA TO BE PREPARED BY LSTK CONTRACTOR.
3 A R X INSPECTION & TEST PROCEDURES.
IN THE ORDER/PS/PR
EQUIPMENT
6 H H W X ROUTINE TEST CONSISTS OF:
STRAIGHTNESS, ALIGNMENT, PAINT SHADE & QUALITY
- VISUAL / GENERAL WORKMANSHIP / DIMENSIONS.
- BILL OF MATERIAL, INCLUDING ACCESSORIES & NAME PLATE.
- LAYOUT CHECK. BUS BAR SIZE, CLEARANCE, SLEEVING,LABELS
- REQUIREMENT OF ENCLOSURE PROTECTION.TERMINATION
ARRANGEMENT/WIRING, EARTHING, SHROUDING.
7 R R X REVIEW OF DOCUMENTS AS BELOW:
- INTERNAL QA TEST REPORT.
- TEST CERTIFICATE FOR ALL COMPONENTS.
CALIBRATION REPORT OF ALL INSTRUMENTS. .
8 H H W X PERFORMANCE & ACCEPTANCE TEST CONSISTING OF:
INVERTER OUT PUT VOLTAGE & WAVE FORM
SIMULATION OF FAULTS & ANNUNCIATION SCHEME
RAMP UP ACCELERATION TIME OBSERVING VOLTAGE &
CURRENT
OSCILLOGRAM RECORDS OF DRIVE OUTPUT FOR 100% LOAD &
LOAD REJECTION
ALL OTHER ROUTINE TEST LIKE, COUTINUITY, INTERLOCKS ETC
OPERATION OF SWITCHES,ANNUNCIATION & DIAGNOSTICS,
START UP, AUTO/MANUAL OPERATION, DRIVE SYSTEM,
DYNAMIC RESPONSE (UPTO 100% SPEED & LOAD) TIME.
NOISE LEVEL TEST.
H.V.TEST.
IR TEST BEFORE AND AFTER HV TEST.
INPUT SIGNAL/OUTPUT SIGNAL AT EXTREME CONDITION
SOFTWARE SIMULATION TEST.
ANY OTHER TESTS AS PER PR/PS.
Page 647 of 674

APPENDIX - A

PROJECT
EQUIPMENT / ITEM DESCRIPTION : AC/DC DRIVES VENDOR :
P.O. NO. :
C
I
9 H X SPARES & PACKINIG LIST CHECK. PACKING & LOADING OF

LEGENDS : H - HOLD, W - WITNESS, R - REVIEW, A APPROVAL, I INFORMATION, X SUBMIT

- OWNER/PMC RESERVES RIGHT TO WITNESS INSPECTION OF ANY ITEM AT ANY STAGE WHICH SHALL BE INDICATED ON
QAP / INSPECTION & TEST PLAN AT THE TIME OF APPROVAL AND SAME TO BE COVERED AS PART OF PURCHASE ORDER
CONDITION ISSUED BY CONTRACTOR.
Page 648 of 674

Page 1 of 2

(A group company of Indian Oil)

AT
MANALI REFINERY
VENDORS LIST
DOCUMENT NO : 44NC-4600:00:R:01:0005:A4
Prepared and Issued by:
Jacobs Engineering India Private Ltd.

Navi Mumbai
Rev. Issue Date Pages Rev. Description Prepared Checked Approved
No. By By By
0 16.06.2010 Issued for Clients review / comments NRK AMN SBN
1 20.07.2010 Revised as per client comments NRK AMN SBN
2 23.08.2010 Revised as per client comments NRK AMN SBN
3 14.09.2010 Revision as per client comments NRK AMN SBN

(only for Instrumentation)
4 22.09.10 Revision as per client comments NRK AMN SBN

(only for Electrical)
Page 649 of 674

44NC-4600 VENDOR LIST CPCL. Manali Refinery
Revision : 4 Doc. No. 44NC-4600: 00:R:01:0005:A4 Page 2 of 2
INDEX
No. of
Sheets
NOTES ON VENDOR LIST 2
i. STATIC EQUIPMENT (Fabrication Equipment) 14
ii. HEAT TRANSFER EQUIPMENT 12
iii. MECHANICAL EQUIPMENT 13
iv. ROTARY EQUIPMENT 14
v. PIPING 29
vi. ELECTRICAL 22 4
vii. INSTRUMENTATION 26
viii. ARCHITECTURAL ITEMS 9
ix. MISCELLANEOUS 4
x. REFRACTORIES AND INSULATING FIBER BLANKET 2
Page 650 of 674

44NC-4600:CPCL
NOTES ON VENDORS LIST
A) Part of the unit / plant from OWNER / CONSULTANT approved vendors only. This shall
include sub-ordered items / components also. The Approved Vendors shall be items
specific.
B) OWNER / CONSULTANT approved vendors list for the following items is enclosed in this
section.
i. Pressure Vessels (Fabrication equipment)

ii. Rotating Equipment.
iii. Piping
iv. Electrical
v. Instrumentation
vi. Mechanical Equipment
vii. Heat & Mass Transfer Equipment
viii. Architectural Items
ix. Miscellaneous
C) CONTRACTOR may procure material from any of OWNER / CONSULTANT approved

vendors. However, workload, stability and solvency need to be verified by the
CONTRACTOR before placement of order. In case where such vendors are not
available prior approval to be taken from OWNER / CONSULTANT before issue of
enquiry.
Vendors on OWNER / CONSULTANT holiday list shall not be considered for ordering.
Names of such vendors who are put on OWNER / CONSULTANTHoliday List
subsequent to vendor approval at bidding stage shall be informed to the CONTRACTOR
at any stage of the Project. CONTRACTOR shall comply with this requirement without
any time or cost implication to the OWNER.
D) Compliance to procurement of material from approved vendors is mandatory and shall be

fully complied with. No deviation to approved vendor list shall generally be acceptable.
E) For items not covered in the above list, the vendors list shall be approved by OWNER /
CONSULTANT prior to placement of order by CONTRACTOR. CONTRACTOR shall list
down the proposed suppliers / vendors for such items and submit the same for OWNER /
CONSULTANTs review / approval along with necessary documents / credentials. Non-
acceptance of a particular proposed vendor due to any reasons whatsoever shall not be
a cause of schedule and cost implication.
F) CONTRACTOR shall make an independent assessment of capability of all the vendors

for timely deliveries of material / equipment. Any delays in deliveries by vendor(s) shall
not be a cause of schedule and cost implication.
G) For vendors included in each category, it will be Contractors responsibility to ensure that
item being ordered on approved vendor has been manufactured and supplied by them
(range, thickness, size, capacity, MOC etc.) on past projects of CPCL / CONSULTANT or
any reputed Refinery / Hydrocarbon Sector under TPI.
Doc. No. 44NC-4600:00:R:01:0005:A4 Page 1 of 2
Page 651 of 674

44NC-4600:CPCL
NOTES ON VENDORS LIST
H) At any stage of the project, if it comes to the notice of OWNER / CONSULTANT that
CONTRACTOR have procured material / equipment, intentionally or unintentionally
whatsoever, from an unapproved vendor and/or items not falling in approved range of
vendor(s), the same shall be rejected forthwith and CONTRACTOR shall be liable to
replace such material / plant / machinery without any schedule and cost implication to the
OWNER.
I) List of vendors appearing anywhere else in the contract document, except for the
vendors list provided by PROCESS LICENSOR, shall not be considered by
CONTRACTOR and shall be superseded by the vendor list enclosed herewith.
Wherever, vendors list is given by Process Licensor, for specific items, it shall be
mandatory. If contractor intends to procure from any other vendors, clearance has to be
obtained from Licensor. Also other aspects like capability, timely delivery, solvency etc.
has to be ascertained by Contractor before placement of Orders.
J) It is understood that, should the name of vendors be changed due to change in their
Company or Corporate share holding, OWNER will accept such Vendors under its new
name with prior approval.
Any such approval shall, however, not release the CONTRACTOR from any of his
obligations under the contract; neither shall any such approval signify nominations or
instruction to use such a vendor. All approved vendors are deemed to have been freely
chosen by the CONTRACTOR at his own risk.
K) The approved vendors list for fabricated equipment (Vessels, Columns, Heat
Exchangers, Ejectors etc.) is for fabrication alone. Where mechanical design of the
equipment is included in CONTRACTORs scope, CONTRACTOR shall either himself or
through his Detailed Engineering sub-contractor be responsible for designing and
obtaining approval / review of Mechanical design calculations as per codes /
specifications specified elsewhere in the Bid / Contract document, from OWNER /
CONSULTANT.
Doc. No. 44NC-4600:00:R:01:0005:A4 Page 2 of 2
Page 652 of 674

(vi)
ELECTRICAL
C:\Documents and Settings\Mfernandes\Desktop\Vendor List for Tender Rev 4_23.09.10\08_Electrical Vendor list.doc
Page 653 of 674

Revision : 4 ELECTRICAL Page 2 of 22
VENDOR NAME COUNTRY
1. SWITCH GEAR HT (INDOOR) WITH VCB

1. ABB Ltd (Nasik) India
2. Areva T&D Ltd. India
3. Bharat Heavy Electricals Ltd. India
4. Crompton Greaves Ltd India
5. Jyothi India
6. Siemens Ltd India
2. SWITCHBOARDS MV MCC / PCC / PMCC FIXED TYPE

1 Control & Switchgear Co Ltd India
2 GE Industrial India Pvt. Ltd. India
3 Larsen & Toubro Ltd. India
4 Schneider Electric India Pvt. Ltd India
5 Siemens Ltd India
3. SWITCHBOARDS MV MCC / PCC / PMCC DRAWOUT

1. Control & Switchgear Co Ltd India
2. GE Industrial India Pvt. Ltd. India
3. Larsen & Toubro Ltd. India
4. Schneider Electric India Pvt. Ltd India
4. TRANSFORMERS POWER ABOVE 5 MVA

1 ABB Ltd (Nasik) India
2 APEX India
3 Areva T&D Ltd. India
4 Bharat Bijlee Ltd India
5 Bharat Heavy Electricals Ltd. (BHOPAL)/JHANSI India
6 Crompton Greaves Ltd India
7 EMCO Ltd India
8 Transformers & Rectifier India
9 Voltamp Transformers (P) Ltd India
5. TRANSFORMERS POWER UPTO 5 MVA

1. Areva Ltd. India
2. Bharat Bijlee Ltd India
4. EMCO Ltd India
5. Hackbridge Hewitic & Easun Ltd. india
6. Indo Tech India
7. Kirloskar Electric Co. Ltd. India
8. Transformers & Rectifiers India Ltd India
9. Voltamp Transformers (P) Ltd India
Page 654 of 674

VENDOR NAME COUNTRY
6. DRY TYPE TRANSFORMERS (LIGHTING) UPTO 1000 KVA

2 Kirloskar Electric Co. india
3 Vijay Electricals India - Hyderabad
4 Voltamp Transformers Pvt. Ltd. India
7. INSTRUMENT TRANSFORMERS CT & PT (HV)

1 ABB Ltd India Vadodara
2 Areva T&D Ltd. India
3 Electrical Controls & Systems India
4 Jyoti India
5 Kalpa Electricals India
6 Kappa Electricals India
7 Pragati Electricals Pvt. Ltd. India
8. INSTRUMENT TRANSFORMERS CT & PT (MV)

1. AE
2. Gilbert & Maxwell Electricals Pvt. Ltd India
3. Jyoti India
4. Kalpa Electricals India
5. Kappa Electricals India
6. Narayan Powertech Pvt. Ltd India
7. Pragati Electricals Pvt. Ltd. India
8. Precise Electricals India
9. Silkaans Electricals Pvt. Ltd. India
9. CABLES COMMUNICATION (JELLY FILLED)

1 CMI Ltd.
2 Cord Cable
3 Delton Cables Ltd India
4 Elkay
5 Finolex Cables Ltd India
6 KEI
7 Reliance
8 Rpg Cables Ltd India
9 Usha Beltron Ltd India
10 Vindhya Telelinks Ltd India
10. HIGH VOLTAGE XLPE CABLES

1 Cable Corporation Of India India
2 Industrial Cable
3 KEI Industries Ltd India
4 Nicco Corporation Ltd India
5 Polycab Wires Pvt. Ltd India
Page 655 of 674

VENDOR NAME COUNTRY
6 RPG Cables Ltd India

7 Torrent Cable Ltd Upto 33kv India
8 Uniflex Cables Ltd India
9 Universal Cables Ltd India
11. MEDIUM VOLTAGE POWER CABLES XLPE & PVC

1 Associate India
2 Cable Corporation of India India
4 Gemscab Industries Ltd
5 Havells
6 Industrial Cable India
9 Polycab Wires Pvt Ltd India
10 Radiant Cables Pvt. Ltd. India
11 Ravin Cables Pvt. Ltd India
12 RPG
13 Torrent Cables Ltd India
12. CABLES CONTROL

1 Associated Cable Pvt Ltd India
2 Associated Flexibles and Wires (P) Ltd. India
3 Brooks Cables Pvt. Ltd. India Mumbai
4 CMI Limited India
5 Cords Cable Ind Ltd India
7 Ecko Cables INDIA
8 Elkay Telelinks (P) Ltd India
9 Evershine Electricals India
11 Gemscab Industries Ltd India
12 Goyolene Fibres (I) Pvt. Ltd. India
13 Havells India Pvt. Ltd. India
14 Hindustan Vidyut Product India
15 Industrial cables (I) Ltd. India
18 North Eastern cables Pvt. Ltd. India
19 Paramount Communications Ltd. India
(Manufacturing Unit Paramount Cable Corporation)
20 Polycab Wires (P) Ltd India
21 Radiant Cables Pvt. Ltd. India
22 Ravin Cables Pvt. Ltd. India
Page 656 of 674

VENDOR NAME COUNTRY
23 Reliance Engineers Ltd India

24 RPG Cables India
25 Suyog Electricals India
26 Thermocables Ltd. India
27 Torrent Cables Ltd India
13. CABLES FIRE ALARM & COMMUNICATION

1 CMI Ltd India
2 Cords Cable Industries Ltd India
4 Elkay Telelinks Ltd India
6 Reliance Engineers Ltd India
14. NEUTRAL GROUNDING RESISTORS - HV

1 AMP Control Equipment Pvt. Ltd. India Pune
2 RSI Switchgear Pvt. Ltd India Haryana
3 S R Narkhede Engineering Pvt. Ltd India
15. CAPACITOR HIGH VOLTAGE

1 ABB Ltd India Bangalore
2 BHEL India Bhopal
3 CG Power Systems India
16. PLANT COMMUNICATION SYSTEM

1 Industrionic GmbH & Co KG GERMANY
2 Neuman Elektronik GmbH &Co GERMANY
3 Siemens Enterprise Communications INDIA
17. MOTOR INDUCTION HV (INDL. TYPE SAFE AREA)

1 ABB LTD India - Faridabad
2 Alstom Moteurs SA (C/o Alstom Limited) India / France
3 Bharat Bijlee Limited India
5 Jyoti India
6 Kirloskar Electric Co Ltd India
7 Laxmi Hydrolics India
8 Siemens Limited India
9 BHEL (Bhopal) India
Page 657 of 674

VENDOR NAME COUNTRY
18. MOTOR INDUCTION MV (FLAMEPROOF)

1 Alstom Ltd India
2 Bharat Bijlee Ltd India
19. MOTOR INDUCTION HV (INCREASED SAFETY ZONE - 2)

1 ABB Limited (Only for safe area) India Baroda
2 Alstom Ltd India
3 BHEL India Bhopal
20. MOTOR INDUCTION MV (ZONE 2 TYPE e & n)

1 Alstom Ltd India
2 Asea Brown Boveri Ltd (Type E & N) India Faridabad
3 Bharat Bijlee Ltd (Type N Only) India
4 Crompton Greaves Ltd (Type E & N) India
5 Kirloskar Electric Co Ltd (Type E & N) India
6 Siemens Ltd (Type E & N) India
21. A.C. (MV) VARIABLE SPEED DRIVE

1. ABB India
2. Alstom Moteurs SA France
3. Alstom Projects India Ltd India
4. BHEL (Bangalore) India
5. Control Technique India
6. Eurotherm
7. Fuji Electrical Co Ltd Japan
8. Hitachi Ltd India
9. Kirloskar
10. L & T Ltd India
11. Meidensha corp India
12. Reliance Electric Co USA
13. Rockwell Automation Pvt Ltd India
14. Siemens Ag Germany
16. Siemens Allis Energy Pro International
17. Toshiba Corporation India / Japan
18. Vacon OYJ International
Page 658 of 674

VENDOR NAME COUNTRY
22. ACTUATORS - MOV

1 Auma India Ltd India
2 Limitorque Ind Ltd India
3 Rotork Controls Ind Ltd India
4 Marsh Engineers ( only for Safe Area) India
23. BATTERY CHARGERS

1 Amara Raja Power System Ltd India
2 Caldyne Automatic (P) Ltd India
3 Chhabi Electricals (P) Ltd India
4 Dubas Engineering Pvt. Ltd. India
5 HBL Power Systems Ltd India
6 Kerala State Elect Dev Corp Ltd. India
7 Mass Tech Control Pvt. Ltd. India
8 Universal Ind. Products India
9 Universal Instrument Mfg Co (P) Ltd India
24. UPS SYSTEM

UPS SYSTEM INDIGENOUS
1 DB Power Electronics Pvt Ltd India
2 Emerson Network Power Pvt Ltd India
3 Hi-Rel Electronics India
4 Kerala State ELECT Dev Corp Ltd India KRKULM
UPS SYSTEM FOREIGN

1 Chloride Industrial Systems UK
2 Fuji Electric Co Ltd Japan
3 Gutor Electronics Ltd Switzerland
4 MGE Asia Pte Ltd Singapore
Saftnife AB
5 Toshiba Corporation Sweden
6 India/Japan
25. FIRE ALARM SYSTEM

1 Honeywell Inc India
2 Kidde India Ltd. India
3 Mather & Platt India Ltd India
4 New Fire Engineers (P) Ltd India
26. RELAY & CONTROL PANEL

1 ABB Ltd. India Mumbai
2 Areva T&D Ltd India Chennai
3 Bharat Heavy Electricals India
4 Controls & Switchgear India
Page 659 of 674

VENDOR NAME COUNTRY
5 Easun Reyrolle Ltd India Hosur

6 ECIL India
7 Power Gear Pvt. Ltd. India
8 Pyrotech India Udaipur
9 Siemens India Mumbai
27. CONTROL PANEL (FLP)

1 Baliga Lighting Eqpt Ltd India
2 Cooper Crouse-Hinds. India
3 FCG Flameproof Control Gears Ltd India
4 FCG Power Industries Ltd India
5 Flameproof Eqpts Pvt Ltd India
6 Flexpro Electicals Pvt Ltd India
7 Prompt Engineering Works India
8 Sudhir Switchgears Pvt. Ltd. India
28. LIGHTING FITITING & ACCESSORIES (HAZARDOUS)

1. AT X S A France
2. Bajaj Electricals Ltd India
3. Baliga Lighting Eqpt Ltd India
4. Cooper Crouse-Hinds India
6. FCG Flameproof Control Gears Pvt. Ltd. India
7. FCG Power Industries Pvt Ltd India
8. Flameproof Eqpts Pvt Ltd India
9. Flexpro Electricals Pvt Ltd India
10. Govan Industries (India) Pvt.Ltd. India
11. Prompt Engg. Works India
12. R Stahl Germany / India
13. Sudhir Switchgears Pvt. Ltd. India
14. Victor Product PLC India
29. JUNCTION BOXES (FLAME PROOF)

1 Baliga Lighting Eqpts Ltd India
2 FCG Flameproof Control Gears Pvt. Ltd. India India
3 FCG Power Industries pvt. ltd.
4 Flame Proof Eqpts Pvt Ltd India
5 Flexpro Electricals Pvt Ltd India
6 Govan Industries (India) Pvt Ltd. India
8 Sudhir Switch Gears Pvt Ltd India
Page 660 of 674

VENDOR NAME COUNTRY
30. CONTROL STATIONS (FLAME PROOF)

1 Baliga Lighting Eqpts Ltd India
2 FCG Flameproof Control Gear Pvt. Ltd India
3 FCG Power Industries Pvt. Ltd. India
4 Flame Proof Eqpts Pvt Ltd India
5 Flexpro Electricals Pvt Ltd India
6 Govan Industries (India) Pvt Ltd. India
8 Sudhir Switch Gears Pvt Ltd India
31. LIGHTNING ARRESTORS

1 Areva
3 Elpro International Ltd India
4 Oblum Electrical Ind Pvt Ltd India
5 W. Insulation Of India India
32. BATTERIES LEAD ACID (VRLA)

1 Exide Ind Ltd India
2 Amara Raja Batteries Ltd India
3 HBL Power System Ltd India
33. BATTERY (NI-CAD)

1 Amaraja
2 Amco Saft
3 HBL Nife
34. AIR CIRCUIT BREAKER

1 Controls & Switchgear Co Ltd India
2 GE Power Control Ind Ltd India
3 Larsen & Toubro Ltd. (Mumbai) India
4 Schneider Electric India Pvt Ltd India
5 Siemens Ltd India
35. BUS DUCT (HV)

1 Controls & Switchgears Co Ltd India
2 Enpro Engg. India
3 Powergear India
4 Reep Industries India
5 Stardrive Busducts Pvt Ltd India
Page 661 of 674

VENDOR NAME COUNTRY
36. BUS DUCT (MV)

1 Controls & Switchgear Co Ltd India
2 Enpro Engg. India
3 Powergear India
4 Reep Industries India
5 Stardrive Busducts Pvt Ltd India
37. CABLE GLANDS (FOR HAZARDOUS AREA)

1. Baliga Lighting Eqpts Ltd India
2. Commet Brass Product
3. Commet Industries
4. FCG Flameproof Control Gears Pvt. Ltd India
5. FCG Power Ind Pvt Ltd India
6. Flameproof Equipment Pvt Ltd India
8. Prompt Engineers
9. R Stahl India
10. Standard Metals
11. Sudhir Switchgear
38. CABLE TERMINATION & JOINTING KIT (HEAT SHRINKABLE TYPE)

1 Mahindra Engineering & Chemical India
2 Raychem RPG Ltd. India
3 REPL Engineering Ltd. India
4 Yamuna Gases & Chemicals Pvt Ltd India
39. CIRCUIT BREAKER SF-6 OUT DOOR EHV

1 ABB Ltd. India Baroda
2 Areva Ltd. India Bangalore
3 BHEL India Mumbai
4 Crompton Greaves Ltd India Mumbai
40. HIGH MAST LIGHTING SYSTEM

1 Bajaj Electricals Ltd India
3 Philips India Ltd India
41. ISOLATORS / LOAD BREAK SWITCHES (HV INDOOR)

1 Elpro International India Mumbai
2 GE Power
3 G P Power Switchgear India Hyderabad
4 S & S Power Switchgear Ltd India Chennai
5 Siemens Ltd India Hyderabad
Page 662 of 674

VENDOR NAME COUNTRY
42. LIGHTING & POWER PANEL

1 Controls And Switchgear Co Ltd India
2 Havell's India Pvt Ltd India
3 Indo Asian Fusegear Ltd India
4 Legrand (India) Pvt. Ltd India
5 MDS Switchgear Ltd India
6 Standard Electricals Ltd India
43. PLUGS / SOCKETS / HANDLAMPS (FLAMEPROOF)

1. Bajaj India
2. Baliga Lighting Eqpts Ltd India
3. FCG Flameproof Control Gears India
4. FCG Power Industries India
5. Flameproof Eqpts Pvt Ltd India
7. Govan Industries India
8. Sudhir Switchgears Pvt Ltd India
44. LIGHTING TRANSFORMERS

1 Automatic Electric Ltd India
2 Crompton
3 Indcoil Products India
4 Kappa Electricals India
5 Kirloskar
6 Vijay
7 Voltamp Transformers Pvt. Ltd India
8 Transformers & Electricals Kerala Ltd India
45. SIGNAL INTERFACE FOR ECS

1. INTERPOSING RELAYS : ABB (RXMSI)/ALLEN BRADLEY
(TYPE 700hg WITH MAGNETIC BLOW OUT) /
POTTER & BRUNFIELD (P&B) / AREVA (ALSTOM)
2. GCE
3. Jyothi
4. L&T
5. Schineder
6. Siemens
46. SIGNAL INTERFACE FOR ECS

1 TRANSDUCERS : ABB/SOUTHERN TRANSUDERS
OIL LUBRICATED HDPE PIPE : BHARTI DURALINE / RELIANCE
TRANDUCER PANELS/INTERPOSING RELAY PANELS/DUMMY
PANELS : RITTAL
2 Elstar
Page 663 of 674

VENDOR NAME COUNTRY
3 MECO
4 Pyrotech Electronic
5 Vitronic
47. INSTALLATION CONTRACTOR FOR CATHODIA PROTECTION SYSTEM

1 Consultech Cathodic Protection Engrs & India Consultants India
2 Raychem RPG Limited India
3 Correctech International Pvt. Ltd. India
4 Corrosion Control Services Pvt. Ltd. India
5 Raychem USA
48. MMO WIRE ANODES FOR CP SYSTEM

1 Macor USA
2 Tyco Adhesives USA
49. CONDUCTIVE POLYMER ANODES FOR CP SYSTEM

1. Raychem USA
50. MMO COATED TITANIUM ANODES FOR CP SYSTEM

1 Titanor Components India
2 Oranzio De Nora Italy
3 Magnetochemie Netherlands
4 Actel Limited UK
5 Eltech Systems Corporation USA
6 Ceranode Technologies USA
51. TRANSFORMER RECTIFIER UNIT FOR CP SYSTEM

1. Canara Electric Controls, Mumbai India
2. Advance Electronics, Baroda India
52. ANODES & CATHODE JUNECTION BOXES (FLAMEPROOF)

1 Baliga Lighting Equipments Ltd. India
2 Cooper Crouse-Hinds India
3 Flexpro Electricals (P) Ltd. India
4 Flameproof Equipment Pvt. Ltd India
53. CALCINED PETROLEUM COKE BREEZE

1 Loresco DW3 . USA
2 Goa Carbon, Goa India
3 Indian Carbon, Kolkata India
4 Petrocarbon & Chemical Cormpany, Haldia India
Page 664 of 674

VENDOR NAME COUNTRY
54. PERMANENT REFERENCE ELECTRODES

1 Harco. USA
2 Borin Manufacturer USA
3 M.C. Miller USA
55. HEAT SHRINK CAP FOR ANODE TO CABLE JOINT

1. Raychem USA
56. DIGITAL MULTIMETER FOR OPERATION & MAINTENANCE

(minimum 10M ohm input resistance complete with leads and leather case)
1. BECKMANN
2. FLUKE
3. AVO
4. KEW
57. PORTABLE HALF CELL REFERENCE ELECTRODES FOR O&M

(Portable copper/ copper sulphate type having PVC Sch. 40 body, transparent window And threaded ceramic
porous plug)
1 M. C. MILLER USA
2 TINKER RASOR USA / Canada
3 CORRTECH India
58. DC CLIP ON AMMETER FOR O&M

1. HCK Germany
2. Kyoritsu Electricals Japan
59. ELECTRICAL CONTROL SYSTEMS (SCADA)

1 ABB Automation Netherlands
2 Areva T&D Ltd. France / India
3 ESVAN
4 L&T India
5 Schineder India
6 Siemens India
60. VFD
VFD INDIGENOUS
1 BHEL India
2 Eurotherm dell india Ltd. India
3 Kirloskar Electric co. Ltd. India
4 L&T India
5 Rockwell Automation Ltd. India
6 Siemens India
Page 665 of 674

VENDOR NAME COUNTRY
VFD FOREIGN
1 ABB
2 Fuji electronic co. Ltd.
3 Hitachi Ltd. Japan
4 Meidensha corp.
5 Reliance electric co.
6 Siemens AG International
7 Siemens Allis Energy Products
8 Toshiba corporation
9 Vacon oyj
61. LIGHTING & DISTRIBUTION BOARD, CONTROL PANEL- FLAMEPROOF

1 Baliga
2 FCG Flameproof control Gears
3 FCG Power Industries
4 Flameproof Equipment Pvt. Ltd.
5 Flexpro
6 Sudhir switchgear
62. ENERGY EFFICIENT LUMINARIES & FITTINGS FOR FLUORESCENT TUBE

LIGHTS (FTL) & COMPACT FLUORESCENT LAMPS (CFL)
1 BAJAJ India
2 Crompton Greaves Ltd. India
3 GE Consumer & Industrial India
4 PHILIPS India
63. LED TYPE STREET LIGHTING FITTING

1 GE Consumer & Industrial India
2 Innov Lite (I) Pvt. Ltd. India
3 PHILIPS India
64. CABLE TRAY

1 Allied Engineering Co
2 Anand Udyog
3 Amptech Engineering services
4 Dy Engineers
5 Indiana
6 Indian Electrical syndicate
7 MEK Engineering and construction
8 Patny Systems
9 Primier Power Products
Page 666 of 674

VENDOR NAME COUNTRY
65. ALARM & ANNUNCIATOR

1 Advani Oerlikon Ltd. (Elect. Division) India New Delhi
2 Aplab Ltd. India Pune
3 Digcon India
4 ECU India
5 Industrial Instruments & Controls India Mumbai
66. NUMERICAL RELAYS (LV SYSTEMS)

1 ABB India
2 Alstom India
3 Easun reyrole India
4 L&T India
5 Schneider India
6 Siemens India
67. NUMERICAL RELAYS (HV SYSTEMS)

1 ABB India
2 Alstom India
3 Easun Reyrol India
4 Siemens India
68. LV 1.1 KV POWER CABLES

1 Associated Flexibles And Wires (P) Ltd. India
2 Cable Corporation Of India Limited India
3 Finolex Cables Limited India
4 Gemscab Industries Limited India
5 Havells India India
6 Industrial Cables (I) Limited India
7 Kei Industries Limited India
8 Nicco Corporation Limited India
9 Polycab Wires India
10 Radiant Cables Pvt. Limited India
11 Ravin Cables Limited India
12 RPG Cables Limited India
13 Torrent Cables Limited India
14 Universal Cables Limited India
69. HV POWER CABLES(6.6 KV)

1 Industrial Cables (I) Limited India
2 Nicco Corporation Limited India
3 Polycab Wires Pvt.Ltd. India
4 Torrent Cables Limited India
5 Uniflex Cables Limited India
6 Universal Cables Limited India
Page 667 of 674

VENDOR NAME COUNTRY
70. AUXILIARY RELAYS

1 ABB Limited India
2 Areva T&D India
3 GEC India
4 Jyothi India
5 L&T India
6 Schneider India
7 Siemens India
71. THERMAL O/C RELAYS (BIMETAL RELAYS)

1 ABB Limited (Bangalore) India
2 Bhartia Industries Limited India
3 Controls & Switchgears Co. Limited India
4 GE India India
5 Larsen & Toubro Limited India
6 Schneider Electric India (P) Limited India
72. POWER CONTACTORS/AUXILIARY CONTACTORS

1 ABB Limited India Bangalore
4 Electric India (P) Limited India
5 GE India (P) Limited India
6 Larsen & Toubro Pvt. Limited India
7 Schneider
73. CONTROL SWITCHES/SELECTOR SWITCHES

1 Areva T&D India
2 Hotline Switchgear & Controls India
3 Jyoti India
4 Kaycee Industries Limited India
6 Recon India
7 Reliable Electronic Components India
9 Switron Devices India
74. CONTROL SWITCH BREAKER

1 Areva T&D India
2 Reliable Electronic Components India
3 Switron Devices India
Page 668 of 674

VENDOR NAME COUNTRY
75. EARTH LEAKAGE CIRCUIT BREAKER

1 Datar Switchgear Pvt. Limited India
2 Havells India
3 Indo Asian Fusegear Limited India
4 Legrand (India) Pvt. Limited India
76. FUSES
1 Cooper Bussman India
77. FUSE SWITCH COMBINATION

1 ABB Limited (Bangalore) India
3 GE India India
4 Havells India Pvt. Limited India
9 Standard Electricals Limited India
78. MCCB
1 AEG India
5 Siemens India
79. HEAVY DUTY SWITCHES (POWER SWITCHES)

1 ABB India
3 EE India
Page 669 of 674

VENDOR NAME COUNTRY
80. MCB
1 Datar Switchgear Pvt. Limited India
2 Havells India Pvt. Limited India
3 Indiana Current Control Limited India
5 Legrand (India) Pvt. Limited (Mds) India
7 Siemens India
8 Standard Electricals Limited India
81. METERS
1 Areva T&D India
2 Automatic Electric Limited India
3 Imp India
4 Meco Instruments Pvt. Limited India
5 Nippen Electrical Instruments
6 Rishabh Instruments Pvt. Limited India
82. TIMERS
1 ABB India
3 Electronic Autiomation Pvt. Limited India
4 GEC India
5 Larsen & Toubro Limited
6 Schneider India
7 Siemens Limited
83. PUSH BUTTON AND INDICATING LAMPS

2 Cands
4 Essen Deinki
5 Hotline Switchgear & Controls
6 Larsen & Toubro Limited
7 Precifine Products Pvt. Limited (Led Type Indicating Lamps Only) India
8 Schneider Electric India (P) Limited
9 Shri Tulsi Switchgears Limited India
11 Technic
12 Teknic Controls
Page 670 of 674

VENDOR NAME COUNTRY
84. INSTRUMENT TRANSFORMERS (CT/PT)-LV

1 AE
2 Gilbert & Maxwell Elect. Pvt. Limited India
3 Jyoti India
4 Kalpa Electricals
5 Kappa
6 Narayan Powertech Pvt. Limited India
7 Pragati Electricals Pvt. Limited India
8 Precise Electricals India
9 Silkaans Electrical Mfg. Co. Limited
85. VACUUM BOTTLES

1 Areva T&D India
2 Crompton Greaves India
86. CABLE GLANDS FOR HAZARDOUS AREA

1 Baliga India
2 Comet Brass Products India
3 Comet Industries India
4 FCG Flameproof Control Gears India
5 FCG Power Industries India
6 Flameproof Equipment Pvt. Limited India
7 Flexpro India
8 Prompt Engineers India
9 Standard Metal India
10 Sudhir Switchgear India
87. LT ISOLATOR
1 GE Power India
2 L&T India
3 Siemens India
88. TRANSDUCER
1 ABB India
2 ELSTER India
3 MECO India
4 Pyrotech Electronics India
5 Vitronics India India
Page 671 of 674

VENDOR NAME COUNTRY
89. CONTROL TRANSFORMERS

1 Kappa India
2 Powerpack India
3 Pragati India
4 Silcon India
90. DISTRIBUTION BOARDS

2 Controls & Schematics Limited India
4 GE Industrial India Pvt. Limited India
5 Larsen & Toubro Ltd.
6 MK Engineers & Controls Pvt. Limited
7 Schneider Electric India (P) Limited
8 Siemens (I) Limited
91. CONTROL TERMINAL CLIPTON TYPE

1 Connect Well India
2 Elmex India
92. DOUBLE COMPRESSION CABLE GLAND WEATHER PROOF

1 Baliga India
2 Comet Brass Products India
3 Comet Industries India
4 Flexpro India
5 Flameproof Equipment Pvt. Limited India
6 FCG Power Industries India
7 FCG Flameproof Control Gears India
8 Prompt Engineers India
9 Standard Metal India
10 Sudhir Switchgear India
11 Electromag India
93. CONDUIT
1 M Chandra India
2 Nagarjuna India
3 Senco India
Page 672 of 674

VENDOR NAME COUNTRY
94. CABLE LUGS

1 Crown India
2 Dowell India
3 Forward Engg.
4 Niko India
95. PVC WIRES

1 Anchor
2 Finolex India
3 Kundan India
4 Mardia
5 Orbit
6 Q-Flex India
96. SWITCHBOARDS H.V. (INDOOR) WITH VCB

1 ABB Limited India Nasik
2 Areva T&D India Limited (T&D Group) India
3 Bharat Heavy Electricals India Bhopal
4 Crompton Greaves Limited India
5 Jyoti Limited India
97. 110 KV CT
1 ABB Limited India Mumbai
2 Areva Instrument Transformers Ltd. India Bangalore
3 Bharat Heavy Electricals Ltd. India Mumbai
4 Crompton Greeves Ltd. India Mumbai
98. 110 KV LIGHTINING ARRESTOR

1 Areva Instrument Transformers Ltd. India Bangalore
2 Elpro International Ltd. India Mumbai
3 Oblum Electricals Ind Ltd. India Hyderabad
99. 110 KV INSULATORS AND BUSHINGS

1 BHEL India Bangalore
2 Jayashree Insulators India Baroda
3 Saravana Insulators India Cuddalore
4 W S Insulators Ltd. India - Chennai
Page 673 of 674

VENDOR NAME COUNTRY
100. DIESEL GENERATOR

1 Garden Reach Builders & Engineers Ltd. India
2 GMMCO India
3 Jeevan Diesels & Electricals Ltd. India
4 Kirloskar electric Co. India
5 Parry Engineering & Exports Ltd. India
6 Powerica India
7 Southern Power Systems India
8 TIL Ltd. India
9 Trading Engineers International Pvt. Ltd.
Note:-
For Electrical Equipment / Components please refer the above Vendor list. For any other Electrical Component
which is not covered in this Vendor List shall be as per Engineering Design Guidelines Electrical Clause 10.0
(44 NC-4600-0000/E.02/0002/A4
Page 674 of 674

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* Ref.: RC/A133-086-LZ-MR-4140/1005 Date: 23-SEP-2013

PRE-BID MEETING At 1100 HRS. (IST) on 01-Oct-2013 (at Business Centre, EI

4. Bidders are requested to submit e-bids in e-tendering portal (https://www.tenderwizard.com/eil) in

Bids should be submitted separately in two parts as follows:

Part-I: UNPRICED BID : The techno-commercial Part consisting of following:

i) Offer Covering letter (in bidders letter head)

RFQ NO. RC/A133-086-LZ-MR-4140/008 Page 1 of 8

Part-II: PRICED BID

b) A Ready Reckoner for e-tendering is available on e-tendering website

RFQ NO. RC/A133-086-LZ-MR-4140/008 Page 2 of 8

7. Technical specifications should be strictly as per the material requisition attached.

15. The order, if placed will be issued by EIL.

18. Preference to MSEs

RFQ NO. RC/A133-086-LZ-MR-4140/008 Page 3 of 8

21. FRAUDULENT PRACTICES

23. SPECIAL INSTRUCTIONS TO FOREIGN BIDDERS

RFQ NO. RC/A133-086-LZ-MR-4140/008 Page 4 of 8

It is mandatory for the foreign supplier/contractor/consultant to furnish the following information in

ii) Tax Residency Certificate (TRC)

iii) Form 10F

24. SHIFTING OF ORDER

Deleted (Not Applicable)

25. CLARIFICATION REQUESTS FROM BIDDERS

26. SETTLEMENT OF DISPUTE BETWEEN CPSEs OR CPSEs & GOVERNMENT DEPARTMENTS

Deleted (Not Applicable)

27. PRE-BID MEETING

RFQ NO. RC/A133-086-LZ-MR-4140/008 Page 5 of 8

a) Latest annual report including Profit & loss account

Extension in bid due date shall not generally be granted.

28. REVERSE AUCTION

29. OFFER VALIDITY

RFQ NO. RC/A133-086-LZ-MR-4140/008 Page 6 of 8

31. Delivery/Completion Period :

32. PRICE REDUCTION SCHEDULE

As per clause No. 12.2 & 12.3 of Instruction to Bidders.

RFQ NO. RC/A133-086-LZ-MR-4140/008 Page 7 of 8

ii) Shri P. R. Balasubramanian

34. Contact Persons for this RFQ are:

Ms. Rekha ChoudharyAsst.General Manager(C&P)Phone:91-11-26763457, r.choudhary@eil.co.in

* Please specify Ref. No. (i.e. RFQ No.) in all correspondence

THIS IS NOT AN ORDER Very truly yours,

Enclosures : Refer Page 8 of 8

RFQ NO. RC/A133-086-LZ-MR-4140/008 Page 8 of 8

Reply/ Acknowledgement letter

Format C1 ( for Indigenous Supply of 2 Years O & M Spares)

Format D1 ( for Indigenous Unit Rates for Addition / Deletion)

Standard Commercial Documents Containing:

RFQ NO. RC/A133-086-LZ-MR-4140/008 Page 9 of 8

FAX Nos. : 00-91-11-26191714, 26167664

Engineers India Limited

Attn. : Ms. Rekha Choudhary Asst. General Manager (C&P)

Further, our response is as under:- (Bidders to put a tick , as applicable).

1. We will submit the bid within due date.

2. We regret to submit our offer/quote because of the following reasons:

Very truly yours,

We..hereby authorise following representatives (s) to attend the Pre-

1. Name & Designation Signature ..

2. Name & Designation Signature

Name & Designation .

For & on behalf of .

1) PARTICIPATION IN E-TENDERING, REQUEST FOR USER ID and PASSWORD:

Instructions To Bidders For E-Tendering Page 1 of 4