DRE125B155 Lining up agency for Installation of High Volume Long Range HVLR Fire Monitors inside Refinery and laying of Drinking water line for New Centralized Transit Accommodation

Civil works for HVLRM system at DR

Earth work in excavation by mechanical means (Hydraulic excavator) / manual means in foundation trenches or drains (not exceeding 1.5 m in width or 10 sqm on plan) including dressing of sides and ramming of bottoms, for all lift including getting out the excavated soil and disposal of surplus excavated soil as directed, within a lead of 50 m: All kinds of soil.

Filling available excavated earth (excluding rock) in trenches, plinth, sides of foundations etc. in layers not exceeding 20cm in depth, consolidating each deposited layer by ramming and watering, lead up to 50 m and for all lift.

Excavating, supplying, stacking and filling of local earth (including royalty) by mechanical transport upto a lead of 5km also including ramming and watering of the earth in layers not exceeding 20 cm in foundation trenches, plinth, sides of foundation etc. complete for all lift.

Felling trees of the girth (measured at a height of 1 m above ground level) including cutting of trunks and branches, removing the roots and stacking of serviceable material and disposal of unserviceable material:

Beyond 30 cm girth up to and including 60 cm girth.

Supplying and filling in plinth with Jamuna sand under floors, including watering, ramming, consolidating and dressing complete.

Providing and laying in position cement concrete of specified grade excluding the cost of centring and shuttering - All work up to plinth level :

1:1.5:3 (1 Cement : 1.5 coarse sand (Zone-III) derived from natural sources : 3 graded stone aggregate 20 mm nominal size derived from natural sources).

1:3:6 (1 Cement : 3 coarse sand (Zone-III) derived from natural sources : 6 graded stone aggregate 20 mm nominal size derived from natural sources).

Providing and laying cement concrete in retaining walls, return walls, walls (any thickness) including attached pilasters, columns, piers, abutments, pillars, posts, struts, buttresses, string or lacing courses, parapets, coping, bed blocks, anchor blocks, plain window sills, fillets, sunken floor etc., up to floor five level, excluding the cost of centring, shuttering and finishing:

1:2:4 (1 Cement : 2 coarse sand (Zone-III) derived from natural sources : 4 graded stone aggregate 20 mm nominal size derived from natural sources).

Providing and laying in position specified grade of reinforced cement concrete excluding the cost of centering, shuttering, finishing and reinforcement - All work up to plinth level :

1:1.5:3 (1 cement : 1.5 coarse sand (Zone-III) derived from natural sources : 3 graded stone aggregate 20 mm nominal size derived from natural sources).

Reinforced cement concrete work in walls (any thickness), including attached pilasters, buttresses, plinth and string courses, fillets, columns, pillars, piers, abutments, posts and struts etc. up to floor five level excluding cost of centering, shuttering, finishing and reinforcement :

1:1.5:3 (1 cement : 1.5 coarse sand (Zone-III) derived from natural sources: 3 graded stone aggregate 20 mm nominal size derived from natural sources).

Steel reinforcement for R.C.C. work including straightening, cutting, bending, placing in position and binding all complete up to plinth level:

Thermo-Mechanically Treated bars.

Steel reinforcement for R.C.C. work including straightening, cutting, bending, placing in position and binding all complete above plinth level:

Thermo-Mechanically Treated bars of grade Fe-500D or more.

Centering and shuttering including strutting, propping etc. and removal of form for :

Foundations, footings, bases of columns, etc. for mass concrete.

Columns, Pillars, Piers, Abutments, Posts and Struts.

Lintels, beams, plinth beams, girders, bressumers and cantilevers.

Providing and fixing mild steel round holding down bolts with nuts and washer plates complete.

Brick work with common burnt clay F.P.S. (non modular) bricks of class designation 7.5 in foundation and plinth in:

Cement mortar 1:4 (1 cement : 4 coarse sand).

Brick work with common burnt clay F.P.S. (non modular) bricks of class designation 7.5 in superstructure above plinth level up to floor V level in all shapes and sizes in :

Cement mortar 1:4 (1 cement : 4 coarse sand).

Half brick masonry with common burnt clay F.P.S. (non modular) bricks of class designation 7.5 in foundations and plinth in:

Cement mortar 1:3 (1 cement : 3 coarse sand).

12 mm cement plaster of mix :

1:4 (1 cement: 4 coarse sand).

12 mm cement plaster finished with a floating coat of neat cement of mix :

1:4 (1 cement: 4 fine sand).

Structural steel work in single section fixed with or without connecting plate including cutting, hoisting, fixing in position and applying a priming coat of approved steel primer all complete.

Structural steel work riveted, bolted or welded in built up sections, trusses and framed work, including cutting, hoisting, fixing in position and applying a priming coat of approved steel primer all complete.

Steel work welded in built up sections/ framed work including cutting, hoisting, fixing in position and applying a priming coat of approved steel primer using structural steel etc. as required:

In gratings, frames, guard bar, ladder, railings, brackets, gates and similar works.

Providing and fixing hand rail of approved size by welding etc. to steel ladder railing, balcony railing, staircase railing and similar works, including applying a priming coat of approved steel primer:

M.S. tube.

STEEL SCAFFLODING (MATERIALS IN CONTRACTOR'S SCOPE) The job includes supply of all scaffolding materials, transportation to work site, erection of scaffolding at site as per ISMS (IndianOil Safety Management System) Standard-1007 on Scaffold Safety with safest and reliable design. Scaffolding design should consider the worst load combination expected during its service period. The supporting structure should be sufficient in strength, stability, and rigidity; The safety of personnel associated with the erection, alteration, and dismantling of the scaffold; the safety of persons using the scaffold; and the safety of persons in the vicinity of the scaffold to be considered mandatorily. Standard Tags for "Fit for Use" in Green Color and "Not Fit for Use" in Red Color to be fitted on scaffolding as per ISMS Standard-1007. Note: 1. For measurement in SQM: 2 (length + width) X height area covered by the scaffolding is to be taken. 2. Scaffolding measurement to be done by breaking the height into parts as per height slab mentioned below and adopting respective rates against mentioned height slabs.

Upto 6 M

Aliphatic amine cured epoxy zinc phosphate primer to achive a minimum DFT of 75-125 microns (2 or more coats of 40-65 micron each)

Two pack Acrylic Poly-urethane (PU) to achive a minimum DFT of 40-50 microns (one or more coat of 40-50 micron).

Painting with synthetic enamel paint of approved brand and manufacture to give an even shade-Two or more coats on new work.

PF/EsI for line item 10

PF/EsI for line item 10

Civil works for CTA DW Line water supply

Earth work in excavation by mechanical means (Hydraulic excavator) / manual means in foundation trenches or drains (not exceeding 1.5 m in width or 10 sqm on plan) including dressing of sides and ramming of bottoms, for all lift including getting out the excavated soil and disposal of surplus excavated soil as directed, within a lead of 50 m: All kinds of soil.

Filling available excavated earth (excluding rock) in trenches, plinth, sides of foundations etc. in layers not exceeding 20cm in depth, consolidating each deposited layer by ramming and watering, lead up to 50 m and for all lift.

Supplying and filling in plinth with Jamuna sand under floors, including watering, ramming, consolidating and dressing complete.

Providing and laying in position cement concrete of specified grade excluding the cost of centring and shuttering - All work up to plinth level :

1:1.5:3 (1 Cement : 1.5 coarse sand (Zone-III) derived from natural sources : 3 graded stone aggregate 20 mm nominal size derived from natural sources).

Providing and laying in position specified grade of reinforced cement concrete excluding the cost of centering, shuttering, finishing and reinforcement - All work up to plinth level :

1:1.5:3 (1 cement : 1.5 coarse sand (Zone-III) derived from natural sources : 3 graded stone aggregate 20 mm nominal size derived from natural sources).

Centering and shuttering including strutting, propping etc. and removal of form for :

Foundations, footings, bases of columns, etc. for mass concrete.

Brick work with common burnt clay F.P.S. (non modular) bricks of class designation 7.5 in foundation and plinth in:

Cement mortar 1:4 (1 cement : 4 coarse sand).

Structural steel work in single section fixed with or without connecting plate including cutting, hoisting, fixing in position and applying a priming coat of approved steel primer all complete.

Dismantling manually/ by mechanical means including stacking of serviceable material and disposal of unserviceable material within 50metres lead as per direction of Engineer-in-charge :

Bituminous portion.

Water bound macadam.

Dismantling manually/ by mechanical means including stacking of serviceable material and disposal of unserviceable material within 50metres lead as per direction of Engineer-in-charge :

Bituminous road.

Carriage of lime, moorum, building rubbish and debris including refractory / insulation debris etc. by mechanical transport for following leads or part thereof including loading, unloading and stacking all complete as per the direction of the Engineer-in-Charge (The rates will be applicable to net quantities after deduction of 20 percent for voids):

Upto a lead of 1 km.

PF/EsI for line item 20

PF/EsI for line item 20

Mech services for HVLRM at DR

CARBON STEEL PIPING JOINTS FOR NON-HYDROCARBON SERVICE (WITH WELDING ELECTRODE E-6013) Transportation of all piping items from owner's storage points to work site and / or pre-fabrication yard and to site after pre-fabrication; cutting, grinding, edge preparation of pipes and fittings, like flanges, elbows, tees, reducers etc. to match the mating edges of different thickness; fit-up, bending, welding using approved welding electrodes as per owners quality requirements etc. as per codes/specifications, drawing etc., threading, laying, erection and alignment of pipes upto a height of 5 meters on sleepers, pipe racks etc. or upto 5 meters depth in trenches, anchoring wherever required, connecting with equipment, nozzles, steam traps, strainers, orifice assemblies (including tapping upto first block valve), spray nozzles, rotameters; tapping for instrument connections like pressure gauges, thermowells, sample connections, vents, drains etc. including fixing of all types of SW valves, gaskets, nuts and bolts, all inline instruments, elbows, tees, flanges, reducers, full coupling or half coupling, reinforcement pads, earthing strip wherever required; welding prefabricated shoes and supports (including alignment) as per the drawings including preparation of small bore isometrics upto 1.5 inch NB, specifications, codes etc. and as per the instructions of the Engineer-in-Charge to his entire satisfaction. The scope also includes supplying of all types of tools and tackles, lifting arrangements, equipment, machineries, all consumables and labour etc. to complete the work in all respects including area preparation for hot jobs, area cleaning after completion of work, flushing wherever required, cleaning of pipes externally off all foreign materials like weld beads, clamps fixtures etc. used in fabrication as directed by the Engineer-in-Charge. NOTE : 1. Proper safety arrangements for carrying out the job is under contractor's scope and the same has to be complied with as per the d irections of the Engineer- in-Charge. 2. For job execution beyond 5 Mtr. elevation above or below ground level, rates are to be escalated by 10% for every 5 meters. 3. Requirement of scaffolding to be envisaged and decided by Engineer in Charge as per site requirement and scaffolding item to be paid separately. 4. Piping up to 40mm NB shall be fully TIG welded. Piping size 50mm NB & above, where TIG welding is used for root run only, the rates to be escalated by 15% and where TIG welding is used for entire joints the rates to be escalated by 20%. 5. Payment of tapping points will also be made extra on joint basis, as the measurement is on joint basis.

100 mm NB, Schedule upto 40

150 mm NB, Schedule upto 40

200 mm NB, Schedule above 20 but upto 40

20mmNB Sch above 80 but upto 160(TIG)

TIG welding used for root run only

Transportation from owner's storage points to work site and/ or pre-fabrication yard and to site after pre-fabrication; cutting, gr inding, edge preparation as per the instructions of the Engineer-in-Charge to his entire satisfaction including supplying of all types of tools and tackles, lifting arrangements, equipment, machineries, all consumables and labour etc. to complete the work in all respects in a workman like manner including area preparation for hot jobs, area cleaning after completion of work, pneumatic testing, cleaning of pipes externally off all foreign materials like weld beads, clamps fixtures etc. used in fabrication as directed by the Engineer-in-Charge. NOTE : Proper safety arrangements for carrying out the job is under contractor's scope and the same has to be complied with as per the dire ctions of the Engineer- in-Charge.

Branch size 4 inch

Branch size 6 inch

Branch size 8 inch

DYE PENETRATION TEST FOR PIPING WORKS Performance of dye penetration test including supply of all necessary materials, penetrant, developer etc. along with all equipment’s, labour, for carrying out the work as per specification and direction of engineer -in-charge at all elevations. Test has to be carried out in all metallurgy the test has to carry out on all schedules of pipes.

For Pipes (Per Inch Dia)

RADIOGRAPHY OF PIPING WORKS Performance of radiographic inspection on all type and sizing of piping/ pipe fittings in position at all heights inclusive of providing sources, film, chemicals, and all necessary equipment, consumables etc. complete in all respect as per specification and instruction of the Engineer-in-Charge.

For Pipes (Per Inch Dia)

HYDROTESTING OF GATE/GLOBE/ CHECK/ BUTTERFLY/ PLUG VALVES Job involves collection of valves from stores, go-down etc. transportation to testing bay or contractors' own premises, test the val ves for seat, body and backseat at recommended pressure including cleaning and greasing, transport back as per instruction and satisfaction of the Engineer-in-Charge. Requirement of heavy equipment to be envisaged by Engineer in Charge and to be arranged separately, if required, as the same in not included in the item rate.

HYDROTESING OF PIPING WORKS Hydrostatic testing of pipelines at the specified pressure including blinding/deblinding, fabrication and fixing of testing connections, pressure gauge installation. Hose pipe connection and making all other arrangements as required and dewatering, flushing and boxing up after fixing proper gaskets with supply of all labour, tools andtackles, instruments and instruction of the Engineer-in-Charge. The job has to be carried out at all elevations. In case of Hydrotest Failure, Re-testings shall be carried out at no extra cost. Requirement of scaffolding to be envisaged and decided by Engineer in Charge as per site requirement and scaffolding item to be paid separately.

FIXING / REMOVAL OF FLANGES / BLIND FLANGES OF RATING UPTO 300# Opening / fixing etc. of flanges / blind flanges / spool pieces at the two flange joint (rating upto 300#) as and when required for elbow reversing, wedge opening etc. or any other job including handling of flanges and preparation of gaskets from the sheet including tools and tackles, consumables, supervision etc. and as per direction of the Engineer-in-Charge.

INSTALLATION OF FLANGED / RTJ VALVES/ LEVEL TROLL/ FIRE HYDRANT/ MONITORS/ SAFETY VALVES ETC. Transportation of all types of flanged / RTJ valves, level troll, fire hydrant, monitor, gaskets, nut bolts etc. either from owner's storage point to workshop and/ or worksite. Installation at ground level i.e. up to a height of 5 meters on sleepers, pipe racks etc. or up to 5 meters depth in trenches including assembly of valve accessories, cleaning of flanged faces, lapping of RTJ rings, providing new gasket (IOCL supplied) or cutting of new gaskets to proper size if required, placing the gaskets / RTJ ring properly, installation in position with correct direction, tightening of studs, providing earthing protection by way of fixing strips, complete the job in all respect as per drawings and direction of the Engineer-in-Charge, including all labour, tools, tackles, consumables and supervision etc. and tightening of the gland to ensure zero leak including hot bolting wherever applicable. For job execution beyond 5 Mtr. elevation above or below ground level, rates are to be escalated by 10% for every 5 meters. Requirement of heavy equipment (other than transportation) to be envisaged by Engineer in Charge and to be arranged separately, if r equired, as the same in not included in the item rate. Requirement of scaffolding to be envisaged and decided by Engineer in Charge as per site requirement and scaffolding item to be paid separately.

For Valves (other than RTJ)

Mech services for CTA DW Line at DR

CARBON STEEL PIPING FOR NON-HYDROCARBON SERVICE (WITH WELDING ELECTRODE E-6013)- OFFSITES Transportation of all piping items from owner's storage points to work site and / or pre-fabrication yard and to site after pre-fabrication; cutting, grinding, edge preparation of pipes and fittings, like flanges, elbows, tees, reducers etc. to match the mating edges of different thickness; fit-up, bending, welding using approved welding electrodes as per owners quality requirements etc. as per codes/specifications, drawing etc., threading, laying, erection and alignment of pipes upto a height of 5 meters on sleepers, pipe racks etc. or upto 5 meters depth in trenches, anchoring wherever required, connecting with equipment, nozzles, steam traps, strainers, orifice assemblies (including tapping upto first block valve), spray nozzles, rotameters; tapping for instrument connections like pressure gauges, thermowells, sample connections, vents, drains etc. including fixing of all types of SW valves, gaskets, nuts and bolts, all inline instruments, elbows, tees, flanges, reducers, full coupling or half coupling, reinforcement pads, earthing strip wherever required; welding prefabricated shoes and supports (including alignment) as per the drawings including preparation of small bore isometrics upto 1.5 inch NB, specifications, codes etc. and as per the instructions of the Engineer-in-Charge to his entire satisfaction. The scope also includes supplying of all types of tools and tackles, lifting arrangements, equipment, machineries, all consumables and labour etc. to complete the work in all respects including area preparation for hot jobs, area cleaning after completion of work, flushing wherever required, cleaning of pipes externally off all foreign materials like weld beads, clamps fixtures etc. used in fabrication as directed by the Engineer-in-Charge. NOTE : 1. Proper safety arrangements for carrying out the job is under contractor's scope and the same has to be complied with as per the d irections of the Engineer- in-Charge. 2. For job execution beyond 5 Mtr. elevation above or below ground level, rates are to be escalated by 10% for every 5 meters. 3. Requirement of scaffolding to be envisaged and decided by Engineer in Charge as per site requirement and scaffolding item to be paid separately. 4. Piping up to 40mm NB shall be fully TIG welded. Piping size 50mm NB & above, where TIG welding is used for root run only, the rates to be escalated by 15% and where TIG welding is used for entire joints the rates to be escalated by 20%.

80 mm NB, Schedule upto 40

20mmNB Sch above 80 but upto 160(TIG)

TIG welding used for root run only

DYE PENETRATION TEST FOR PIPING WORKS Performance of dye penetration test including supply of all necessary materials, penetrant, developer etc. along with all equipment’s, labour, for carrying out the work as per specification and direction of engineer -in-charge at all elevations. Test has to be carried out in all metallurgy the test has to carry out on all schedules of pipes.

For Pipes (Per Inch Dia)

RADIOGRAPHY OF PIPING WORKS Performance of radiographic inspection on all type and sizing of piping/ pipe fittings in position at all heights inclusive of providing sources, film, chemicals, and all necessary equipment, consumables etc. complete in all respect as per specification and instruction of the Engineer-in-Charge.

For Pipes (Per Inch Dia)

HYDROTESTING OF GATE/GLOBE/ CHECK/ BUTTERFLY/ PLUG VALVES Job involves collection of valves from stores, go-down etc. transportation to testing bay or contractors' own premises, test the val ves for seat, body and backseat at recommended pressure including cleaning and greasing, transport back as per instruction and satisfaction of the Engineer-in-Charge. Requirement of heavy equipment to be envisaged by Engineer in Charge and to be arranged separately, if required, as the same in not included in the item rate.

HYDROTESING OF PIPING WORKS Hydrostatic testing of pipelines at the specified pressure including blinding/deblinding, fabrication and fixing of testing connections, pressure gauge installation. Hose pipe connection and making all other arrangements as required and dewatering, flushing and boxing up after fixing proper gaskets with supply of all labour, tools andtackles, instruments and instruction of the Engineer-in-Charge. The job has to be carried out at all elevations. In case of Hydrotest Failure, Re-testings shall be carried out at no extra cost. Requirement of scaffolding to be envisaged and decided by Engineer in Charge as per site requirement and scaffolding item to be paid separately.

FIXING / REMOVAL OF FLANGES / BLIND FLANGES OF RATING UPTO 300# Opening / fixing etc. of flanges / blind flanges / spool pieces at the two flange joint (rating upto 300#) as and when required for elbow reversing, wedge opening etc. or any other job including handling of flanges and preparation of gaskets from the sheet including tools and tackles, consumables, supervision etc. and as per direction of the Engineer-in-Charge.

INSTALLATION OF FLANGED / RTJ VALVES/ LEVEL TROLL/ FIRE HYDRANT/ MONITORS/ SAFETY VALVES ETC. Transportation of all types of flanged / RTJ valves, level troll, fire hydrant, monitor, gaskets, nut bolts etc. either from owner's storage point to workshop and/ or worksite. Installation at ground level i.e. up to a height of 5 meters on sleepers, pipe racks etc. or up to 5 meters depth in trenches including assembly of valve accessories, cleaning of flanged faces, lapping of RTJ rings, providing new gasket (IOCL supplied) or cutting of new gaskets to proper size if required, placing the gaskets / RTJ ring properly, installation in position with correct direction, tightening of studs, providing earthing protection by way of fixing strips, complete the job in all respect as per drawings and direction of the Engineer-in-Charge, including all labour, tools, tackles, consumables and supervision etc. and tightening of the gland to ensure zero leak including hot bolting wherever applicable. For job execution beyond 5 Mtr. elevation above or below ground level, rates are to be escalated by 10% for every 5 meters. Requirement of heavy equipment (other than transportation) to be envisaged by Engineer in Charge and to be arranged separately, if r equired, as the same in not included in the item rate. Requirement of scaffolding to be envisaged and decided by Engineer in Charge as per site requirement and scaffolding item to be paid separately.

For Valves (other than RTJ)

WRAPPING & COATING OF VESSELS/ UNDERGROUND PIPING ETC. Providing wrapping and coating as per the specifications including supply of all materials, tools and tackles, etc. The detailed spe cification for wrapping and coating is as under: 1. The surface preparation of pipes shall be done by grit/ shot blast cleaning to Swedish standard SA-2. 2. The grit/ shot blasting operation shall be carried out in the day time. Blast cleaning operation shall not be carried out in humid condition. 3. Only approved quality grit/ shot shall be used for grit/ shot blasting. The grit/ shot used shall be dry and free from any other impurities. 4. The grit/ shot blasted surface shall have a shining and near white metal appearances. 5. After grit/ shot blast cleaning, the surface shall be dry brushed to remove deposits. 6. The grit/ shot blasted surface should be inspected by quality control/ Inspection agency of owner and contractor. COATING SYSTEM Following steps shall be followed: 1. Application of one coat of primer. 2. Application of one coat of coal tar enamel. 3. Wrapping fibre glass. 4. Application of 2nd coat of coal tar enamel. 5. Wrapping of craft paper/ coal tar impregnated outer wrap. PRIMING 1. Single coat of coal tar primer shall be applied manually with good quality brushes. Following precautions shall be taken during application of primer. 2. Primer drum shall be inspected for manufacturing date batch No. etc. 3. Primer drum shall be rotated before opening for proper mixing. 4. Primer shall be applied within 12 hrs. of completion of sand blasting. 5. Primer shall be applied evenly all along the pipe surface. 6. Any holiday or bare pipe left over during priming shall be primed again. 7. Primer will not be applied during rainy/ moist weather. 8. After application of primer and before drying, adequate precaution shall be taken to avoid contact of dust/ sand etc. with primed surface. 9. Normal primer requires 1 hr. time for proper drying and becomes dead after 24 hrs. of its application. 10. Coating shall be completed within these limits failing which dead primer shall be cleaned and fresh primer shall be applied again. COATING AND WRAPPING i) When the priming coat has dried and the surface of the primed pipe has been cleaned preferably by clean white rags to remove the settled dust just preceding of the coating operation. The pipe shall be coated with hot application of one coat of coal tar enamel to give a minimum thickness of 2.5 mm and to be securely bonded to the primer. ii) The coal tar enamel shall be cut into lumps preferably at the storage place upon a clean platform with side boards and due care must always be exercised by the contractor to keep the broken enamel absolutely free form dirt, grass, water or any other foreign material up to the time when enamel is charged into the melting kettle. iii) The coal tar enamel shall be slowly heated on reduced fire and maintained to the even temperature recommended for application i.e. 220 deg. C to 240 deg. C. iv) Constant stirring shall be necessary in continuously operating melting kettles. v) Melting kettle should have proper insulation. vi) The melting kettle should be of movable type i.e. wheel mounted and have towing arrangement. vii) The melting kettle should be kept near the work site. However, in no case the molten enamel shall be carried in bucket for more than 50 meter distance. Viii) During pouring of molten enamel, fine wire mesh filter shall be used to avoid the flow of impurity/ dirt/ sand. ix) During temporary interruption of the work the temperature in the kettle not shall be reduced by at least 50 deg. C below the normal specified temperature. x) Any enamel heated to temperature in excess of the maximum allowable temperature shall be rejected and suitably disposed off by the contractor. xi) Melting kettles/ pots shall always be maintained clean and in good working order and must be cleaned whenever deposits form on the heating surface. xii) A uniform thickness of 2.5 mm of enamel shall be applied to the surface of the primed pipe. xiv) The enamel shall be then reinforced by a spirally wrapped fibre glass wrap, pulled and embedded into the hot coating with an over lapping of edges of the wrap not less than 1/2" and not more than 1" xv) This will be followed by another coat of hot coal tar enamel application with a uniform thickness of 1.5 mm followed by craft paper/ coal tar impregnated fibre glass covering. xvi) The coating and wrapping must be absolutely free of wrinkles in the wrappers, pinholes, bubbles, holidays voids thin spots or foreign matter. xvii) Rolls of wrapping material shall not be kept along the right of way and shall be stored properly and brought to site. xviii) Wrapping material shall be so hauled and handled so as to prevent injury to the packages. xix) No package shall be handled with hooks or thrown from trucks. xx) Any such material which shows evidence of deterioration due to weather or any other cause, shall be rejected. COATING THICKNESS Minimum thickness of first coating should be 2.5 mm whereas total thickness should be approx. 4.5 mm. TESTING Following testing shall be undertaken: I) Physical Inspection: All the coated surface shall be visually inspected and all the wrinkles, bubbles, lack of overlap etc. shall be marked for repair. Ii) Sound Test: The coating adhesion can be checked easily with small wooden hammer by soft striking on coated surface. Change in sound indicates coating defects and same can be checked there by peel test. iii) Peel Test: The field bond test for coal tar enamel adhesion shall be preformed at 50-80F normal operating temperature of steel piping. If the coating temperature is above 80 °F or below 50 deg. F, pour cold or hot water over the test area to adjust the enamel temperature within this range. Using a knife, heated if necessary make two parallel cuts through the coating about 4 inch in length and 3/4 inch apart. With the edge of knife blade cut under the enamel strip at one end and loosen the enamel from the pipe the full width of the strip for about a 1/2" place the knife blade under the loosened end and apply a slow, steady pull upward on enamel strip. iv) If the peel length exceeds 1/8", the test is a failure and two additional tests shall be made at two different locations on the same section. If the additional tests are satisfactory then the section shall be approved. If anyone additional test fails, the pipe section shall be rejected. SPECIFICATION OF COAL TAR PRIMER The primer consists of processed coal tar pitch and refined coal tar oil suitably blended with a solvent without pigment or inert filler or other substances (to be applied cold) for brushing or spraying as liquid coat to the clean surface piping as provided for in AWWA specification C-203-73. The primer should have no tendency to settle down in the container and when applied without producing bubbles, becomes dry and hard to touch within specified time ensuring and effective bond between the metal pipe surface and the enamel coating. The main characteristics of the coal tar primer should be as follows: 1. Drying time to touch dry, at normal humidity at 32 deg. C is less than 1 hr. 2. Max Boiling point of solvent 25 deg. C. 3. Penetration of residue at 25 deg. C. 4. Softening point of residue (ASTM-D-36) 104 deg. C. 5. Flash point of (ASTM 1310) 37 deg. C. 6. Pigment 7. Solvent Benzol solvent or highly toxic volatile solvents excluded. Reputed Indian Supplier (for Coal Tar Enamel and Coal Tar Primer). i) M/s Shalimar Tar Products, Calcutta. ii) M/s Lloyd Insulation (India) Ltd., New Delhi. 2. SPECIFICATION FOR COAL TAR ENAMEL The enamel shall be a WWA coal tar enamel Type-I conforming to AWWA C-203-86. The enamel shall be composed of a specially processed coal tar type blended with an inert mineral filter, properly graded, cleaned, dust free and without asphalt of either petroleum or nature base, to be applied to a recommended temperature. The main characteristics of the enamel shall be as follows: S. No. Test Enamel Type - 1 Min Max. 1. Softening Point, ASTM-D-36 104 deg.C 116 deg. C 2. Filter(ash) ASTMD-71 25% 35% 3. ineness fillet through 90% 200 mesh. ASTM-D-54G 3. SPECIFICATION OF FIBRE GLASS INNER WRAP The fibre glass inner wrap of high tensile long monofilament, chemically inert glass fibre in jack straces patterns mat reinforced by longitudinal continuous stands of glass fibre yarn blended with insoluble inert resinous binder compatible with hot coal tar enamel and should conform to the following specifications: Tensile Strength (transverse) Kg/sq.cm 0.50 + 0.10 Weight 41gm/sq.m Reputed Indian Supplier for Fibre Glass paper and Kraft Paper: i) M/s United Paper Product, Saharanpur, U.P. ii) M/s FGP Limited New Delhi. 4. SPECIFICATION OF KRAFT PAPER The kraft paper shall be smooth bituminised to be supplied in rolls. The average weight of a composite bituminised craft paper shall be a minimum 120 Gms/sqm. A negative weight tolerance upto 5% of the composite weight may be permitted at the discretion to the owner (bituminised kraft paper with average weight less than 120 gm/sqm. in not acceptable). The bituminised kraft paper shall be composed of two layers of kraft paper each weighing not less than 45 gm/sqm and laminated with a layer of bitumen approachments weight 50 gm/sqm to have a proper bond between the two layers of paper. The bituminised craft paper for field application shall be able to resist penetration. Specific Gravity at 25 deg. C ASTM D-71 1.4 1.6 Penetration, ASTM-D-5 10 a) At 25 deg. C 100 gms. Weight 5 secs. High temperature test at 71 deg.C 1/32 (Sag O AWWA C-203. Sec. 2.8.9 Low temperature test at 23 deg. C (Cracking), AWWAC-203 sec. 2.8.10 Peel Test, AWWAC-203 sec. 2.8.11 No peeling Electrical Resistance test at 17000 Volts and low amperage (1.5 mm thickness) Other Requirements (For wrapping and coating) 1. Third party Inspection certificate for all materials by any IOCL approved TPIA or providing IOCL approved manufacturers test certificate shall be in contractors scope. 2. Holiday testing machine shall be arranged and provided by contractor. 3. Vendor to submit transportation and Handling procedure 4. Vendor to submit and Get quality assurance plan (QAP) for wrapping and coating approved by owner/ Inspector. 5. The wrapping and coating surface must have machine finish in workmanship. Note: Civil works (earth excavation and back filling) required for wrapping & coating of underground piping, shall be paid separately.

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