sec23-26

Tender No.T/Q4/656/04 Section 3

SCOPE OF WORK 1.00 Scope of Work

1.1 The scope of work shall include removal of existing rubberlining, supply of all requisite material, tools, tackles, and other accessories, preparation of surface for rubber lining by grit / shot blasting, carry out rubber lining, testing of the lining as per attached specification sheet / data sheet.

1.2 During removal of existing rubberlining from the tank, there may be

a possibility of thinning of the thickness of the shell, bottom plate, roof or the nozzles and appurtenances attached to the tank or repair works to be undertaken on the tank from the dimensions as mentioned in the drawing. Any such steel repair work including supply of materials required shall be in the scope of the tenderer. The extent of steel repair work shall be decided after inspection by MFL on removal of rubberlining.

1.3 The scope of work shall include removal of existing FRP lining,

supply of all requisite materials, tools, tackles, and other accessories, preparation of surface for FRP lining and its application on the tank roof and structures.

1.4 The lining is to be provided to protect the tank roof and structures

against corrosive atmosphere. 1.5 The scope also shall include disposal of old rubberlining & FRP

lining material from the site to the designated yard immediately, after completion of removal of old lining job.

1.6 After completion of entire job, the external surface of the shell shall

be shot / grit blasted and painted. 1.7 Asphalt lining shall be provided at the periphery of the tank bottom

….2

This watermark does not appear in the registered version - http://www.clicktoconvert.com

http://www.clicktoconvert.com

:: 2 ::

Tender No. T/Q4/656/04 Section 3

2.00 Specification For Rubber Lining

2.1 The thickness of rubber lining shall be as given below: a On the inside of roof : 3 mm b On the floor and the shell : 10 mm (two distinct upto a height of 1 M min. layers of 5 mm each) Acid level. c On the remaining portion : 5 mm of shell d Tolerance of thickness : + 10%

2.2 British standard CP 3003 lining of vessels and equipment for

chemical process Part I rubber, shall be followed. 2.3 The rubberlining shall be carried out by “Cold Bond” method as per

IS 4682 – Part I and BS CP 3003 Part I using pre-vulcanised natural rubber of proper grade and hardness suitable for the service specified in Section 4.

2.4 The rubber lining shall have shore hardness of 52 + 5 deg A

-----------------

2.5 The compound / adhesive shall be such that it will give necessary bondage, strength, etc., with the metal surfaces as per British Standard Code of Practice (Code CP 3003 – Part I – Rubber).

2.6 The grade of rubber shall be such that it should have the required

chemical and physical conditions specified, non-standing properties and do not deteriorate by prolonged contact with the liquid whose analysis is given in Section 4.

2.7 The tenderer shall furnish all specifications and make the approve

mix and samples of vulcanised natural rubber sheet for test and for future reference in case of dispute, and shall not change the mix in any way without the approval of MFL.

…..3



:: 3 :: Tender No.T/Q4/656/04 Section 3

2.8 The compound / adhesive and the compounding of rubber shall be such that the lining shall be cured at ambient temperature without any detriment to the adhesion, strength, hardness, etc., of the lining.

2.9 All materials shall be supported by manufacturers test certificate

and guarantee certificate.

2.10 Before despatching the materials to site, the tenderer shall offer the rubber materials for material test which will be conducted / witnessed by MFL Engineer at his works. Only after getting clearance from MFL Engineer, the tenderer shall despatch the materials to site.

3.00 Bonding

3.1 The tenderer shall supply bonded samples using identical materials and methods employed on the equipment, to show the level of adhesion obtained before and after exposure to the same conditions of use. It is important that the samples be bonded in a similar way to that which will ultimately be employed on the equipment to be lined.

4.00 Surface Preparation

4.1 Surfaces to be rubber lined shall be grit / shot blasted by the tenderer thoroughly to a bright metal finish, and shall be free from rust, scale, weld splatter or any other foreign matter. The surfaces shall be prepared by grinding, where necessary.

4.2 The surfaces shall then be cleaned thoroughly with solvent and a

thin coat of resin must be applied within 4 hours of completion of grit / shot blasting.

4.3 Compressor, grit / shot and any other facilities required for grit / shot

blasting shall be arranged by the tenderer. Any hoses provided in the compressed air line shall be tested with air before commencing the grit / shot blasting job.

4.4 Any scaffolding provided by the tenderer shall be of steel only.

…..4



:: 4 ::


4.5 The grit / shot blasting machine shall be provided with safety valve

as a protection against over pressure. 5.00 Rubber Lining

5.1 The lining including surface preparation of the tank shall be carried out at site.

5.2 Any necessary pre-shrinking of the rubber shall be carried out at

shop / site before hand tailoring the sheet to fit the surface to be rubber lined.

5.3 The side of the sheet which will be in contact with the adhesive shall

be wiped with a rubber solvent and edge of the rubber sheet shall be tapered suitably.

5.4 The sheet shall be applied to the metal as soon as the solvent has

evaporated and while the sheet sill remains its surface tank.

5.5 All edges and seams shall be laid straight.

5.6 The sheets shall be joined by strapped joints as per BS Code of Practice CP 3003 Part I. The minimum size of the strap shall be 75 mm wide and 1.5 mm thick.

5.7 The rubber lining shall extend out over the full face of all flanges of

nozzles and manholes unless otherwise noted. All manhole covers and blind flanges shall be lined. Nozzles shall be lined so as to provide a smooth opening of maximum possible diameter. Circumferential joints shall be located so as not to restrict the opening.

5.8 All lapped seams shall be made by overlapping adjacent sheets by

not less than two inches. Overlapping edges shall be sized and turned down to give smooth and neat appearance. The number of seams shall be kept to a minimum consistent with good workmanship. The bond between adjacent sheets of overlaps shall be such that separation cannot occur without tearing the lining.

…..5



:: 5 :: Tender No.T/Q4/656/04 Section 3 6.00 Testing

6.1 The sheet shall be examined to ensure that it is free from blisters and any other imperfection which would affect the performance of lining.

6.2 The adhesion test shall be conducted as per procedure given in BS

CP 3003 at 20 + 5 deg C after minimum during period of 10 days.

6.3 Hardness test shall be carried out on completion of bonding the sheets.

6.4 Hardness shall be measured with a portable hardness meter

calibrated in accordance with BS 2719 (Method of use and calibration of pocket type rubber hardness meters). Readings shall be taken for each Sq.M of lining, where the repairs have been carried out, the areas concerned shall be tested separately.

6.5 High voltage spark test shall be carried out to check the continuity

and absence of pinholes. The spark length shall be not less than 32 mm. The spark test shall be conducted on the entire rubber lined area and joint seams before and after the application of the strips.

7.00 Specification for FRP lining

7.1 FRP lining shall be of two layers of fibre glass chopped strand mat of 450 gm/Sq.mtr., density followed by a top layer of surface mat impregnated with isopthalic polyester resin. The laminate thickness shall be minimum 2mm. The minimum glass resin ratio shall be 1:2.5. The reinforcement materials shall be M/s PGP or M/s Ceat Tyres or M/s Naptha Resins & Chemicals Pvt. Ltd., make and polyester resin shall be of M/s Bakelite Hylam make. Material from any other manufacturer will not be accepted.

7.2 The addition to hardness, catalysts and accelerators to resin system

shall be as per the recommendations of the resin suppliers. 7.3 Test certificates for the materials shall be furnished along with the

supplies. …..6



:: 6 ::

Tender No.T/Q4/656/04 Section 3 8.00 Surface Preparation

8.1 All the steel surfaces to be FRP lined shall be grit / shot blasted thoroughly to a greyish finish by the tenderer.

8.2 Compressor and any other facilities required for grit / shot blasting

shall be arranged by the tenderer. Any hoses provided in the compressed air line shall be tested with air before commencement of grit blasting job.

8.3 The grit / shot blasting machine shall be provided with safety valve

(safe trip) as a protection against over pressure.

8.4 Any scaffolding provided by the tenderer shall be of steel only. 9.00 FRP Lining

9.1 The lining shall completely cover the roof, roof structure, roof

handrails, curb angle, stairway hand rails and supporting angles of gratings.

9.2 A thin coat of isopthalic grade of polyester resin must be applied

within four hours after completion of grit / shot blasting to prevent rusting of the surface to be lined.

9.3 After the prime coat, putty made from isopthalic polyester resin shall

be applied to produce smooth, rounded contours and to eliminate sharp angles that might cause difficulty in the application of laminate coating. Pits, if any, shall be filled with putty.

9.4 After the primer resin is cured, the area shall be laminated with FRP

by the hand lay up technique. A top coat of FRP surface mat shall be applied over the two layers of FRP laminates.

The thickness of the lining shall be 2 mm\ 9.5 The rain water drain holes on the roof purlins should not be covered

with the FRP lining.

…..7



:: 7 ::


10.00 Inspection and Testing of FRP lining

10.1 Lining shall be visually inspected to ensure free from poorly weed out fibres, entrapped air and exposed fibres. Defects are to be repaired by sandering a generous area around the defected portion and applying a layer of FRP mat saturated with activated resin.

10.2 Spark test shall be carried out on the entire lining area of the roof

surface including roof structure, manhole, manhole covers in the presence of MFL Engineers.

11.00 Metal Rectification 11.1 The metal repair work includes dismantling, supply, fabrication and

erection of identified portions of the tank shell, bottom & roof plate, roof structures and appurtenances. The extent of steel repair work shall be decided after inspection by MFL on removal of rubberlining.

11.2 All materials supplied shall be from standard suppliers supported by

Material Test Certificate and shall be duly submitted to MFL before despatch. The material shall conform to the specification of IS:2062 / equivalent and gratings for the stairway shall be of G.I. material. However, on receipt of material, MFL shall take random sample of plates for analysis / testing to carry out ultrasonic testing to check for the presence of lamination, if required.

11.3 The fabrication and erection work shall be strictly adhered to API-

650 for welding and other structural attachments. 11.4 The successful tenderer shall carry out the rectification work with

their own tools, tackles, welding equipment, cables, scaffolding and all other necessary equipment required for the job.

12.00 Inspection & Testing 12.1 Welders engaged in the job shall be qualified by MFL before job

commencement.

….8



:: 8 ::

Tender No.T/Q4/656/04 Section 3 12.2 After completion of metal rectification work, the surface shall be

made suitable for subsequent rubberlining inside and FRP lining over the tank roof and if any defects found shall be rectified till MFL’s acceptance.

12.3 Fabrication & Welding shall be inspected as per API-650 and MFL

approved QAP. 12.4 Inspection & Testing shall be as below : Bottom Plate : Vacuum box method Shell Plate : Radiography & Waterfill test Reinforcement Pad for the : Air test at 1 ksc nozzle & manway Shell to bottom joint : Liquid Penetrant Test Fillet welds : By visual inspection Butt welds : 10% Radiography 12.5 After completion of entire metal rectification work, the entire tank

shall be tested with potable water for checking any leaks and necessary arrangement required for the test shall be arranged by the successful tenderer.

13.00 Painting 13.1 After completion of entire job, the external surface of the shell shall

be shot / grit blasted to Swedish SA 2.5 Gr. 13.2 Subsequently, System II painting shall be carried out on the

shell.and the specification shall conform to one coat EPILUX 610 Primer to dft 25 microns + one coat of EPILUX MIO to a dft. 75 microns + 2 coats of EPILUX 4 Finish paint to a dft 40 microns per coat and total to min. 180 microns. Finally, a coat of black Epoxy Coal tar shall be applied upto a height of 1 m from the bottom of the tank throughout the entire tank circumference.

14.00 Asphalt Lining 14.1 Asphalt lining shall be provided at the periphery of the tank bottom

upto the height of outer circumference of the tank bottom plate and proper outward slope to be maintained.

…..9



:: 9 :: Tender No.T/Q4/656/04 Section 3 15.00 General

15.1 Any deviations from technical specification in the tender shall be prominently indicated by the tenderers in their offers.




DATA SHEET

1 Internal Dia of tank : 24 M 2 Height of tank (Nominal) : 9 M 3 Liquid handled : 54% P205 Merchant grade Phosphoric acid (Refer Analysis) 4 Slope of roof : Conc 1 in 6 with supporting structures at outside roof 5 Drawing No. : 2-10-30-2026 The thickness of rubber lining on internal surface of the tank, physical properties of the rubber used shall be as given below : a. On the Roof (inside) : 3 mm

b. On the floor and the shell : 10 mm (two distinct layers of upto a 1 height of 1 m from 5 mm each) bottom (minimum acid level)

c. On the remaining portion of shell : 5 mm d. Tolerance on thickness : ± 10% e. Tensile Strength : 150 KSC to 180 KSC f. Elongation break in % : 400 min. g. Modulus @ 300% : 50 to 100 Kg / cm2

h. Shore Hardness : 52 ± 5°A

……2



:: 2 ::


ANALYSIS OF 54% MERCHANT GRADE PHOS. ACID

Phosphoric Pentoxide (P205) % 52.0 to 54.0 Sulphuric Acid (H2S04) % 2.0 to 4.0 Chlorine (Cl) % Trace to 0.02 200 ppm max. Flourine (F) % 0.5 to 0.8 0.8 max. Calcium Oxide (Ca0) % 0.05 to 0.15 0.15 max. Ferric Oxide (Fe203) % 0.5 to 1.5 1.5 max. Chromium Oxide (Cr203) % 0.02 to 0.05 Aluminium Oxide (Al203) % 0.5 to 1.5 1.5 max. Magnesium Oxide (Mg0) % 0.5 to 1.2 1.2 max. Silicon Dioxide (Si02) % 0.1 to 0.3 Sodium Oxide (Na20) % 0.1 to 0.5 Potassium Oxide (K20) 0.01 Zinc Oxide (Zn0) % 0.01 to 0.5 1.2 max. Suspended solids % 0.1 to 0.5 1.2 max. Viscosity CPS @ 60 deg F 100 to 155 155 max. @ 100 deg F 50 to 65 65 max. Specific Gravity @ 60 deg F 1.65 to 1.75 1.75 max. Temperature Ambient (Refer Special Conditions of Contract)




ADDITIONAL TECHNICAL AND COMMERCIAL CONDITIONS 1.00 These conditions are in addition to the General terms and conditions and

special conditions of contract attached and carry precedence over the same in case of any contradictory provisions.

2.00 The tenderer is requested to visit the site at Madras Fertilizers Limited,

Manali, Chennai and ascertain the site conditions thereof before quoting for the job in question.

3.00 Guarantee

3.1 The complete rubber lining / FRP lining / painting and metal rectification shall be guaranteed against defective materials and poor workmanship for a period of 18 months from the date of final acceptance or 12 months from the date of actual use, whichever is earlier.

3.2 In the event of notice of any defects during guarantee period, the

tenderer shall immediately arrange replacement / rectification free of cost, failing which MFL reserves the right to arrange rectification / replacement of the same at the tenderer’s cost.

4.00 Time Schedule

4.1 The entire job of procurement, inspection, supply, removal of existing rubberlining, steel repair work, re-rubberlining, FRP lining, painting and inspection of the tank has to be completed within 7 months from the date of handing over of the tank.

4.2 Tenderer shall submit time schedule for the work along with the

tender indicating the schedule for various stage of work for the tank.

4.3 The time completion of as stated above shall be deemed to be the essence of the contract and the successful tenderer shall make every effort to complete the job in time.

5.00 Inspection

5.1 You shall clearly indicate the proposed inspection schedule at various stages of the work. MFL reserves the right to inspect the work during any stage.

…..2



:: 2 ::


5.2 All material, workmanship, instruments, equipment etc. shall be

inspected as per relevant codes and MFL approved Quality Assurance Plan and detail drawing prepared by the tenderer and approved by MFl.

5.3 MFL Engineer’s decision as regards the acceptance of the work

shall be final and binding . 6.00 Rules & Regulations

6.1 Tenderer shall provide all amenities to his staff and labour at site as per local Rules and Regulations.

6.2 Tenderer shall strictly follow the rules and regulations of Madras

Fertilizers Ltd.

6.3 Tenderer throughout the pendency of the contract, shall observe all the provisions, relevant rules, regulations and acts of Government of India, Government of Tamil Nadu and also local authorities as in force from time to time.

6.4 The tenderer is fully responsible for the safety of his staff and

workmen and must equip them with safety appliances and tools.

6.5 All the workmen and staff shall be covered under Group Accident Insurance Scheme at his cost for the duration of the contract, without which the tenderer will not be permitted to commence the work.

6.6 The tenderer shall also observe all rules and regulations framed by

MFL, for work in the area, which houses other acid storage tanks. The tenderer shall only use tested equipment, tools & tackles to the satisfaction of MFL Engineer.

7.00 Progress Report

7.1 Tenderer shall submit weekly progress reports of the work.

…..3



:: 3 ::


8.00 Site Facilities and Construction of Stores & Site Office

8.1 MFL shall make available electric power and water at one point only. The tenderer shall extend the same to the work site at their cost. Water and power for site work will be supplied to the tenderer free of cost.

8.2 MFL will only provide an open space for the tenderer to make

arrangements for storing his equipment, materials, tools and tackles at the work spot and also to put up a temporary site office.

8.3 The tenderer will be solely responsible for watching and guarding of

his stores and office. The tenderer shall cover all his equipment and materials with requisite insurance against theft, larceny, fire, flood, earthquake etc.

8.4 Any other facility like compressed air, blower etc., shall be arranged

by the tenderer.

8.5 MFL will not provide any scaffolding, tools and tackles for carrying out the work.

8.6 On completion of the work undertaken by the tenderer, he shall

remove all temporary works erected by him and clear the site as directed by MFL Engineer. MFL reserves the right to ask the tenderer at any time during the pendency of the contract to vacate the site by giving 7 days notice for security or any other reasons by allocating alternate location within or outside the premises

9.00 Supervision

9.1 MFL carry out the inspection of the rubber lining work during all stages of work.

9.2 Tenderer shall afford the company complete access and inspection

at all reasonable times and give all information desired about the progress of work.

……4



:: 4 ::


10.00 Insurance

10.1 Tenderer shall take comprehensive erection insurance policy to cover all the risks during the pendency of contract till acceptance of job by the company. Tenderer shall arrange immediate replacement of material damaged or lost in transit and also shall be responsible for proceesing the claims with Insurance Company.

11.00 Working Condition and Safety

11.1 The tenderer shall strictly follow all the safety and entry rules and regulations of MFL and shall be fully responsible for the safety of your staff and workmen and must equip them with safety appliances like safety helmets, safety belts, gloves, goggles, tools etc.,

11.2 All the workmen and the staff shall be covered under ESI, PF and

Group Accident Insurance Scheme at your cost for the duration of the contract without which you shall not be permitted to start the work. The ESI payment challans shall be furnished to MFL.

11.3 The tenderer shall indemnify MFL against any claims which may be

under the Workmen’s Compensation Act and / or payment of wages act or any other statutory obligations or otherwise, as in force from time to time and any subsequent modification therefore in respect of any damage or compensation payable in consequence of any accident or injury sustained by any workmen or other person whether in the employment of tenderer or not.

11.4 Until the acceptance of the complete work, the tenderer shall also

be liable for and shall indemnify the company in respect of all damages to any property of the company or of others occasioned by the negligence of your workmen or by defective work or otherwise.

……5



:: 5 ::


12.00 Deduction from Contract Process

12.1 All costs, damages or expenses, if any, incurred by the company, for which as per terms of the contract, the tenderer is liable, shall be deducted by the company from any money due or becoming due to the tenderer under this tender or any other order or a may be recovered by legal action or otherwise from tenderer.

12.2 All equipment and material brought to the site shall be deemed to

be the property of the company and shall not be removed from the site without the permission in writing from the company.

13.00 Legal Construction

13.1 The contract shall in all respects be constructed and operated as

an Indian Contract and in conformity with Indian Laws and Regulations in force and is subject to the jurisdiction of the Chennai Court.

14.00 Removal of Rejected Material / Equipment

14.1 Goods rejected by the company shall be removed by the tenderer within 15 days from the date of intimation. MFL shall in no way be responsible for any loss, deterioration or damage to the rejected goods under any circumstances whatsoever.

15.00 Losses due to Non-compliance of Instructions

15.1 The company has the right to make any investigation necessary to satisfy itself of compliance by the tenderer of the specifications and instructions and reject any material / work that does not conform to specification or instructions by the company. Losses, damages occuring to the company owing to the tenderer’s failure to adhere to any of the instructions given by the company will be recoverable from the tenderer.

…..6



:: 6 ::


16.00 Modification

16.1 The company reserves the right to modify the requirement both in quantity and scope of work and the tenderer shall carry out such modifications without any prejudice to the contract. Revision in prices and times, if any, occasioned due to modification in scope of Work shall be informed in writing to the company by the tenderer within a week. The price change due to variation of scope will be based on unit rates already quoted, a fresh unit rate will be decided by mutual negotiation, wherever possible on prorata basis. The price change due to modification in scope will be finally decided by mutual negotiations.

17.00 Coverage of Contract

17.1 The contract for the work is a complete one for labour, materials and workmanship with tenderer’s overheads and profit including all temporary works and the provision and use of construction, equipment, tools, tackles etc. The tenderer shall make his own arrangements for all the materials and equipment required for the due performance of the contract.

18.00 Information to be supplied along with the tender

18.1 Completed properties such as tensile strength, adhesion strength, hardness etc., and source of the rubber proposed for the services mentioned in Section 4.

18.2 Method of adhesion test / spark test / peel off test.

18.3 Properties and make of adhesives / compound proposed.

18.4 Availability of special tools and equipment necessary to carry out

the rubber lining.

18.5 Proof of previous experience in similar type of jobs, value of contracts executed, the parties, preferably with photographs of the installations carried out by them.

……7



:: 7 ::


19.00 Liquidated Damages

19.1 In case of delay in completion, company shall at its option, entitled to levy unconditional penalty charges at 0.5% of the week of delay or part thereof subject to a maximum of 5% of the contract value. If the completion of the job is delayed (for which company will be the sole judge), the company reserves the right to make alternative arrangement for procurement of materials and get the job completed at tenderer’s costs.




PRICE SCHEDULE AND PAYMENT TERMS

Sl. No. Particulars Approx. Unit Rate Amount Qty. Rs. Rs. P.

1 Removal of existing rubber 1600 M2 lining 2 Grit / Shot blasting 1600 M2

3a Dismantling of existing 25 MT shell courses, bottom plate,

nozzles, manway, roof structures, curb angle and stairway under replacement 3b Supply and execution of 25 MT

steel repair work on the tank including shell courses, bottom plate, nozzles, manway, roof structures, curb angle and stairway

4 Rubber lining - Supply & lining 4a 10 mm thk. lining on 530 Sq.M.

floor and shell upto a height of 1 m min. Acid level floor in two layers of 5 mm each.

4b 5 mm thk. lining of shell 605 Sq.M.

to the remaining height 4c 3 mm thk. lining of inside 480 Sq. M.

the roof

…….2



:: 2 ::


PRICE SCHEDULE AND PAYMENT TERMS

Sl. No. Particulars Approx. Unit Rate Amount Qty. Rs. Rs. P.

5 Removal of existing FRP 850 M2 lining from the roof of the tank 6 FRP lining on the shot / grid 850 M2 blasted roof area of the tank including roof, roof structures, curb angles, roof hand rails, stairway hand rails and grating supporting angles etc. 7 Dismantling of existing Asphalt lining and redoing With fresh asphalt etc….. To a desired level & thickness As existing one to make good 8 Surface preparation and 690 Sqm

application of painting per specification (system II) with material for the entire external surface of the tank

9 * Disposal of peeled off rubberlining sheet per pieces as a scrap weight basis * Amount payable to MFL ------------------------------------------------------------------------------------------------------ ** Quantity mentioned in the Price Schedule is only indicative and the payment shall be made only on the actual quantity erected / job completed. Price quoted shall be firm and free from any kind of escalation

…..3



:: 3 :: Tender No.T/Q4/656/04 Section 6 For records, the tenderer shall also indicate the rate included in their quotation for (a) excise duty, (b) custom duty, if any, and (c) sales tax. Any variation of these levies / taxes compared to the rates ruling at the date of supplier quotation due to statutory regulations / Government action shall be to MFL’s account, subject to submission of documentary evidence.

This tender does not come under projects. So there shall be no exemption in excise duty and customs duty.

Terms of Payment 1 10% as advance against the Bank Guarantee in MFL proforma to remain

valid till completion of contract. 2 75% payment against completion of the job on prorata basis. 3 10% on completion of Inspection and clearance of the tank. 4 5% shall be retained towards Security Deposit till the expiry of guarantee

period. However, this amount shall be released earlier, if you furnish a bank guarantee in MFL prescribed proforma for this amount.



sec23-26

Documents

thickness of rubber

lining of vessels

asphalt lining

removal of existing

scope of work

grade of rubber

old lining job

removal of rubberlining