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SCHEDULE OF RATES
Bharat Petroleum Corporation Ltd Kochi Refinery, Ambalamugal 682
302 Ernakulam Dist. Kerala.
Mott MacDonald Consultants (India) Pvt. Ltd. Kothari House, CTS
No. 185 Off Andheri - Kurla Road Andheri (East) Mumbai 400 059
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PMC SERVICES FOR SUPPLY, CONSTRUCTION & INSTALLATION OF 1NO.
ELECTROSTATIC PRECIPITATOR FOR CO-BOILER OUTLET
Title : SCHEDULE OF RATES
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List of Content Page No
1 FORM SP 0 TOTAL LUMPSUM PRICE 4
2 FORM SP I DETAILS OF CENVATABLE EXCISE DUTY 6
3 FORM SP II SERVICE TAX 7
4 FORM SP III INPUT TAX CREDIT UNDER VAT ACT (ITCV) 8
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1 FORM SP 0 TOTAL LUMPSUM PRICE Sr. No. Description
Qty. Unit Unit Rate Amount (In Figures)
Amount (In Words)
SUPPLIES : = Qty x Rate
1 Design & Supply of ESP, as per the specification &
Scope of Work, including all Materials, Commissioning spares, etc.
(including taxes & duties)
1 Lump Sum
2 Supply of 2 years' Operational & Maintenance Spares of the
ESP, as per the detailed list furnished by the Vendor (including.
taxes & duties) 1 Lump Sum
A TOTAL SUPPLIES (1 + 2)
SERVICES :
3 Erection, Installation, Testing & Commissioning of ESP,
including PGTR including all labour, supervision, tools, tackles,
etc.(excluding Service tax) 1 Lump Sum
4 Non comprehensive AMC for Two YEers after completion of
Defects Liability Period (excluding Service tax)
I 1st Year including Maintenance, Periodic Visits &
Emergency Visits 4 Quarterly Lump sum
II 2nd Year including Maintenance, Periodic Visits &
Emergency Visits 4 Quarterly Lump Sum
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5 Service Tax Payable on 3 & 4 (i) & (ii) on submission
of all necessary supporting documents
____%
B TOTAL SERVICES [3 + 4 (i) + 4 (ii) + 5]
GRAND TOTAL (A + B)
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2 FORM SP I DETAILS OF CENVATABLE EXCISE DUTY / CVD + SAD Sr.
No.
ITEM / MATERIAL Central Excise Tariff / Customs Tariff
Chapter
Heading
Central Excise Duty (CED) / CVD+SAD Amount available to owner as
CENVAT Credit
INR 1 2 3 4 5 (In Figures) (In Words)
A] Indigenous Items (Central Excise Duty Amount) 1. 2. B]
Imported Items (CVD + SAD Amount) 1. 2.
C] Total (A + B)
NOTE: 1. Total of CENVATable Excise duty amount / CVD+SAD
indicated in Col. 4 / Col. 5 above shall be deducted from total
quoted price for the purpose of evaluation 2. CED/CVD+SAD Amount
component, as mentioned in Col. 4/Col. 5 in this FORM shall be
considered as mandatory discount and shall be adjusted from all
supply bills on pro-rata basis. This CED/CVD+SAD Amount shall be
reimbursed to the contractor upon submission of documentary
evidence enabling Owner to claim CENVAT credit benefit, subject to
the ceiling mentioned in Col. 4/Col. 5 of this FORM. Further such
CED/CVD+SAD Amount shall be reimbursed only for the items which are
eligible for CENVAT CREDIT benefit as per excise rules and
provisions of bidding document. 3. In case of change in Quantity
for any of the items during execution, the CENVATable CED/CVD+SAD
amount for such items shall be adjusted proportionately.
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3 FORM SP II SERVICE TAX
Sr. No.
DESCRIPTION Amount of Taxable Value of Service
(in INR)
Amount of Service Tax Claimed (in INR)
Amount of Service Tax Credit available to the Owner 94% of Col.
4
(In INR) 1 2 3 4 5 6 (In Figures) (In Words)
1. 2. 3.
TOTAL
NOTE: 1. Bidder to note that service tax credit under CENVAT
Credit Rules 2004 is available to Owner to the extent of 94% of the
Total Service Tax Amount. 2. Amount of service tax credit available
to Owner, as mentioned in Col. 5/Col.6 shall be deducted from the
total quoted price for the service (including. service tax) for the
purpose of evaluation 3. Service Tax billed by the Contractor shall
be paid by Owner subject to compliance with clause no. 6.2.3 of
SCC. 4. In case of change in the "Final executed value of work",
the amount of Service Tax quoted above shall be adjusted
proportionately.
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4 FORM SP III INPUT TAX CREDIT UNDER VAT ACT (ITCV)
Sr. No.
ITEM / MATERIAL TOTAL KVAT AMOUNT (in INR)
Amount of Input Tax Credit available to owner under KVAT Act
(ICTV) 25% of Col. 3
(in INR) 1 2 3 4 5 (In Figures) (In Words)
1. 2. 3.
TOTAL
NOTE: 1. Bidder to note that input tax credit under KVAT Act
(ICTV) is available to Owner to the extent of 25% of the Total KVAT
Amount only. 2. Amount of input tax credit available to OWNER, as
mentioned in Col. 4/Col.5 shall be deducted from the total quoted
price for the purpose of evaluation 3. KVAT Amount component, as
mentioned in Col. 3 in this FORM shall be considered as mandatory
discount and shall be adjusted from all supply bills on pro-rata
basis. This KVAT Amount shall be reimbursed to the contractor upon
submission of documentary evidence enabling Owner to claim ITCV,
subject to the ceiling mentioned in Col. 3 of this FORM. The KVAT
amount shall not be payable in case Owner is not able to avail the
credit, based on the documentation provided by the contractor. 4.
In case of change in Quantity for any of the items during
execution, the KVAT amount for such items shall be adjusted
proportionately.
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SPECIFICATION
FOR
FIELD INSTRUMENTS
Bharat Petroleum Corporation Ltd Kochi Refinery P.O. Ambalamugal
Kochi- 682302, India
Mott MacDonald Consultants (India) Pvt. Ltd. Kothari House, CTS
No. 185 Off Andheri - Kurla Road Andheri (East) Mumbai 400 059
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List of Content Page No 1 Introduction 4 2 General 4 3 Codes and
standards 4
3.1 Deviations to Specification 6
4 Hazardous Area Classification & Environmental Protection
6
5 Pressure Ratings 6
6 Instrument Material Selection Philosophy 7
7 Scope 7
8 General Requirements 8
9 Pressure 8 9.1 Pressure Transmitter 8 9.2 Differential
Pressure Transmitter 10 9.3 Pressure instruments application
practices 11 9.4 Pressure / Differential Pressure Switch 11 9.5
Pressure Gauges 11
10 Flow Measuring Instruments 12
11 Temperature 12 11.1 Temperature Gauges 12 11.2 Thermocouple
13 11.3 Thermowell 13 11.4 Temperature Transmitter 14
12 Level 15 12.1 Level Gauge 15 12.2 Hopper Level Measurement
15
13 Identification 15
14 Tests 15
15 Shipping 16
16 Approved Vendor List 16
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1 Introduction This specification provides the minimum
requirements for design, manufacture, supply, transportation
/shipment, unloading & storage at site, installation,
inspection, testing, calibration and commissioning of Field
Instruments for Electrostatic Precipitator at BPCL, KOCHI.
The intent of this document is to define the basis of design and
to define the standards and functional requirements for field
instrument. This specification is part of PMC Services for Supply,
Construction, Installation and Commissioning of one No.
Electrostatic Precipitator for Co-Boiler Outlet at BPCL, KOCHI and
it shall be read in conjunction with tender document.
The requirements which have not been explicitly identified, but
required for the completion and efficient performance of the entire
system are in Bidders scope.
Definitions Owner : Bharat Petroleum Corporation Ltd (BPCL).
Consultant : Mott MacDonald Consultants (I) Pvt. Ltd. (MMCI) Bidder
: Vendor of Electrostatic Precipitator Engineer In-charge
: Means the Resident Engineer or a person acting on behalf of
BPCL/MMCI at site
Shall : This is to be understood as a mandatory in relation to
the requirements of this document
Should : This is to be understood as a strong recommendation
2 General
It shall be the responsibility of the Bidder to supply all
equipment that are in accordance with standards of engineering,
design and workmanship, suitable for the intended service as
described herein and consistent with generally accepted standards
& practices.
3 Codes and standards Instrumentation Specifications and Data
sheets shall be compliant with the current edition of
International Codes and Standards listed, specification, guide
etc. wherever indicated and applicable, unless indicated otherwise.
If the conflict between these standards may exist; in that case
most stringent requirements shall be applicable.
ANSI/ASME American National Standards Institute/American Society
of Mechanical Engineers.
B 1.20.1 Pipe Threads General Purpose
B 16.5 Pipe Flanges and Flanged Fittings
B 16.20 Metallic Gaskets for pipe Flanges, Ring Joint, Spiral
wound and Jacketed.
C
C
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ASME PTC 19.2 ASME Performance test codes - supplement on
instruments and apparatus, Part 2 pressure measurement
ASME PTC 19.3 ASME Performance test codes - supplement on
instruments and apparatus, Part 3 temperature measurement
API American Petroleum Institute
API RP 500 Electrical Area Classification
API RP 551
Process Measurement Instrumentation Part I - Process Control and
Instrumentation
German Industrial Standards Organization
DIN 43760 Resistance Temperature Detection
IEC International Electro technical Commission
IEC 189 Instrumentation and signal cables
IEC 60079 Electrical Apparatus for Explosive Gas atmosphere
IEC 60085 Thermal Evaluation and Classification of Electrical
Insulation.
IEC 60331 Test for Electric Cables under fire condition-circuit
integrity part II fire alone at a flame temp at 750 Deg.C
IEC 60332 Test on bunched wires or cables under fire
condition.
IEC 60529 Degree of protection provided by enclosures. (IP
code)
IEC 60751 Industrial Platinum Resistance Thermometer Sensors
IEC 61000-4
Electromagnetic compatibility for Industrial Process measurement
and control equipment.
IEC 61000-4-2, 61000-4-3 and 61000-4-4 Electromagnetic
compatibility requirements
IEC 61508 Functional Safety (Safety Related System)
IEC 61511 Functional Safety, Safety Instrument Systems.
IEEE 518
Guide for installation of electrical equipments to minimize
electrical noise inputs to controllers from external sources
IEEE-802.3U TCP / IP communication protocol
IEEE Std 999-1992 IEEE Recommended Practice for Master/Remote
Supervisory Control and Data Acquisition (SCADA) Communications. IS
Indian Standard
IS-2147 Degree of Protection Provided by Enclosures for Low
Voltage Switch gears & Control Gears
IS-2952-1964 Recommendation for Methods of Measurement of liquid
flow by means of Orifice Plates & Nozzles.
IS-3624 Specification for pressure and vacuum gauges
IS-5572 Classification of Hazardous area
ISA Instrumentation, Systems and Automation Society
ISA S 5.1 Process Instrumentation Terminology
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ISA RP 12.6 Installation of intrinsically safe systems for
hazardous (Classified) dust location
ISA S18-1 Alarm Sequence
OISD Oil Industry Safety Directorate
OISD-STD 163 Safety of Control Room for Hydrocarbon Industry
PESO/CCOE & CMRI
PESO/CCOE & CMRI Certifications
Petroleum And Explosives Safety Organisation (PESO)/ Chief
Controller of Explosives (CCOE), Nagpur or Director General of
Mines Safety (DGMS) in India.
Note:- The above list is suggestive & not exhaustive. Apart
from these basic codes any other code referred-to in this document
and/or any other related code shall also be followed wherever
required.
3.1 Deviations to Specification 3.1.1 The Bidder shall provide
an itemised list of any deviations to this specification. These
shall be
listed on the compliance sheet with seal & duly signed by
his authorised signatory & shall be submitted along with
offer.
3.1.2 Where a conflict between standards occurs then the Bidder
shall seek a clarification ruling from the Owner. Where a deviation
from the standard is required, then the Bidder shall make a formal
request with full supporting information.
3.1.3 Only those deviations that are agreed between the Owner
and the Bidder will be incorporated into the requisition at the
time of order.
4 Hazardous Area Classification & Environmental Protection
4.1 Location of new Electrostatic Precipitator shall be in Safe
Area. Environment condition shall
be followed as mentioned elsewhere in the tender document. All
field instruments shall be weatherproof to IP 65 minimum.
4.2 Ingress protection / Weather Proof : The Following minimum
degree of Protection as per IEC 60529 & IS: 2147 shall apply to
all
the Instrumentation equipment. Indoor
Instruments/Equipment/Panel - IP 42 Outdoor Instruments/Equipment -
IP 65
4.3 In addition to the above, field Instruments located
outdoors, exposed to direct sunlight shall be protected with
sunshades. All electrical components shall be tropicalized to
protect against humidity, moisture and fungal growth by means of
hermetically sealed units, protective coating on circuit boards,
gold plated edge connectors, etc.
5 Pressure Ratings 5.1 All instruments shall be fully rated to
system design pressure as per process details given in the
tender elsewhere. All flange ratings shall be ANSI class as per
details given in the tender.
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6 Instrument Material Selection Philosophy 6.1 In general,
Wetted parts for all Inline instruments shall be of SS 316
material.
6.2 In general, Instrument enclosures shall be of Die Cast
Aluminium with copper free or less than 0.4% of copper by mass.
6.3 All Cable Glands shall be of brass with nickel
electroplating or SS304 material & Junction Boxes shall be SS
304 or die-cast aluminium material. Cable glands shall be supplied
with PVC shroud of appropriate sizes.
6.4 Instrument Sun Sheds shall be provided if it is expose to
sunlight.
6.5 All Tubes and Fittings for Hook Up shall be of SS316 or
better suitable material.
6.6 All instrument support structural steel shall be of MS.
6.7 Piping Material Specification shall be followed for the
selection of valve material.
7 Scope 7.1 The scope covered under this specification document
shall include but not be limited to the
following.
7.2 Design, material selection, manufacture, assembly, shop
testing, Inspection at manufacturers works shipment, site storage,
installation, testing, calibration and commissioning of field
instruments.
7.3 All type of field instruments along with accessories
required for ESP to meet the efficient and safe performance of
equipment.
7.4 Process installation arrangements, Mounting Brackets,
Enclosures, Hardware/ fittings, cable glands, plugs, gland
reducers/adapters, sun shades etc. as required.
7.5 Necessary spares for the ease of Operation &
Maintenance.
7.6 Supply of all consumables like calibration kits etc.
required for commissioning and performance testing during
appropriate time.
7.7 Bidder shall indicate recommended and mandatory spares list
and quote spares.
7.8 Providing all labour, materials and equipment for Testing at
shop as required.
7.9 Procurement, Inspection of all other bought out items.
7.10 Inspection at manufacturers work
7.11 Installation, testing, calibration & commissioning
7.12 Documentation
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7.13 Inspection at site of total integrated system
7.14 Preparation and submission of drawings/documents for
approval/ information to Purchaser / consultant, as per the drawing
/ document submission schedule.
7.15 submission of Test certificates
7.16 All the scope of supply and services as indicated above but
without excluding other necessary components and services not
mentioned but necessary to complete the work in all respects
stipulated, regardless of any omission in this specification.
8 General Requirements
7.1 All materials required to make the system complete but not
specifically mentioned in this specification shall also be deemed
to be included.
7.2 All materials supplied under this contract shall be new and
unused.
7.3 The Instruments provided shall be reliable and sufficient to
meet process requirements specified in enclosed data sheets
7.4 Design of electronic instruments shall be in compliance with
the electromagnetic compatibility requirement as per IEC-61000. The
transmitter electronics shall be protected against transients
introduced by lightening and power supply surges. Transient
protection electronics shall be preferably provided in the terminal
block. The transient protection shall meet the requirements
specified in IEC-60587.
9 Pressure All pressure measuring instrument shall in general
follow below specification.
9.1 Pressure Transmitter 9.1.1 As there are chances of catalyst
carryover, all Pressure transmitters shall be Remote Seal
Capillary type to avoid impulse tube plugging.
9.1.2 Flange material shall be according to piping class but
minimum SS316 & the diaphragm material shall be minimum SS316
or better depending on process requirement. Capillary shall be of
minimum SS316 material and shall have SS 304 armouring with PVC
covering. Length of capillary shall be 5 Mtrs minimum. Seal fluid
shall be suitable for process temperature.
9.1.3 Flange for Remote Seal diaphragm pressure transmitter
shall be 2 as per ANSI B 16.5, class 300 minimum.
9.1.4 Transmitters shall be SMART, 2 wire system, 4-20 mA output
with HART protocol, 24VDC loop powered capable of delivering rated
current signal into external load of 600 ohms and will be generally
powered from vendor supplied control panel. Transmitters shall have
the capability of online calibration facility having digital
communication via open protocol (HART).
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9.1.5 All transmitters shall have integral local LCD indicator.
For indicating face shatter proof glass shall be used. All
transmitters shall have dual compartment.
9.1.6 Pressure transmitter accuracy shall be 0.075%; turndown
shall be 100:1.
9.1.7 All transmitter wetted parts in contact with the process
fluid shall be SS 316 (min) or better.
9.1.8 The process connection for the pressure transmitter shall
be 1/2 NPTF or as per ESP Bidders standard installation.
9.1.9 Cable entry to all instruments shall be NPT.
9.1.10 Over range protection shall be 130% of range or maximum
design pressure whichever is higher.
9.1.11 All pressure transmitters shall be capable of
withstanding process static pressure without permanent damage or
loss of calibration.
9.1.12 Transmitters shall be supplied with 2 Pipe mounted
brackets, clamps & suitable fasteners.
9.1.13 All hardware components, metal accessories &
fasteners supplied with transmitter shall be corrosion resistant
painted.
9.1.14 Following units of measurement shall be applicable to the
transmitter, unless indicated specifically otherwise; Transmitter
shall be configurable to these units - Engineering Unit. %
mmH2O.
9.1.15 It shall be possible to connect the HART configurator
/terminal at any location in the transmitter loop without affecting
the loop function while communication is going on between
transmitter and the configurator /terminal.
9.1.16 All transmitters shall be located outdoors and exposed to
direct sunlight. Transmitter shall perform its normal function
without any impact of direct sunlight.
9.1.17 Pressure Transmitter shall have external zero and span
adjustment with cover plate.
9.1.18 Instrument tags should be permanently attached to the
device. If this is not possible, the instrument tag should be
fastened to the instrument with stainless steel wire.
9.1.19 Accessories like snubbers for pump discharge applications
shall be considered.
9.1.20 Selection of Ranges
The ranges of the instruments shall be selected based on the
following philosophy indicated below:
For pressure and vacuum measurements, the maximum operating
pressure shall be within 70 to 80% of the maximum scale range.
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All suction measurement shall cover the negative pressure range
also and all vacuum measurements shall cover the negative pressure
as well as the positive pressure.
9.2 Differential Pressure Transmitter 9.2.1 As there are chances
of catalyst carryover, all Differential Pressure transmitters shall
be
Remote Seal Capillary type to avoid impulse tube plugging.
9.2.2 Flange material shall be according to piping class but
minimum SS316 & the diaphragm material shall be minimum SS316
or better depending on process requirement. Capillary shall be of
minimum SS316 material and shall have SS 304 armouring with PVC
covering. Length of capillary shall be 5 Mtrs minimum. Seal fluid
shall be suitable for process temperature.
9.2.3 Flange for Remote Seal diaphragm type differential
pressure transmitter shall be 2 as per ANSI B 16.5, class 300
minimum.
9.2.4 Transmitters shall be SMART, 2 wire system, 4-20 mA output
with HART protocol, 24VDC loop powered capable of delivering rated
current signal into external load of 600 ohms and will be generally
powered from vendor supplied control panel. Transmitters shall have
the capability of online calibration facility having digital
communication via open protocol (HART).
9.2.5 All transmitters shall have integral local LCD indicator.
For indicating face shatter proof glass shall be used. All
transmitters shall have dual compartment.
9.2.6 For differential pressure measurement, the transmitter
shall be able to withstand the full differential pressure on any
port of the transmitter without any damage to the sensor and
without shift in zero and calibration.
9.2.7 Differential Pressure transmitter accuracy shall be
0.075%; turndown shall be 100:1.
9.2.8 All transmitter wetted parts in contact with the process
fluid shall be SS 316 (min) or better.
9.2.9 Differential Pressure Transmitter shall have external zero
and span adjustment with cover plate. Instrument tags should be
permanently attached to the device. If this is not possible, the
instrument tag should be fastened to the instrument with stainless
steel wire.
9.2.10 The total response time for monitoring and control of
transmitters shall be of 250 millisecond or less.
9.2.11 All differential pressure transmitters shall be capable
of withstanding process static pressure without permanent damage or
loss of calibration.
9.1.21 Transmitters shall be supplied with 2 Pipe mounted
brackets, clamps & suitable fasteners.
9.2.12 Cable entry to all instruments shall be NPT.
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9.3 Pressure instruments application practices 9.3.1 The
transmitter shall have both, Over-range protection rated as per
design pressure and Under-
range protection for full vacuum.
9.3.2 The pressure and differential pressure measuring
instruments shall be located above the taps for gas and non
condensable and below the taps for liquids and condensable.
9.3.3 Pulsating service installations shall be provided with
pulsation dampeners and/or snubbers.
9.4 Pressure / Differential Pressure Switch 9.4.1 As there are
chances of catalyst carryover, Pressure Switch shall be Diaphragm
seal type with
flange connection of 2, ANSI B 16.5, class 300 minimum. Flange
material shall be according to piping class but minimum SS316.
9.4.2 When required as per standard package of ESP for efficient
and safe performance of ESP, Pressure or DP Switches shall be
considered for checking the choking conditions.
9.4.3 Pressure element shall be diaphragm with adjustable
setting.
9.4.4 Switch shall be SPDT/DPDT with 220 V AC / DC, 3 Amp
contact rating.
9.5 Pressure Gauges 9.5.1 Pressure gauges shall be ranged such
that normal operating range shall be between 30 70% of
scale; except on pulsating service where it shall be restricted
to 60 % of scale.
9.5.2 As there are chances of catalyst carryover, all Pressure
gauges shall be Direct mounted flange type or Remote seal capillary
type.
9.5.3 Flange for Remote Seal diaphragm type or direct mounted
flange type pressure gauge shall be 2 as per ANSI B 16.5, class 300
minimum. Flange material shall be according to piping class but
minimum SS316.
9.5.4 Pressure gauges shall have 150 mm minimum case size;
smaller gauges shall only be used on filter regulators and where
they are part of a pneumatic instrument.
9.5.5 Outer casing of Field pressure gauge cases shall be of SS
304.
9.5.6 All gauges shall be provided with indication in black
letters on white background. The pressure gauges shall have over
range protection of 1.3 times the maximum scale range. Where a
gauge is subjected to a greater pressure, a gauge protector shall
be used. Gauges shall be solid front with back blow out
protection.
9.5.7 All pressure gauges shall be provided with suitable
mounting arrangement.
9.5.8 Pressure gauges shall be solid front type with 3mm
shatterproof glass for 25 Kg/cm2 and above.
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9.5.9 Differential pressure gauges shall be capable of
withstanding full line static pressure on either side of the
element without damaging or affecting calibration and accuracy.
9.5.10 Where pressure pulsations are present, then glycerine
fill shall be applied to pressure gauges.
9.5.11 Bidder to supply all necessary and required accessories
for the pressure gauge.
9.5.12 For diaphragm seal gauges, Capillary shall be of minimum
SS316 material and shall have SS 304 armouring with PVC covering.
Length of capillary shall be 5 Mtrs minimum. Size of capillary
shall be selected to ensure that the response time of the gauge
shall be less than 5 seconds.
9.5.13 The sealing liquid for diaphragm seal gauges shall be
inert liquid, compatible with the process fluid and its
temperature.
9.5.14 For diaphragm seal pressure gauges with flanged ends, the
diaphragm shall be rated for the maximum allowable pressure of the
associated flange.
9.5.15 20 % Spare Pressure gauges shall be provided.
10 Flow Measuring Instruments 10.1 Any type flow meters required
for ESP as per Bidders package requirement, detail technical
specification shall be provided by Bidder to Owner/Consultant
for their approval.
11 Temperature All temperature measuring instrument shall in
general follow below specification.
11.1 Temperature Gauges 11.1.1 For local indication, gas filled
actuated dial thermometers shall be used.
11.1.2 Case and capillary compensation shall be used for filled
thermal system where required for ambient temperature changes.
11.1.3 In general 150mm dial, all angle temperature gauges shall
be used.
11.1.4 Bi-metal temperature gauges shall be of stainless steel
construction with a demountable bezel (head ring) complete with
heavy plate glass and heat resistant gasket.
11.1.5 The identifying tag number shall be neatly and clearly
marked on the back of each thermometer.
11.1.6 The scale plates of the temperature gauges shall be
anodized aluminium with white face and black figures.
11.1.7 Flange type Thermowell shall be supplied with the
temperature gauge.
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11.1.8 All gauges shall be provided with C indication. Positive
temperature range shall be in black numerals on white
background.
11.1.9 For locations at which measurement is to be taken
precludes a direct mounted thermometer, a gas or liquid filled
instrument with an external capillary (SS armour with PVC coated)
shall be used.
11.2 Thermocouples .
11.2.1 Thermocouples shall generally be Nickel-Chrome /
Nickel-Aluminium (Chromel-Alumel) ANSI Type K (Class 1) suitable
for 0-1000 C.
11.2.2 The element shall be a spring loaded assembly, mineral
insulated or provided with insulators of porcelain or better with
the transition sealed.
11.2.3 The thermocouple sheath shall be 316SS, minimum. Inconel
800 sheath for temperature greater than 600 deg C for non
sulphurous atmospheres whereas SS446 shall be considered for
sulphurous atmospheres.
11.2.4 The thermocouple head material shall be aluminium alloy,
threaded cover and entry shall be inch NPT having separate
terminals for connecting the element and the cable. Grounding
terminal shall be provided for connecting the shield of the
extension cable.
11.2.5 Thermocouples for standard applications shall be selected
from the following types:
ISA /ANSI Letter Design.
Type AWG
Temperature Range
K Chromel - Alumel 18 upto 1000 C
R Platinum 87%-Rhodium 13% -Platinum
22 Above 1000 C
11.2.6 Thermocouple material, tolerance and calibration shall be
as per ANSI MC96.Thermocouples in air pre heaters shall be straight
element type with ceramic insulators installed in a ceramic
protection tube.
11.3 Thermowell 11.3.1 Material for Thermowell shall be ANSI
type SS 316 minimum or better suitable to process
condition, machined from single bar stock in a tapered
configuration, capable of withstanding as a minimum the operating
temperature and maximum. Other materials and ratings may be
specified as per Piping Material Specification. They shall be
suitable for fluid velocities in which they are located and shall
have their Wake Frequency checked as prescribed in ASME PTC
19.3.
11.3.2 Thermowell connections to vessel or pipeline shall be 40
NB (1.5) flanged as per ANSI B 16.5 with instrument connection in
general. Their flange shall be rated as per piping class, minimum
class 300.
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11.3.3 Other process connection may be used if flanged process
connection is not possible, Bidder to take prior approval from
Owner/Consultant before manufacturing.
11.3.4 Thermowells shall be capable of withstanding the maximum
design temperature and pressure of the system. The Thermowell
flange material shall be selected based on the associated piping
class, and shall withstand the associated pressure or temperature
rating.
11.3.5 For 4" pipe and smaller, the Thermowell shall be
installed in an elbow or tee branch. When this is not feasible, the
line shall be swaged to larger size, minimum of 4". For 4" pipe and
smaller, the insertion length shall be selected such that the tip
of the temperature elements is located in approximately the centre
of the pipe.
11.3.6 For pipe sizes larger than 4" or for the vessels, the
insertion length specified shall be such that the temperature
elements are in the main flow of the pipe or vessel.
11.3.7 Vibration analysis/ wake frequency calculation shall be
carried out for all Thermowell where line velocity is higher. If
the Thermowell design fails vibration analysis, an alternate design
may be used.
11.3.8 Standout (stub end) dimension for all Thermowell should
be 200 mm.
11.3.9 Immersion Length of Thermowell shall be selected as
follows; Line Sizes Immersion Length 4 280 mm
6 & 8 300 mm 10 350 mm
16 & 18 400 mm 20 500 mm
Above immersion lengths are based on Thermowell nozzle standout
of 200 mm (between flange face and inner wall of the pipe). However
in case of special application where Thermowell nozzle standout is
larger, immersion length shall be increased in proportion with the
increase in nozzle standout.
11.4 Temperature Transmitter 11.4.1 Temperature transmitters
shall be electronic "SMART" type 2-wire, 24 VDC loop powered
output with HART Protocol and accuracy +/- 0.25 % of URV as a
minimum. Field mount temperature transmitter with integral display
shall be used in general. Temperature transmitter shall have dual
compartment. Display unit & termination assembly shall be
isolated. Head mounted transmitters are not acceptable.
11.4.2 All temperature transmitter shall have inbuilt
linearising function to produce output linear to temperature
range
11.4.3 Temperature transmitter shall be remote mounted type.
11.4.4 TC shall be fixed to a pipe clamp and the wiring tails
connected to temperature transmitter.
11.4.5 Required compensating cables shall be supplied by
Bidder.
11.4.6 All transmitters shall have local digital readouts in
engineering units.
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11.4.7 The response time of smart transmitter shall be of less
than 250ms or better.
11.4.8 In the event of failure, the output shall be driven to
predefined value or safe value.
11.4.9 Design of electronic instruments shall be in compliance
with the electromagnetic compatibility requirement as per
IEC-61000.
11.4.10 Temperature transmitter shall be provided with burn out
protection. Upscale and downscale protection shall be decided based
on the application to ensure fail safe operation for all
temperature input devices.
12 Level 12.1 Level Gauge 12.1.1 As per ESP Bidder standard
package requirement, suitable Level gauges shall be supplied.
12.2 Hopper Level Measurement 12.2.1 For ESP Hopper Level
Measurement, suitable to application, most reliable and proven
instrument shall be used.
12.2.2 Bidder to provide detail technical specification with
proven track record along with offer. Previous track record shall
be at least for 2 years satisfactory operation of Hoper level
instruments for similar application.
12.3 Bidder shall provide detail technical specification for all
the instruments which are to be required and supply for efficient
performance of ESP.
13 Identification Each instrument shall be provided with an
identification plate, with all data clearly and
indelibly stamped on a stainless steel plate, permanently
attached to the instrument by means of SS rivets or screws. In
addition, a stainless steel tag shall be provided that is
permanently attached to the instrument support wherever possible
otherwise attached by a chain or wire to the body of the
instrument.
14 Tests 14.1 Calibration test with minimum 5 points for both
rising / falling of pressure range. (Calibration
shall be carried out under reference conditions traceable to
National Standards) 14.2 Hydro test (1.5 times max. Pr.), leak test
for flow chamber/ tube wherever required.
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14.3 Material traceability test as per EN 10204. 14.4 For flow
meters, Hydrostatic test (pressure shall be as outlet flange ANSI
rating for 20
minutes.), leak test shall be as per API 598 standard. 14.5 All
tests shall be witnessed by owner/ consultant/ owners appointed
third party inspector. 14.6 Radiography shall be as per ASME B
16.34.
15 Shipping
15.1 Instruments or its parts which can be damaged during
shipment shall be packed separately in the original manufacturer
boxes. All items shall be properly packed, made see worthy and
protected from damage during shipment.
15.2 Each package shall be identified with purchase order number
and content list in a weather proof envelope.
15.3 All openings shall be sealed & threads shall be
protected with suitable caps to prevent damage.
15.4 All flanged openings shall be protected with suitable
closures to protect the flange face & instrument.
15.5 All machined surface subject to atmospheric corrosions
prior to installation on site shall be treated with easily
removable rust preventive
15.6 A desiccant shall be provided to prevent moisture damage
due to high humidity.
16 Approved Vendor List
16.1 All filed instruments required for efficient and safe
operation of ESP shall be from following approved vendor list.
Sr.No. Instruments Approved Vendor Name General Instruments Pyro
Electric 1 Temperature Gauges ANI Forbes Marshall Pyro Electric
General Instruments
2 Thermocouple
Detrive Instruments Waree Wika 3 Pressure Gauges Manometer India
Pvt. Ltd. Yokogawa Honeywell 4 Transmitters (FT, PT, DPT, TT)
Emerson Sherman Instruments (SOR) Indfoss Industires Ltd. 5
Pressure Switches Switzer Instrument Ltd.
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TECHNICAL SPECIFICATION
FOR
PLAIN AND REINFORCED
CEMENT CONCRETE WORKS
Bharat Petroleum Corporation Ltd Kochi Refinery, Ambalamugal 682
302 Ernakulam Dist. Kerala.
Mott MacDonald Consultants (India) Pvt. Ltd. Kothari House, CTS
No. 185 Off Andheri - Kurla Road Andheri (East) Mumbai 400 059
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List of Content Page No
1 Scope 6
2 Applicable Codes 6
3 Materials 7 3.1 Cement 7 3.2 Aggregates 7 3.3 Water 8 3.4
Brick Aggregates 8 3.5 Reinforcement 8 3.6 Jointing/Sealing
Materials 8 3.7 Admixtures 8
4 Storage of Materials 9 4.1 Cement 9 4.2 Aggregates 9 4.3
Reinforcing Steel 9 4.4 Miscellaneous 9
5 Grades of Concrete 9
6 Type of Concrete Mix 10 6.1 General 10 6.2 Nominal Mix
Concrete 10 6.3 Design Mix Concrete 11
7 Concrete Mix Proportioning 11 7.1 Free Water Cement Ratio 12
7.2 Consistency 12 7.3 Workability 12 7.4 Durability 13
8 Batching 14
9 Concrete Mixing 14 9.1 General 14
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10 Transportation, Placing and Compaction 14 10.1 General 14
10.1.1 Vibrators 15 10.1.2 Transportation 15 10.1.3 Placing and
Compaction 15 10.1.4 Items Embedded in Concrete 15
11 Construction Joints 16
12 Expansion Joints / Isolation Joint 16
13 Protection of Freshly Laid Concrete 16
14 Curing 16
15 Field Tests 17 15.1 Workability 17 15.2 Work Tests 17 15.3
Standard Deviation 18 15.4 Acceptance Criteria 18
16 Finishing of Concrete 19 16.1 General 19
17 Form Work 19 17.1 General 19 17.2 Cleaning and Treatment of
Formwork 19 17.3 Chamfers and Fillets 19 17.4 Reuse of forms 20
17.5 Removal of Forms/Stripping Time 20
18 Exposed / Architectural Concrete Work 21 18.1 Form Work
21
19 Reinforcement 21 19.2 Straightening, Cutting and Bending 21
19.3 Placing and Fixing 21 19.4 Splicing/Overlapping 22 19.5
Tolerance to Cover 22
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20 Grouting 22
21 Clean Up 23
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1 Scope This specification establishes the minimum requirements
of materials, quality, batching, mix proportioning, transporting,
placing, protecting, curing, repairing, finishing & testing
etc. of all types of cast-in-situ and precast concrete used in
foundations, underground and aboveground structures, floors,
pavements etc. Any special requirements as shown or noted on the
drawings shall supersede over the provisions of this
specifications.
2 Applicable Codes Apart from this specification, construction
of plain and reinforced concrete works shall be in accordance with
the Indian Standard Code of Practice for "Plain and Reinforced
Concrete" IS:456 and other relevant codes mentioned therein.
The following Indian Standards including all amendments and
revisions shall be considered as part of this specification.
IS: 269-1989 Specification for Ordinary. Rapid hardening &
Low heat Portland cement IS: 383-1970 Specification for Coarse
& fine aggregates from natural sources for concrete IS:
432-1982 Specification for mild steel and (Part I & II) medium
tensile steel bars and hard
drawn steel wire for concrete reinforcement. IS: 455-1989
Specification for Portland Blast Furnace Slag cement. IS: 456-2000
Code of Practice for Plain and Reinforced Concrete. IS: 516-1959
Methods of Tests for Strength of Concrete. IS: 650-1991
Specification for standard sand for testing of cement. IS:
1139-1966 Specification for hot rolled mild steel and medium
tensile steel deformed bars for
concrete reinforcement. IS: 1199-1959 Methods of Sampling and
Analysis of Concrete. IS: 1200-1992 Methods of measurement of
building works. IS: 1489-1991 Specification for Portland Pozzolona
Cement. IS: 1566-1982Specification for plain hard drawn steel wire
fabric for concrete reinforcement. IS: 1786-1985 Specification for
High Strength Deformed Steel Bars and Wires for
Concrete Reinforcement. IS: 1791-1985Specification for Batch
Type Concrete Mixers. IS: 2386-1963 Methods of Test for Aggregates
for Concrete: Part 3, Specific gravity, density,
voids, absorption and bulking. IS: 2396(I)-1988 Flakiness index
of aggregates IS: 2502-1963 Code of Practice for Bending and Fixing
of Bars for Concrete Reinforcement. IS: 2505-1992 Specification for
concrete vibrator immersion type. IS: 2645-2002 Specification for
integral cement water proofing material.
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IS: 2750-1964 Specification for steel scaffolding IS: 2751-1979
Recommended Practice for Welding of Mild Steel Plain and Deformed
Bars for
Reinforced Concrete Construction. IS: 2772-1982 Specification
for portable swing weigh-batchers for concrete IS: 3696-1987 Safety
code for scaffolding and ladders IS: 4014-1967 Code of Practice for
steel tubular (Part I & II) Scaffolding IS: 4031-1996 Method of
physical tests for hydraulic cement IS: 4926-2003 Ready Mixed
Concrete IS: 4990-1993 Specification for plywood for concrete
shuttering work IS: 7861 Code of Practice for Extreme Weather
Concreting. Part I-1975 Recommended Practice for Hot Weather
Concreting. Part II-1981 Recommended Practice for Cold Weather
Concreting. IS: 9013-1978 Methods of Making, Curing and Determining
Compressive Strength of
Accelerated Cured Concrete Test Specimens. IS: 9103-1999
Specification for Admixtures for Concrete. IS: 9417-1989
Recommendation for Welding Cold Worked Steel Bars for Reinforced
Concrete
Construction. IS: 10262-1982 Recommended Guidelines for Concrete
Mix Design. IS: 14687-1999 Guidelines for Formwork for Concrete
Structures. IS: 12330-1987 Specification for sulphate resisting
Portland cement.
IS: 8112-1989 Specification for 43 grade ordinary portland
cement.
3 Materials 3.1 Cement
Ordinary Portland Cement shall conform to IS: 269, Portland
Blast Furnace Slag Cement shall conform to IS: 455. Use of Portland
Pozzolana Cement shall be only with prior approval of the MMCI/BPCL
Engineer-in-charge.
3.2 Aggregates Aggregates in general designate both fine and
coarse inert materials used in the manufacture of concrete. The
fine aggregate is aggregate which passes through 4.75 mm IS Sieve.
Coarse aggregate is aggregate most of which is retained on 4.75 mm
IS Sieve.
All aggregates shall conform to IS: 383. Fine aggregate shall
consist of natural sand, i.e. river or pit sand. Coarse aggregate
shall consist of crushed gravel, natural gravel, crushed stone or
combination thereof conforming to requirements of grading and
physical properties called for. However, bank run gravel shall not
be permitted for coarse aggregates.
The fineness modules of sand should be between 2.2 to 3.2 for
concrete works.
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The maximum size of coarse aggregate shall be 38 mm except for
slabs and walls less than 250 mm thick which shall have a maximum
size of 19 mm.
Blast furnace slag and manufactured sand shall not be used as
aggregates.
3.3 Water Water used for both mixing and curing shall be free
from injurious amounts of deleterious materials and shall be of
potable quality conforming IS: 456.
3.4 Brick Aggregates The brickbats shall be new bricks well
burnt, hard durables, broken to sizes and well graded. It shall be
free from dust, earth and any other impurities.
3.5 Reinforcement Reinforcement shall be of tested quality M.S.
round rods conforming to IS:432, IRC wire mesh fabric conforming to
IS:1566, mild steel and medium tensile steel deformed bars
conforming to IS:1139 and cold twisted steel bars conforming to
IS:1786 as shown in drawings.
All reinforcement shall be clean, free from grease, oil, paint,
loose mill scale, loose rust, dust, bituminous material or any
other material or substance that will destroy or reduce the
bond.
16 SWG (1.6 mm) approved soft annealed steel wire shall be used
for binding the reinforcement bars.
Reinforcements in piles shall be High Yield Strength deformed
TMT Bars conforming to IS: 1786
3.6 Jointing/Sealing Materials All joint fillers, sealing
materials etc. used for joints in concrete shall be from approved
standard manufacturer and shall conform to relevant IS codes. The
extent, type, method of use and control shall be as per
manufacturer's recommendation, subject to approval of the MMCI/BPCL
Engineer-in-charge.
3.7 Admixtures Admixtures shall be used strictly in accordance
with the manufacturer's instructions and shall conform to the
relevant IS codes (for eg. IS: 9103). Vendor's instruction shall be
successfully incorporated in the trial mix. The extent, type,
method of use and control shall be subject to approval of the
MMCI/BPCL Engineer-in-charge in all cases.
Integral water proofing compound shall conform to IS: 2645.
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4 Storage of Materials 4.1 Cement
Cement shall be stored in a damp-proof hopper or in sealed bags
in a weather proof shed, on a floor above ground and shall be used
in the order of its delivery. Different types or brands of cement
shall be stored separately. Not more than 12 bags shall be stacked
in any tier.
4.2 Aggregates Aggregates of different sizes shall be kept
separately. Aggregates of similar grading but from different
sources or different types shall not be stored together unless
approved. All aggregates shall be stored in such a way that they
are free from contact of deleterious matter.
4.3 Reinforcing Steel Reinforcing steel members and wire mesh
which are stored at the project site shall be above ground on
platforms, skids or other supports.
Steel shall be protected from rain, moisture and kept free from
dirt, oil or contaminant injuries. 4.4 Miscellaneous
All other materials shall be stored in a weather tight and dry
place and be protected from open flame or sparks.
All packed materials shall be stored in their original unbroken
package or container.
5 Grades of Concrete Unless otherwise noted on the drawings, or
called for in the schedule of rates, the grades of concrete shall
generally be as per Table-1.
TABLE - 1
GRADES OF CONCRETE
Grade Designation Specified Characteristic Compressive Strength
of 150 mm cube at 28 days (N/mm2)
M 7.5 7.5
M 10 10
M 15 15
M 20 20
M 25 25
M 30 30
M 35 35
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M 40 40
M 45 45
M 50 50
M 55 55
Note for Table - 1 : The characteristic strength is defined as
the strength of material below which not more than five (5) percent
of the test results are expected to fall.
In the designation of concrete mix the letter M refers to the
mix and the number to the specified characteristic compressive
strength of 15 cm cube at 28 days expressed in N/sq. mm.
6 Type of Concrete Mix 6.1 General
Unless otherwise noted on drawings, all lean/plain and
reinforced concrete shall be nominal mix and design mix types,
respectively.
6.2 Nominal Mix Concrete This concrete shall be made (without
preliminary tests) by adopting nominal concrete mix with
proportions of materials as specified in Table-1 A
TABLE - 1A PROPORTIONS FOR NOMTNAT. MIX CONCRETE
Nominal mix of concrete (by mass) Quantity of water per 50 kg of
cement (max) Litres 1:5:10 60 1:3:6 34 1:4:8 45 M 15(1:2:4) 32
20(l:1l/2:3) M 34
Note: 1. The proportions of the fine to coarse aggregates should
be adjusted from upper 1. The proportions of the fine to coarse
aggregates should be adjusted from upper limit to
lower limit progressively as the grading of the fine aggregates
becomes finer and the maximum size of coarse aggregates becomes
larger. Graded coarse aggregates shall be used.
2. The cement content of the mix shall be proportionately
increased if the quantity of water in a mix has to be increased to
overcome the difficulties of placement and compaction, so that the
water-cement ratio, as specified, is not exceeded.
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6.3 Design Mix Concrete The mix shall be designed to produce the
grade of concrete having the required workability and
characteristic strength not less than appropriate values given in
Table-1. The target mean strength of concrete mix shall be equal to
the characteristic strength plus 1.65 times the standard
deviation.
As long as the quality of materials does not change, a mix
design done earlier may be considered adequate for later work.
However, in case the quality of materials changes or there is a
break in the continuity of construction and the same work is
allocated to a new contractor, the MMCI/BPCL Engineer-in-Charge
shall ask for a new design mix.
Irrespective of the grade of concrete required to be produced as
per characteristic.
The strength criteria, the minimum cement content and maximum
free water cement ratio in the design concrete shall be strictly
maintained as stipulated in Table 2A for the corresponding grade of
concrete.
The contractor at his own cost; grade the aggregates and control
the water/cement ratio, design & conduct the different trial
mixes to required strength and workability & obtain MMCI/BPCL
Engineer-in charges approval for the same. Duly approved mixes in
accordance with IS: 456 shall be used for construction.
All concrete shall be machine mixed and no hand mixing shall be
permitted. The concrete shall continuously agitate from mixing to
pouring. The use of non agitating equipment in transporting ready
mixed concrete or the use of partially hardened concrete is not
allowed.
Where reinforcement is too closely spaced for the maximum size
of aggregate in a range, the largest suitable range will be used
with the approval of the MMCI/BPCL Engineer-in-charge.
7 Concrete Mix Proportioning Proportioning, as used in this
specification, shall mean the process of determining the
proportions of the various ingredients to be used to produce
concrete of the required workability when fresh/green and strength,
durability and surface finish, when hardened. The following
information shall be collected prior to design of the concrete
mix.
a) Grade designation b) Type of cement c) Maximum nominal size
of aggregate d) Minimum cement content e) Maximum free water cement
ratio f) Workability requirements.
The MMCI/BPCL Engineer-in-Charge shall verify the strength of
the concrete mix, before giving his sanction of its use. However,
this does not absolve the Contractor of his responsibility as
regards achieving the prescribed strength as per Para 6.3. If
during the execution of the work,
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cube tests show lower strengths than required, the MMCI/BPCL
Engineer-in-Charge shall order fresh trial mixes to be made by the
Contractor. No claim to alter the rates of concrete work shall be
entertained due to such changes in mix variations. Any variation in
cement consumption shall be taken into consideration for material
reconciliation. Preliminary mix designs shall be established well
ahead of start of work.
7.1 Free Water Cement Ratio Once a mix, including its free water
cement ratio, has been determined and approved for use by the
MMCI/BPCL Engineer-in- Charge, that free water cement ratio shall
be maintained. The Contractor shall determine the water content of
the aggregates frequently as the work progresses, and the amount of
mixing water shall be adjusted so as to maintain the approved free
water cement ratio.
7.2 Consistency The concrete shall have a consistency such that
it shall be workable in the required position and when properly
vibrated it flows around reinforcing steel, all embedded fixtures,
etc. The consistency of concrete shall have to be controlled as per
IS: 456 and the slump tests shall be carried out by the contractor
in accordance with IS: 1199.
7.3 Workability 7.4.1 The concrete mix proportion shall be such
that the concrete is of adequate workability for the
placing condition and can be properly compacted with the means
available. Use of additives of approved make shall be taken
recourse to where required for attaining proper workability as
specified under Cl. 7.4.2.
7.4.2 The suggested ranges of values of workability of concrete
measured in accordance with IS:1199 are indicated in Table-2 below.
However, the actual values to be followed shall be established
depending on aggregate sizing, mix proportions, placing conditions,
etc and shall be got approved by the MMCI/BPCL Engineer-in-Charge.
At least one slump test shall be carried out per every compressive
test performed. More frequent tests shall be made if there is a
distinct change in work conditions, if required by MMCI/BPCL
Engineer-in-charge.
TABLE - 2 Values of Workability
Placing conditions Degree of workability Slump (mm)
Lightly reinforced sections in slabs, beams, walls, columns,
footings and pavements
Low 25-75
Heavily reinforced sections in slabs, beams, walls, columns,
slip- form work and pumped concrete.
Medium 50-100
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In-situ piling High 100-150
Tremie concrete Very High 150-200
7.4 Durability For achieving sufficiently durable concrete,
strong, dense aggregates, low water-cement ratio and adequate
cement content shall always be used. Workability of concrete shall
be such that concrete can be completely compacted with the means
available. Leak-proof formwork shall be used so as to ensure no
loss of cement-slurry during pouring and compaction. Cover to
reinforcement shall be uniform and as shown on drawings. Concrete
mix design shall always take into account the type of cement,
minimum cement content irrespective of the type of cement and
maximum free water cement ratio and minimum grade of concrete
conforming to the exposure conditions as given in Table-2A.
TABLE -2A Minimum Cement Content, Maximum Free Water Cement
Ratio and
Minimum Grade of Concrete for Different Exposure Conditions
Plain Concrete Reinforced Concrete
Exposure Minimum Cement Content (kg/m3)
Maximum Free
Water Cement Ratio
Minimum Grade of Concrete
Minimum Cement Content (kg/m3)
Maximum Free Water
Cement Ratio
Minimum Grade of Concrete
Mild 240 0.6 M 15 330 0.55 M 20 Moderate 265 0.6 M 15 330 0.50 M
25
Severe 275 0.5 M 20 350 0.45 M 30 Very Severe 280 0.45 M 20 375
0.45 M 35
Extreme 310 0.4 M 20 400 0.4 M 40
Generally, the following types of cement shall be used for Plain
and Reinforced concrete works:
a) 33 Grade Ordinary Portland Cement conforming to IS: 269. b)
43 Grade Ordinary Portland Cement conforming to IS: 8112. c)
Portland Slag Cement conforming to IS:455. d) Portland Pozzolana
Cement conforming to IS: 1489. e) Sulphate Resisting Portland
Cement conforming to IS: 12330
Sulphate Resisting Portland Cement shall be used only for
specific requirements depending on environmental and process
exposure conditions to which the structures may be subjected to
like high sulphate concentrations, processes involving sulphur
handling etc.
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The minimum cement content as mentioned in Table-2A shall be
adjusted for aggregates other than 20mm nominal maximum size. The
minimum cement content in the concrete mix shall be increased by
40kg/m3 and decreased by 30 kg/m3 for 10mm and 40mm nominal maximum
size aggregates respectively.
8 Batching 8.1 No substitutions in materials used on the work or
alterations in the established proportions,
except as permitted in 6.4 shall be made without additional
tests to show that the quality and strength of concrete are
satisfactory. In case the Contractor proposes any change in the
already approved mix design, fresh mix design with supportive
laboratory tests shall be submitted to the MMCI/BPCL
Engineer-in-Charge and his approval has to be obtained prior to
using the revised mix proportion in the works. However, such
proposals for revision shall only be entertained in case of
successive failure of test cubes to achieve the required
strength.
9 Concrete Mixing 9.1 General
The mixing of concrete shall be strictly carried out in an
approved type of mechanical concrete mixer. The mixer shall be
fitted with water measuring devices. The mixing shall be continued
until there is a uniform distribution of the material and the mass
is uniform in colour and consistency. If there is segregation after
unloading from the mixer, the concrete shall be remixed.
Use of Ready Mixed Concrete supplied by Ready Mixed Concrete
Plants or from on/off-site batching plants (IS: 4926) shall be
preferred for structural concrete.
All records and charts for the batching and mixing operations
shall be prepared and maintained by the contractor as per the
instructions of MMCI/BPCL Engineer-in-Charge.
Hand mixing of concrete shall not be permitted. However, for
non-critical applications namely foundations for crossovers,
isolated operating platforms etc. using concrete of maximum grade
M20 and located at far away isolated places, this may be permitted
by the MMCI/BPCL Engineer-in-charge as a special case.
10 Transportation, Placing and Compaction 10.1 General
The entire concrete placing programme including transportation
arrangements, deployment of equipment, layout, proposed procedures
and methods, shall be submitted to the MMCI/BPCL Engineer-in-Charge
24 hours prior to concreting for approval. No concreting shall be
placed until his approval has been received. Approval of the
MMCI/BPCL Engineer-in-Charge for pouring concrete shall be taken as
'conveyed', when the concrete pour card is signed by him.
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10.1.1 Vibrators 10.1.1.1 In placing concrete in layers which
are advancing horizontally as the work progresses, great care
shall be exercised to ensure adequate vibration, bonding and
moulding of the concrete between the succeeding batches.
10.1.1.2 The vibrator shall penetrate the layer being placed and
also penetrate the layer below while the under layer is still
plastic to ensure good bond and homogeneity between the two layers
and prevent the formation of cold joints.
10.1.1.3 Care shall be taken to prevent contact of vibrators
against all embedded reinforcing steel or inserts. Vibrators shall
not be allowed to come in contact with forms.
10.1.2 Transportation 10.1.2.1 All concrete shall be conveyed
from the mixer to the place of final deposit such as formwork
as
early as possible using suitable buckets, dumpers, pumps,
transit mixers containers or conveyors which shall be mortar leak
tight. Care shall be taken to prevent the segregation or loss of
the ingredients and maintaining the required workability. For
structural concrete produced from Ready Mixed Concrete Plants as
per Cl. 9.1, concrete shall be transported from the plants to the
sites only by transit mixers.
10.1.3 Placing and Compaction 10.1.3.1 Before placing concrete,
all soil surfaces upon which or against which concrete is to be
placed
shall be well compacted and free from standing water, mud or
debris. Soft or yielding soil shall be removed and replaced, with
lean concrete or with selected soils/sand and compacted to the
density as directed by MMCI/BPCL Engineer-in-Charge. The surface of
absorptive soil (against which concrete is to be placed) shall be
moistened thoroughly so that moisture is not drawn from the freshly
placed concrete. Similarly, for concrete to be placed on formworks,
all chippings, shavings and sawdust etc. shall be removed from the
interior of the forms before the concrete is placed.
Concrete shall be placed within a maximum period of 25 minutes
of its removal from mixture.
10.1.3.2 Concrete shall not be placed until the formwork, the
placement of reinforcing steel, embedded parts, pockets etc. have
been inspected and approved by the MMCI/BPCL Engineer- in-Charge.
Any accumulated water on the surface of the bedding layer shall be
removed by suitable means before start of placement. No concrete
shall be placed on a water covered surface.
10.1.4 Items Embedded in Concrete 10.1.4.1 Concreting shall not
be started unless the electrical conduits, pipes, fixtures etc.,
wherever
required, are laid by the concerned agency. The Contractor shall
afford all the facilities and maintain co-ordination of work with
other agencies engaged in electrical and such other works as
directed by the MMCI/BPCL Engineer-in-Charge.
10.1.4.2 Anchor bolts shall be set to template and firmly
tied/fixed in vertical & horizontal line at all required
positions.
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10.1.4.3 All embedment, inserts etc. shall be fully held and
secured in their respective positions by the concerned agencies to
the entire satisfaction of MMCI/BPCL Engineer-in-Charge so as to
avoid any dislocation or displacement during the concreting
operations. The Contractor shall take all possible care during
concreting to maintain these embedment/inserts in their exact
locations.
11 Construction Joints 11.1 Construction joints shall be
provided in position as shown or described on the drawings or
as
directed by the MMCI/BPCL Engineer-in-Charge. Such joints shall
be kept to the minimum. These shall be straight and at right angles
to the direction of main reinforcement and shall be placed at
accessible locations to permit cleaning out of laitance, cement
slurry and unsound concrete.
12 Expansion Joints / Isolation Joint 12.1 Expansion/ Isolation
joints in structures shall be formed in the positions and to the
shapes shown
in the relevant drawings. Joints shall be filled with joint
filling material as stipulated in the drawings/schedule of rates.
Isolation joints shall be provided around all equipment
foundations, columns, pedestals, trenches etc. on grade.
13 Protection of Freshly Laid Concrete 13.1 Newly placed
concrete shall be protected, by approved means, from rain, sun and
wind.
Concrete placed below the ground level shall be protected from
falling earth during and after placing. Surface shall be kept free
from contact with such ground or with water draining from such
ground during placing of concrete for a period of at least 3 days,
unless otherwise directed by the MMCI/BPCL Engineer-in-Charge. The
ground water around newly poured concrete shall be kept to an
approved level by pumping or other approved means of drainage and
adequate steps shall be taken to prevent floatation and flooding.
Steps shall be taken to protect immature concrete from damage by
debris, loading, vibration, abrasion, mixing with deleterious
materials that may, in the opinion of the MMCI/BPCL
Engineer-in-Charge, impair the strength and/or durability of the
concrete.
14 Curing 14.1 Concrete shall be cured by keeping it
continuously moist wet for the specified period of time to
ensure complete hydration of cement and its hardening. Curing
shall be started after 8 hours of placement of concrete in normal
weather, and in hot weather after 4 hours. The water used for
curing shall be of the same quality as that used for making of
concrete. Curing shall be assured by use of an ample water supply
under pressure in pipes, with all necessary appliances such as
hose, sprinklers etc. A layer of sacking, canvas, hessian, or other
approved material, which will hold moisture for long periods and
prevent loss of moisture from the concrete, shall be used as
covering. Type of covering which would stain, disfigure or damage
the concrete, during and after the curing period, shall not be
used. Only approved covering shall be used for curing. Exposed
surfaces of concrete shall be maintained continuously in a damp or
wet condition for at least the first 7 days after placing of
concrete.
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14.2 For concretes containing Portland pozzolana cement or
Portland slag cement, the curing period as given in 14.1 shall be
doubled. Curing by ponding shall, however, commence after the first
24 hours of concreting.
15 Field Tests 15.1 Workability 15.2.1 The concrete mix
proportion so chosen, shall be such that the concrete is of
adequate workability
for the placing condition and can be property compacted with the
means available.
15.2.2 The suggested ranges of values of workability of concrete
measured in accordance with IS: 1199 are indicated in Table-5.
TABLE -5
Placing Conditions Degree of Workability Value of
Workability
Concreting of shallow section with vibration Very Low
20-10 seconds, Vee Bee time or 0.75 - 0.80, Compacting
factor
Concreting of lightly reinforced sections with vibration
Low 10-5 seconds, Vee Bee time or 0.8 - 0.85, Compacting
factor
Concreting of lightly reinforced sections without vibration, or
Heavily reinforced sections with vibrations
Medium
5-2 seconds, Vee Bee time or 0.85 - 0.92, Compacting factor or
25-75 mm, slump for 20 mm aggregate
Concreting of heavily reinforced sections without vibrations
High
above 0.92, Compacting factor or 75-125 mm, slump for 20 mm*
aggregate
* For smaller aggregate the values will be lower.
15.2 Work Tests 15.2.1 Over the full period of construction, the
contractor shall carry out work tests of concrete at his
own cost. Sampling from fresh concrete shall be taken as per IS:
1199 and cubes shall be made, cured and tested in accordance with
IS: 516. The number of specimen to be tested and their criteria for
acceptance shall be according to IS: 456. Frequency of work tests
shall be as indicated below:
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15.2.2 Frequency of Tests
15.2.2.1 Unless otherwise specified, for each grade of concrete,
sets of test cube, each set consisting of three (3) twin specimens
(i.e. total 6 Nos.) shall be taken. Number of sets shall generally
be calculated based on the types and corresponding volumes of work
as indicated hereunder unless otherwise directed by the MMCI/BPCL
Engineer-in-charge
Mass Concrete Foundations
: For every 100 Cu. M of concrete placed, one set but not less
than one set for each pouring of concrete
Equipment and building Column foundations :
: For every 50 Cu. m of concrete placed one set but not less
than one set for each pouring of concrete
Frame & thin walled Structural components Columns, beams,
slabs etc.
: For every 30 Cu. m of concrete placed one set but not less
than one set for each pouring of concrete
15.2.2.2 The test cubes shall be sampled in presence of the
MMCI/BPCL Engineer-in-charge, who will also sign the record of
testing in an agreed format.
15.2.2.3 For testing the cube specimen contractor shall
establish his own construction laboratory at site and the cost of
testing of cubes shall be borne by him.
15.2.2.4 Supply of all required consumables, construction and
erection materials including but not limited to gauges, welding,
brazing, gasses and rods, electrodes, oxygen, acetylene, fuel,
bolts, nuts and temporary support etc. shall be by contractor at no
extra cost.
15.3 Standard Deviation Standard deviation shall be calculated
as given in IS: 456.
15.4 Acceptance Criteria 15.4.1 The concrete shall deemed to be
accepted if it fulfils the requirements laid down in IS: 456.
15.4.2 lf the concrete does not comply with IS: 456, the
structural adequacy of the parts affected shall be investigated and
any consequential action as needed shall be taken up by the
contractor at his own cost. Concrete of each grade shall be
assessed separately. Concrete shall be assessed daily for
compliance. Concrete is liable to be rejected if it is porous or
honey-combed; its placing has been interrupted without providing a
proper construction joint; the reinforcement has been displaced
beyond the tolerances specified; or construction tolerances have
not been met. However, the hardened concrete may be accepted after
carrying out suitable remedial measures to the satisfaction of the
MMCI/BPCL Engineer-in-charge.
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16 Finishing of Concrete 16.1 General On striking the formwork,
all surface defects such as bulges, ridges and honey-combing
etc.
observed shall be brought to the notice of the MMCI/BPCL
Engineer-in-Charge. The MMCI/BPCL Engineer-in-Charge may, at his
discretion allow rectification by necessary chipping and packing or
grouting with concrete or cement mortar. However, if honey-combing
or sagging are of such extent as being undesirable, the MMCI/BPCL
Engineer-in-Charge may reject the work totally and his decision
shall be binding. No extra payment shall be made for rectifying
these defects, demolishing and reconstructing the structure.
However, quantity of cement actually used for this purpose may be
considered for reconciliation of materials. All burrs and uneven
faces shall be rubbed smooth with the help of carborundum
stone.
The surface of non-shuttered faces shall be smoothened with a
wooden float to give a finish similar to that of the rubbed down
shuttered faces. Concealed concrete faces shall be left as from the
formwork except that honey-combed surface shall be made good as
specified above. The top faces of slabs not intended to be covered
shall be levelled and floated to a smooth finish to the rises or
falls shown on the drawings or as directed. The floating shall not
be executed to the extent of bringing excess fine materials to the
surface. The top faces of slabs intended to be covered with screed,
granolithic or similar finishes, shall be left with a rough
finish.
17 Form Work 17.1 General 17.1.1 Forms for concrete shall be of
plywood conforming to IS: 6461 or steel or as directed by the
MMCI/BPCL Engineer-in-Charge and shall give smooth and even
surface after removal thereof.
17.1.2 If it is desired by the MMCI/BPCL Engineer-in-Charge, the
Contractor shall prepare, before commencement of actual work,
design and drawings for formwork and get them approved by the
MMCI/BPCL Engineer-in-Charge. For details regarding design,
detailing etc., reference may be made to IS: 14687.
17.2 Cleaning and Treatment of Formwork The surfaces of forms
that would come in contact with concrete shall be well treated with
approved non- staining form release agents such as soft soap, oil,
emulsions etc. Release agents shall be, applied so as to provide a
thin uniform coating to the forms without contaminating the
reinforcement.
17.3 Chamfers and Fillets All corners and angles shall be formed
with 45 degree mouldings to form chamfers or fillets on the
finished concrete. The standard dimensions of chamfers and fillets,
unless otherwise detailed or specified shall be 25x25mm. For
heavier work chamfers or fillets shall be 50x50mm. Care shall be
exercised to ensure accurate mouldings. The diagonal face of the
moulding shall be planed or surfaced to the same texture as the
forms to which it is attached.
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17.4 Reuse of forms Before reuse, all forms shall be thoroughly
scrapped, cleaned, examined and when necessary, repaired and
retreated, before resetting. Formwork shall not be reused, if
declared unfit or un-serviceable by the MMCI/BPCL
Engineer-in-Charge.
17.5 Removal of Forms/Stripping Time In the determination of
time for removal of forms, consideration shall be given to the
location and character of the structures, the weather and other
conditions including the setting and curing of the concrete and
material used in the mix.
Forms and their supports shall not be removed without the
approval of the MMCI/BPCL Engineer-in-Charge. Forms shall not be
released until the concrete has achieved a strength of at least
twice the stress to which the concrete may be subjected at the time
of removal. The formwork shall be removed without shock and methods
of form removal likely to cause over stressing' or damage to the
concrete, shall not be adopted. Supports shall be removed in such a
manner as to permit the concrete to uniformly and gradually take
the stresses due to its own weight.
In normal circumstances when average air temperature exceeds 15
degree Celsius during the period under consideration after pouring
of concrete and where ordinary Portland cement is used, forms may
generally be removed after expiry of following periods.
(a) Walls, columns and vertical faces of all 16 to 24 hours as
may be decided by structural members the MMCI/BPCL
Engineer-in-Charge.
(b) Slabs (props left under) 3 days
(c) Beam Soffits (props left under) 7 days
(d) Removal of props under slabs:
Spanning upto 4.5m. 7 days
Spanning over 4.5m 14 days
(e) Removal of props under beams and arches:
Spanning upto 6m 14 days
Spanning over 6m 21 days
(f) Cantilever Construction Formwork shall remain till
structures for counter acting or bearing down have been erected and
have attained sufficient strength (minimum 14 days).
Notes:
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1. For other cements, the stripping time recommended for
ordinary Portland cement shall be suitably modified as per the
instructions of the MMCI/BPCL Engineer- in-Charge.
2. The number of props left under, their sizes, supporting
arrangement, and disposition shall be such as to be able to safely
carry the full dead load of the slab, beam or arch as the case may
be together with any live load likely to occur during curing or
further construction.
3. Where the shape of the element is such that the formwork has
re-entrant angles, the form work shall be removed as soon as
possible after the concrete has set, to avoid shrinkage cracking
occurring due to the restraint imposed.
4. For rapid hardening cement, 3/7 of the above mentioned
periods shall be considered subject to a minimum of 16 hours.
18 Exposed / Architectural Concrete Work 18.1 Form Work
Other things remaining same as per clause 20.0, formwork shall
be of high quality. Care shall be taken to arrange the forms so
that the joints between forms correspond with the patter