GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED MTA PAC PROJECT ANNEXURE 6.4 SECTION 5 CONSTRUCTION PHILOSOPHY

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1 5.1 OVERALL 1.0 Scope: This document outlines the overall philosophy for Construction work for PAC Project at GNFC, Bharuch. 2.0 Equipment / piping / machinery / structural material & all other components forming a part of the Project shall be safely received, unloaded, transported & stored by the Contractor. 3.0 Installation of static equipment shall be as outlined in Section Installation of pumps, compressors and drives as per the Section Fabrication and erection of above ground / underground piping including piping support, will be according to respective Section. 6.0 Removal of site office, workshop & other temporary facilities arranged by Contractor after acceptance of plant by GNFC. Contractor shall follow all the safety rules & regulations of GNFC. Safety Manual is attached. 8.0 GNFC shall provide construction utilities like construction power & water at one point. Distribution of the same shall be the Contractor s responsibility. 9.0 Supply of manpower for assistance during commissioning for small activities without any additional cost is included House Keeping: The contractor should ensure cleaning of area on daily basis & should follow ISO Guidelines 5.2 PLANNING 1.0 SCOPE This specification provides guide line for activities of Site Planning, Progress Control, and reporting at site. The Contractor shall mobilize at site, adequate number of Computers for proper planning, scheduling, material control, progress reporting & execution of the Project. 1

2 2.0 DETAILED SCHEDULE The Contractor shall prepare detailed schedule using Project Monitoring Soft wares like PRIMA VERA, etc. 3.0 FABRICATION AND ERECTION 3.1 The following information shall be clearly indicated for each activity: Reference quantities Estimated Erection duration Weight percentage assigned to that activity Starting date Completion date Monthly expected progress by activity and by work area The actual progress of the activities shall be monitored weekly/monthly compared with the planned one and update in the schedule. and shall be The following information shall be clearly indicated for each activity. Weekly/monthly and cumulative planned quantities to be executed Weekly/monthly and cumulative actual quantities executed 3.2 REPORTING In addition to the above referenced schedules, Contractor shall produce daily, weekly, monthly reports. Format of the report shall be as per mutual understanding between Contractor, and Owner. However format of reports shall be produced by contractor and approved by Owner. 4.0 CONTRACTOR S DAILY REPORT 4.1 Contractor shall submit a daily report of manpower and major activities as follows: Consolidated Daily Labor Report A- This report relevant to actual manpower in site split up by discipline, work area, main activities has to be submitted by Contractor to Manager before 10 a.m. each morning for same day. B- Daily Production (Fitup, Welding, NDT, Erection etc.) Records along with NDE data, if any C- Welder s Work Records. 4.2 Contractor shall sequentially number the daily reports for each calendar day of site activities. 2

3 5.0 CONTRACTOR S WEEKLY REPORT 5.1 Contractor shall submit weekly progress report to Owner as per agreed cut off and submission date as per agreed format. The contents of the report shall be generally the same as described and the following: Weekly Production (Welding) Records along with NDE data, if any. The records on progressive evaluation of welder s weekly performance. Such weekly report shall be discussed during a weekly progress meeting to be held at site between Contractor and owner, if required. 6.0 DOCUMENT SCHEDULE Contractor shall submit all documents to Owner as per the document schedule. Document schedule shall be the part of the ITB. Documents to be submitted by Contractor shall be in the format approved by Owner. 5.3 EQUIPMENT 1.0 General Scope This document shall outline Contractor s scope of work for static equipment erection. Following activities will be carried out by the Contractor: Check & make good Civil foundation for equipment. Prepare Erection Scheme for the Heavy Lifts. Check vertical alignment using Theodolite only. Shall arrange for testing of Crane. 2.0 Contractor shall not use any column or member of foundation for dragging or lifting the equipments. Foundations and Columns are not designed for the same. 3.0 The actual dimensions taken during alignment such as heights, deviations from the horizontal and vertical etc. shall be recorded on forms supplied to Contractor by the Owner. 4.0 TOLERANCES Following tolerances are valid for fine alignment: Height tolerance for vertical equipment : + / - 1 mm measured at the base ring or foot plat Height tolerance for horizontal equipment: +/- 1 mm when supports are fixed to the foundation +/- 3 mm for sliding supports 3

4 Vertical deviation shall not exceed: 0,2 mm/mt. for columns 0,3 mm/mt. for separators, heat exchangers etc. As a measurement datum the average from various measurements taken of the vessel shall be used. Any deviations over the tolerances needs the written approval of the GNFC. 5.0 LIFTING EQUIPMENT AND TOOLS All construction equipment which is to be used for the execution of the equipment erection shall be in first-class operating condition, safe, fit for the uses for which intended and suitable for the safe and efficient performance of the work. Crane shall not be loaded over 85% of the permitted limit. The load on a rope shall not exceed 25% of the breaking load for shackles and slings. The allowable load for shackles and slings are restricted from 10% to 12,5% of the breaking load. Cables with strands and wires wound in the same direction (long lay) shall only be for guided loads. Two cranes are to be used if length, weight or another special feature predominates. Cross ties are to be used in the event when a tall upright item has to be lifted by 2 Cranes. There shall be no removal or transfer of any of the lifting equipment from the site without the prior written approval of the GNFC. For unloading or lifting the equipment use the weight from the Collie/ Packing list and not the weight stated in the drawing or Inquiry. 6.0 ERECTION PROCEDURE Equipment nozzles shall not be used for lifting. A crane shall not be used for back movement during lifting. When lifting non-ferrous or painted vessels and equipment, hemp ropes, special supports or cross ties shall be used to avoid damage. In the range of the steel wire rope the corner of the aluminum heat exchanger must be protected against damaging with angles out of la-sheet-metal. Prior to lifting thin walled vessels or soft material vessels such as aluminum, all necessary action shall be taken to avoid crushing of the vessel during lifting. Care shall be taken that the guide rope can move unrestricted while lifting equipment. Guidelines shall be used for each piece of equipment during lifting. Shim sheets or plates shall not protrude out past base plates or foot flanges. Shim sheets or plates shall be deburred and planed. Wedges and temporary packing shall be removed after equipment is leveled. 4

5 5.4 MACHINERY 1.0 Scope Scope includes Installation of a machinery item in accordance with the Installation Instructions of the supplier of the Machine. 2.0 Assembly & installation of the coupling and alignment of the machinery. Alignment shall be carried out using Dial Gauges only. The alignment of the machinery shall not get disturbed more than +/-0.03 mm (unless otherwise specified by the manufacturer) in both directions(axial & radial) during assembly and disassembly of the piping connections. 3.0 Progress Report & Data Contractor shall submit to GNFC all information regarding the activities of the machinery erection, on a weekly basis. This information shall consists of: Date of receipt of machinery Date of machinery erection; Date of first preservation; Date of rotation by hand (at least alternate days, unless otherwise stipulated in the manufacturers instructions); Date of first alignment; Date of checking the stress relieving of the piping connections and final machinery alignment; Date of motor or machine test run; Date of last renewal of preservation agent; Date when machinery is ready for operation. Date of acceptance of machinery by owner 4.0 Records 4.1 After completion, a certificate of final alignment acceptance report shall be issued for each machinery. The certificate shall contain the following data: The values of the first and final alignment; The actual tolerances of the connecting flanges; 5.0 ERECTION PROCEDURE 5.1 In case anchor bolts are not installed, bolts shall be unpacked and anchor bolt pockets shall be cleaned. Dosing pump foundation shall be checked for accessibility of oil drainage plug and bottom cover of dosing pump. 5.2 The machinery is to be placed onto the foundation in accordance with the appropriate X-Y-Z coordinates. 5

6 5.3 Shim plates or sheets shall not protrude out of base plates or foot flanges. Shim shall not be stacked in more than three (3) layers. Wedges and temporary packing shall be removed after machinery is leveled. After the proper alignment the base plates shall be grouted after the shuttering by planking boards on each side of the foundation. After the hardening time of the grout, the machine must be realigned and all anchor bolts shall be tightened according to the manufacturer s instructions. Observe special instructions of the machine manufacturer. The grouting shall equally distribute the static and dynamic forces from the machine to the foundation. Only non-shrinking, non-metallic, free of chloride, oil-resistant and easy fluidity grout (size 0-3 mm, crushing strength after 28 days ca N/mm2, deflection strength after 28 days ca N/mm2) shall be Used. 6.0 ALIGNMENT OF MACHINES 6.1 Machine to driver shaft alignment must be set to the values given by the machine manufacturer. Stress free connection of the piping must be assured. During check of the rotation, motor has to be disconnected from pump, compressor etc. During the check of the over speed trip, turbine has to be disconnected from pump, compressor, generator etc. Alignment shall be accepted and documented on prescribed format only after ensuring stress free piping connection with machine. Alignment readings shall be recorded when piping is disconnected and when piping is connected to the machine. Factors of influence: Elevation of base frame, Bearing from base to sectional joint, Diameter of journal, Oil film thickness Limits of alignment: Final alignment shall be executed acc. the different conditions between each machine from the manufacturer. Alignment and checking of alignment shall be made several times to ensure the most possible accuracy. Measuring devices: Dial gauges (scale 0,01 mm) with supports, filler gauges and high precision instruments. 6.2 All outside connected machine parts that may be damaged during the erection shall be removed, marked and stored properly. 7.0 FINAL ALIGNMENT The acceptance protocol for the final alignment can only be signed if the pipes are bolted up. An acceptance protocol has to be provided with disconnected and connected 6

7 pipes. Stress free connection of the connection piping must be assured. During check of rotation, motor has to be disconnected from pump, compressor also. During check of overspeed trip, turbine has to be disconnected from pump, compressor, generator a.s.o. Machine to driver shaft alignment must be set to the values, given by the machinery manufacturer PIPING 1.0 SCOPE:- This specifications outlines the scope of work for the fabrication, installation and testing of the above ground piping. The scope shall includes but not limited to the following activities: Identification of the Material as per the Pipe Class indicated on the drawing. Identification of the Shop & Field Joints. Ensuring availability of WPS / PQR for the relevant pipe classes. Prefabrication. NDT for prefabricated spools & attending repairs. Shifting prefabricated spools to site, erection, & field joints. NDT for field joints and attending repairs. Mechanical completion, including installation of all supports, inline instrumentation, etc. Removal of inline instruments & providing spools for Hydro Test & flushing. Preparation for & completion of Hydro Testing. Draining of Hydro Test Water. Flushing & Drying. Card Board Blasting, for Process Piping. Removal of licking devices from Spring supports. Preparation of Loop Files in triplicate. Handing over for further activities. 2.0 Performance of radiographic examination of weld on all types of piping including provision of all necessary equipments with radioactive source, developing room with air conditioner, consumables and whatever else even though not expressly mentioned here in but required to perform the work up to radiography interpretation as per specifications and instructions of GNFC / Third Party Inspection Agency. Film quality should be D4 for S.S. material while for C.S. it shall be D7/D4 or its equivalent of approved make to obtain quality of image. Contractor shall arrange higher curry source to take radiography in limited time. 7

8 3.0 Contractor shall also provide all facilities for evaluation of films. 4.0 Contractor shall use welding electrodes, filler wire, flux etc. from following manufacturers only. - Advani Oerlikon - D & H Secheron - ESAB 5.0 Stress reliving (PWHT) of the weld joints as per specifications & code requirement. 6.0 Statutory Approval All activities related to statutory approvals shall be as per Annexure PROGRESS REPORT SCHEDULE AND DOCUMENTATION 7.1 Contractor shall schedule and coordinate all planning, supervision and progress activities. Contractor shall promptly submit such schedules, reports to the GNFC. 7.2 Contractor shall prepare & submit complete documentation, as built drawings and isometrics to GNFC. 7.3 The final documentation shall consist of As built marked drawings / plans / isometrics. 7.4 Contractor shall prepare Test Loop File for individual test loop. Each loop file will consist of : Section of P & I D of the loop. As Built piping isometric with joint numbers & welder number duly marked. Line History sheet comprising of fit up release, weld joint visual clearance, correctness as per Isometric, etc. NDT Records such as DP / MP / RT. PWHT * PWHT hardness recods, if any. Final Hydro Test report. Flushing / drying / card board blasting reports. 8.0 Welders will be qualified under relevant ASME Codes. 9.0 QA / QC activities by the Contractor will be done under Third Party Inspection agency, as appointed by GNFC during the Project Execution. 5.6 FLUSHING 1.0 SCOPE 8

9 This specification defines the basis for cleaning and flushing operations in connection with hydrostatic testing as outlined in the Specification for testing in the field of equipment and piping 2.0 FLUSHING MEDIUM Stainless steel piping shall be flushed with potable water or raw water with a ph-value not over 7.0. Carbon steel and alloy piping shall be flushed with potable or raw water. In special cases piping shall be blown out with oil-free air. 3.0 DURATION FOR FLUSHING In an open system, flushing shall be continued until flush water leaving the system is clear and free from all foreign debris. In a closed system, flushing shall be continued until circulating pump strainer is free from foreign debris and circulating water is clear. Unless otherwise agreed, flushing and cleaning operations shall be performed during normal working hours. 4.0 General Requirement: Flushing and blow-out operations shall be performed by qualified and skilled personnel acquainted with the technology of flushing. Contractor is responsible for all damages occurring during flushing - or blow out activities GNFC shall be informed before the start of any flushing or blow-out activity. A work schedule shall be submitted to GNFC for approval. Contractor shall prepare an adequate number of spool pieces for temporary replacements. Flushing operations shall be carried out in connection with hydrostatic testing of complete system. Wherever possible, flushing should be arranged prior to the start of pressure test. The above practice minimizes the number of flange connections to be opened after successful pressure testing. In order to avoid wastage of expensive gaskets, all temporary connections for the flushing operation will be installed using temporary gaskets, resistant against the pressure and temperature of flushing operations. Contractor shall restore all systems to their original condition after flushing as required by GNFC. Contractor shall provide suitable connections to hydrants and drainage to sewers for circulating water. Contractor shall provide circulation and/or flushing pumps. Contractor shall provide suitable temporary pipe connections, hose connections, blind flanges, temporary gaskets, temporary strainers and dummy spools as required for flushing and steam blowing. 5.0 REQUIREMENTS CONCERNING INSTRUMENTS AND EQUIPMENT 5.1 Control instruments : In general all instruments in the system to be flushed must be isolated from the test by test blinds or removed unless otherwise permitted by GNFC. 9

10 Relief valves and rupture discs shall be removed or blanked off from equipment or piping system prior to flushing/ testing. Contractor shall ensure that instrument removal for flushing is performed by skilled craftsmen. Orifice plates flow nozzles or other similar restrictions normally shall not be installed until the system is flushed. Control valves DN < 200 (8 ) will be removed. If there is no by-pass a spool piece shall be installed. All control valves not removed (welded or diameter nominal > 200 (8 ) will be opened prior to flushing at 100% and stay open during flushing activities. Line mounted instruments such as Rotameters and positive displacement meters shall be removed and spool pieces shall be installed instead. In case of an existing by-pass, the open ends will be flushed shortly and blinded. Locally mounted pressure gauges shall be blocked off or removed and their connections to be plugged during flushing. Level instrument floats located inside vessels or float cages shall be blocked off and opened to the air. 5.2 Vessels : Vessels may only be flushed if the feed line has been thoroughly cleaned before. To flush into columns, special permission from GNFC will be necessary. Where possible, all connecting pipes should be flushed starting from the vessel in order to avoid disassembling of flange connections. Filling of those vessels will be done using the deepest possible point for flushing connection. Flushing into tanks is only allowed providing the tank will be thoroughly cleaned after flushing. 5.3 Rotating equipment Pumps, compressors, turbines will never be flushed. Flange connections of these equipments will be disconnected prior to flushing and the above equipments must be protected with blinds. 5.4 Heat Exchangers : Heat Exchangers may be flushed through if the feed line is thoroughly cleaned before. Exception : Plate heat exchangers shall always be blanked off. 6.0 RECORDING The flushing or blowing-out shall be recorded in the test documents, the socalled Pressure circuits. After the flushing or blowing-out is finished, the documents shall be signed by all parties concerned to certify that the system is satisfactorily flushed/blown out and clean. 10

11 4.5.7 SAFETY All construction activities will be executed in the safest possible ways. On mobilization of the Contractor, Safety Manual will be issued to him which shall be strictly adhered to throughout during the execution of the Project. 11