Tender 1142 Section C2

TENDER No.
CMM/MEQ/25-26-2-1142
SECTION – C
SECTION-C CONSIST OF:-
1. SECTION C-2: TECHNICAL SPECIFICATION

FOR ERECTION OF ITEMS
EPC-03
0
Kudankulam Nuclear Power Project 3&4 Document No.I01.KK34.0.0.MRR.TS.P001
TECHNICAL SPECIFICATION FOR

ERECTION OF MATERIAL HANDLING EQUIPMENTS (MHE)
REVISION CONTROL SHEET
Document Number
I01 KK34 0 0 MRR TS P001
Title
TECHNICAL SPECIFICATION
FOR
Details of revision
Sr.No. Revision Date of issue No.of

Reasons for revision
No. pages
1 0 15.05.2017 49
SOQR item numbers and Annexure-2

2 1 03.08.2017 49
list of Free issue materials are revised.
Inclusion of Trestle metal structure
erection specification, Annexure-2 list
3 2 28.02.2018 51 of Free issue materials and Annexure-3
QAP format for guidance are revised
due to revision of TTS.
Date of issue Revision No Page Number

28 February 2018 2 Page 2 of 50

Content:
1. INTRODUCTION
2. SCOPE OF WORK
3. REFERENCE DRAWINGS, DOCUMENTS & SPECIFICATIONS
4. RECEIPT, TRANSPORATATION & STORAGE OF FREE ISSUE MATERIALS
5. SEQUENCE OF ERECTION ACTIVITIES
6. INTERFACING WITH OTHER AGENCIES
7. PREPARATION OF PROCEDURES & QAP
8. MANUFACTURER’S INSTRUCTION AND SUPERVISION
9. ASSEMBLY, WELDING AND ERECTION OF EQUIPMENT
10. ERECTION OF STRUCTURAL STEEL INCLUDING TRESTLE STRUCTURES
11. WELDING REQUIREMENTS
12. QUALITY ASSURANCE
13. COMMISIONING AND TESTING OF EQUIPMENT
14. GRIT BLASTING AND PAINTING
15. ELECTRICAL GROUNDING OF EQUIPMENTS
16. GENERAL TECHNICAL REQUIREMENTS
17. HOUSEKEEPING & CLEANLINESS
18. RECORDS AND REPORTS
19. COMPLETION OF WORK AND SUBMISSION OF CCC & MATERIAL ACCOUNTING
20. CONFIDENTIAL INFORMATION
21. PATENTS AND PATENT RIGHT INDEMNIFICATION
Annexure-1--- List of sample drawings

Annexure-2--- List of free Issue Materials
Annexure-3--- QAP format for guidance


1. INTRODUCTION:
This section defines the general technical requirements for “Handling, transportation, pre-
fabrication, pre-assembly, assembly, welding, erection, inspection, commissioning, load
testing and handing over of the material handling equipments which are in supply scope of
contractor and handling, transportation, pre-fabrication, pre-assembly, assembly, welding,
erection, inspection, commissioning, load testing and handing over of free issue material
handling equipments for KKNPP-3&4".
2. SCOPE OF WORK:
The scope of work includes “Handling, transportation, pre-fabrication, pre-assembly,

assembly, welding, erection, inspection, commissioning, load testing and handing over of the
material handling equipments which are in supply scope of contractor and handling,
transportation, pre-fabrication, pre-assembly, assembly, welding, erection, inspection,
commissioning, load testing and handing over of free issue material handling equipments for
KKNPP-3 & 4".
The erection work includes the MHE issued as free issue materials by NPCIL as well as the
MHE supplied by the contractor under supply scope of contract.
2.1 NPCIL SCOPE OF WORK:
NPCIL scope of work is limited to the following:
1. Issue of drawings for fabrication & erection of cranes and its components,
manufacturer’s manual & guidelines for installation of MHE and for carrying out
commissioning checks for free issue MHE.
2. Issue of free issue materials at delivery point.
3. Issue of fabricated support brackets and anchor fasteners.
4. Erection of LT girder and crane rails for cranes.
5. Release of work front.
6. Power supply sources for commissioning of electrical operated travelling cranes and
hoists at free of cost.

7. Release of test loads for load testing as identified by the contractor.

8. Providing land/area for establishing contractors work shed/office within KKNPP.
9. Providing power supply at one point for establishing construction power supply
network by contractor on chargeable basis.
10. Heavy duty crane for the erection of assembled polar crane, trestle crane and turbine
hall crane will be provided by NPCIL.
NOTE: “Delivery point” means NPCIL stores or any other point within KKNPP site.
2.2 CONTRACTOR’S SCOPE OF WORK:
Contractor’s scope of work comprises but not limited to the following:

1. Handling, Transportation, Pre-fabrication, Pre-assembly, Assembly, Ground
assembly of component parts, cleaning, hoisting, fabrication, welding, erection and
placing of MHE on rails, alignment of span girder, erection and alignment of cross
travel trolley and all the MHE, greasing or filling with oil, checking for free
rotation/movement as applicable, inspection including NDT, commissioning,
functional check, load testing and handing over of “Material Handling Equipments"
(MHE) such as cranes, hoists and lifts as per drawings / manufacturer instructions.
2. Preparation and submission of detailed work schedule to meet the specified targets
and work progress reports (daily, weekly, monthly etc.).
3. Receipt of free issue materials from NPCIL stores or at the delivery point, uncrating,
inspection and preparation of incoming material inspection report (IMIR), reporting
deficiency if any to NPCIL, transportation from NPCIL'S store to contractors store,
storage, transportation from contractor's storage to erection site, handling of materials
during erection/construction and inspection before erection of items.
4. Loading, transportation to place of erection/ contractor stores, unloading, uncrating,
inspection & acceptance of materials as per WD & packing list.
5. Material management, storage, and preservation of the material while at contractor's
store. Returning of empty crates of equipments to engineers store at designated
location specified by the Engineer-in-charge (ENC) shall also be in the scope of
contractor.
6. Fixing of anchor fasteners- Hilti make as specified in drawing (wherever embedded
fasteners/plates are not available).
7. Erection of support brackets.
8. Study of working drawings, inspection of work front, preparation and submission of
various work procedures, quality assurance plans, safety job hazard analysis for all
the equipment for NPCIL acceptance including preparation of erection methodology
for critical equipments.

9. Preparation, submission of welding procedure specification (WPS) & conducting

Procedure qualification record tests (PQR) as per relevant standards.
10. Preparation of various procedures, QAP etc., arranging & carrying out inspections as
per approved QAP, submission of various reports concerning the quality assurance.
11. Non-destructive examination (NDE) and testing as per drawings and specifications.
12. Arrangement of welding machines and apparatuses, all equipments and consumables
for welding as well as for all the tests at site.
13. Supply of welding consumables, argon gas and other gases, for welding purposes,
with required purity & accessories (except welding electrode, filler wire) for erection
of free issue materials.
14. Supply of electrodes and filler wires and welding consumables, accessories for
erection of the material under supply scope of contractor.
15. Arrangement of necessary equipments, P&M, material handling devices such as
cranes, winches & chain pulley blocks etc of required capacity, lifting, rigging,
transporting arrangements, tools & tackles, scaffoldings, platforms, ladders etc.
required to execute entire works of the subject tender as a whole.
16. Deployment of qualified, skilled and unskilled manpower, experienced and qualified
supervisory and technical staff and competent management fully backed by latest
project management tools and facilities, training and qualification of required
personnel for efficient & safe execution of work, committed to total quality
management. The contractor personnel shall be conversant with Russian codes and
standards.
17. Preservation of free issue material at contractor’s store as well as in situ (till handing
over back to NPCIL) shall be done by the contractor. Further, any de preservation of
the free issue material for erection purpose (including but not limited to removal of
caps, protective tapes, de greasing, primer/peel off, paint removal etc.) shall also be
done by the contractor. All the resources including consumables/ non consumables
required for the purpose shall be arranged by the contractor at no extra cost.
18. Adherence to safety guidelines, security guidelines, various work permit system and
compliance of all statutory requirements of the project. Performance of all the
activities with necessary safety precautions. Obtaining necessary permits pertaining
to the safety, field work, load testing and other permits as per the requirement.
19. Arrangement of safe working conditions in the area of work to ensure the protection
of the already erected equipments, pipe lines & other property of NPCIL by proper
protection arrangements. These arrangements shall be elaborated in the work
procedure/ Job hazard analysis.

20. Electrification of crane including installation of down shop leads and connection to
main switch, pre-commissioning, load testing including electrical grounding and
handing over the MHE as per drawing, tender specification and instructions of ENC.
21. Touch up painting after erection of MHE.
22. Keeping the working area clean and materials segregated neatly in coordination with
other contractors.
23. Generating, maintaining and submitting reports concerning the quality assurance,
progress and completion of work and various records such as alignment reports,
progress reports, test certificates, inspection reports, welders qualification records, all
procedures, hand over reports, CCC etc. in order for any reference and scrutiny.
24. Along with the hard copy of final CCC the contractor shall submit scanned copy in
soft form (.pdf format).
25. Material accounting for the free issue materials as well as contractor’s supplied
materials under supply scope of contract and submission to NPCIL for acceptance.
26. In general all materials, plant and machinery and services whatsoever necessary for
satisfactory completion of the work unless specifically provided as the free issue
material by the engineer are deemed to be included in the contractor scope of work.
3. REFERENCE DRAWINGS, DOCUMENTS & SPECIFICATIONS:
1. The KKNPP-3&4 units are designed by Russian Federation. Accordingly assembly,

fabrication, erection, inspection, testing and commissioning activities of all the MHE
and all other technical requirements shall be as per the Russian Standards and Codes.
This Technical Specifications are compiled based on the Russian Standards and are
only for the guidance of the contractor. Erection of MHE shall be done based on the
Working Documents and for more details contractor shall have to follow Russian
NTD/GOST/PB/PNAEG/AERB codes as specified in Working Drawings (WD)
released for construction and manufacturer documents which will be progressively
issued to the contractor during execution of work. The Russian Standards and codes
are available with Engineer In-charge’s library for reference. Working documents
(set of drawings and documents) will generally contain necessary information for
erection and testing of MHE.
2. One set of sample drawings listed in Annexure- 1 of this tender are attached to give
an idea of the nature of the documents on the basis of which the erection would be
carried out. These listed drawings are made from the MHE function point of view
and certain changes are expected in the drawings with respect to detailing. The work
shall be executed as per WD released for construction issued by engineer after award
of contract.

3. It is the responsibility of the contractor to study & understand all the pre-requisites &
conditions like availability of work front, labour, material, consumables etc before
the start of the work. Contractor shall ensure safe storage of all the WD’s issued
during the period of work, till the completion. Along with the hard copies, NPCIL
will issue Soft copies of the WD’s from time to time to the contractor.
4. The specifications listed below are compiled based on Russian standards. These
specifications are available at KKNPP site for reference. The copy of these
specifications will be issued only to the successful bidder. These specifications are
for guidance of contractor. The actual work shall be carried out based on working
documents and Russian standards to be provided to the successful bidder. The
contractor personnel shall be conversant with Russian codes and standards.
Sl. Specification Description

no. Designation
1 I.02.KK.0.0.QA. Specification for Liquid Penetrant Testing of weld joints of
TU.WD.001 equipments and piping during construction of KKNP.
2 I.02.KK.0.0.QA. Specification for Magnetic particle testing of weld joints of
TU.WD.002 equipments a piping during construction of KKNPP.
3 I.02.KK.0.0.QA. Specification for radiography examination of weld joints of
TU.WD.003 equipments and piping during construction of KKNPP.
4 I.02.KK.0.0.QA. Specification for ultrasonic examination of weld joints of
TU.WD.004 equipments and piping during construction of KKNPP.
5 I.02.KK.0.0.QA. Specification for shop and field welding of piping and
TU.WD.006 equipments during construction of KKNPP.
6 GOST 27584-88 Electric Overhead Travelling Cranes and Gantry Cranes
7 AERB/NPP- Safety classification and seismic categorization for systems,
PHWR/SG/D-1 structures and components of pressurized heavy water reactors
8 AERB/NPP- Design of Light water reactor based nuclear power plants
LWR/SG/D
9 2.01.07-85 Construction Norms & Rules (Loads & Effects)
5. In the event of conflicting requirements between the specification and drawings, the
governing requirements shall be at the discretion of the ENC of the work. In the
instance where contractor is unable to achieve the required technical parameters, he
must apply to the ENC with full justification for the regularization of non
conformance. Any deviation from technical requirements must be recorded and duly
approved by the Engineer in-charge.
6. Working drawings will be issued during the course of execution of work to match
the progress of the work in the phased manner. The Contractor shall prepare detailed
fabrication / shop drawings where ever required based on the design drawings
supplied by NPCIL.
7. Any discrepancies or contradictions in, or omissions from drawings, specifications
or other documents or any doubt arising as to the meaning or intent of any part
thereof, shall refer to the Engineer in-charge. Written instructions or explanations
will then be issued by the engineer as soon as possible.
8. In case the Contractor feels that the drawing issued by the Engineer does not provide
sufficient details required to prepare shop drawings, the Contractor shall obtain the
Engineer’s consent in writing, to design the additional details and prepare the shop
drawing from the design drawings issued to him. Where standard joints are not
available, the Contractor shall design connections as per standard practice of design
and shall get Engineer's approval prior to fabrication.
9. Inadequacy in detailing in Engineer’s drawing shall be brought to the notice of the
Engineer within 3 (Three) days of receipt of drawings by the Contractor. Time
consumed beyond the above time frame will not be considered for completion of
schedule of the particular activity.
10. Whenever the contractor is unable to comply with the Engineer’s requirements,
whether it is dimensional or technical, or whenever field changes are inevitable for
any reason, the Contractor must obtain the appropriate authorization from the
engineer.
11. Design Concession Request (DCR) shall be raised for non-generic deviation and non-
conformances and it has to be regularized as per Quality management system.
4. RECEIPT, TRANSPORATATION & STORAGE OF FREE ISSUE MATERIALS:
All the MHE and other associated materials to be issued as free issue materials to the contractor
for erection in this scope of tender are stored in NPCIL designated central stores hereafter
referred to as NPCIL stores. The materials received in stores will be assigned Item no’s to each
packing list of MHE, components and equipment. All the materials received in the NPCIL
stores are subjected to inspection by a Joint Inspection Team (JIT) constituting of personnel
from NPCIL and deviations if any are noted, are recorded. The materials cleared of any
deviation are accepted and are ready for issue to the respective contractor on requisition.
NPCIL stores are maintained by a separate agency.
The materials supplied by contractor shall be stored in contractor's stores after inspection and
acceptance by NPCIL.
4.1 RECEIPT OF MATERIAL FROM NPCIL STORES AND TRANSPORTATION:

1. All such materials which are issued to the contractor by NPCIL during the contract
period shall be treated as Free Issue Material (FIM). A list of all the free issue
materials is given in Annexure-2. The WD’s issued to the contractor contains the list
of the items required for erection MHE. The contractor shall make note of such items
and draw from NPCIL stores on requisition. The free issue material will be issued
against contractor issue voucher (CIV) at NPCIL stores. The contractor shall prepare
Contractor Issue Voucher (CIV) either using NPCIL certified software’s like IPMIS,
IBA-CMM or manually using CIV book which shall be issued to contractor during
the execution of work. Contractor shall establish facility for soft ware based material
management system for free issue materials, compatible with the NPCIL's software.
The CIV should contain all the details of the requested material and the same shall
be submitted to department of stores through ENC. It is the responsibility of the
contractor to collect the requested material from the designated location of the NPCIL
stores once the materials is issued.
2. Any deficiencies in the materials received shall be reported to ENC within two days
of receipt of material. Incoming material inspection report (IMIR) shall be prepared
after inspection with NPCIL engineer. Further loading, transportation to the actual
place of erection and unloading shall also be done by the contractor. In no case the
material will be delivered by NPCIL at the actual place of erection. All the resources
required for the purpose shall be arranged by the contractor. Empty crating shall be
returned to engineers store at designated location specified by the Engineer-in-charge
3. The Contractor shall draw the FIM from the NPCIL's stores located within the plant
premises or in the vicinity of the plant premises. The contractor shall receive the FIM
from the NPCIL at the delivery point (The delivery point can be a designated loading
point at NPCIL stores or either at the contractor’s stores or near and outside the
respective building where the equipment is to be installed). The contractor may also
note that the ENC will decide the delivery point depending upon the practical
feasibility of the access of tractor trailer carrying the cargo outside the nearest point
of actual erection of the respective equipment, size of cargo and weight of the
component.
4. The Contractor shall be responsible for transportation of all the items / general
equipment / material from the NPCIL’s store / Contractor’s store / shop to the place
of work/ installation, except for the materials indicated in the free issue material list,
which will be shifted by NPCIL to outside the building. In no case the equipment will
be delivered by NPCIL at the actual place of erection.

5. Loading and unloading of materials and equipment shall be hoisted or skidded so as

to avoid shock or damage. Under no circumstances materials shall be dropped.
Dragging of unprotected equipment on the ground shall not be permitted.
6. Many rooms (floor & walls) are provided with stainless steel & carbon steel liner.
Contractor shall take extreme care while shifting and erecting the MHE to avoid
damage to the room liners. The scaffolding used in the area shall have rubber bushing
to avoid scratch & dents on the liner.
7. The FIM shall be issued in a lot, in packed/as received condition. No piecemeal

issue/delivery shall be permitted. After the material is issued, the contractor shall be
responsible for uncrating of the free issue material, inspecting the contents for
deficiency if any, checking for the completeness, proper storage, safekeeping,
preservation and handling as per approved procedure while materials are in his
custody, safe transportation and handling from his workshop to the erection point etc.
8. The contractor shall arrange all tools & tackles, machinery and hoisting required for
loading, transportation and unloading of the materials. Wherever the contractor has
to attach his hoisting equipments to project’s existing structure written procedure of
rigging operation must be submitted for the engineer’s approval. In the work area
where the engineer may have installed hoisting equipments in time, which is part of
the project as permanent installation, the contractor may be permitted to utilize it free
of charges for the execution of his work. The engineer will provide competent
operator. The same does not apply in the event of the engineer’s permanent hoisting
equipment if the operator is not available or engaged for his work or being out of
order. This shall not be the cause for claims of extra payment or an excuse for delays
in executing the work. This facility is offered purely on the ground to increase safety
of hoisting operations and to remove unnecessary congestions, if and where possible.
The contractor shall check the lifting capacity of various hoisting equipments before
taking up any erection.
9. Briefly the scope of material transportation covers identification of material,

preparation of CIV, clearance from ENC and its submission to NPCIL's Stores,
receipt, handling, loading on to the truck/trailer, transportation of materials from
NPCIL's stores to contractor's store or erection site, unloading the material at
contractor's store or erection site, uncrating, checking the completeness of
items/physical damage(if any), preparation and submission of incoming material

inspection report (IMIR) and its clearance from ENC, further shifting of materials
from contractor's store to erection site and disposal of the crating/packing material at
the designated place of the NPCIL's stores, returning of un-erected materials to
NPCIL's stores. This work also includes arranging all the necessary tools and tackles,
truck/trailer, plant and machinery, man power and consumables.
4.2 TRANSPORTATION OF HEAVY AND CRITICAL EQUIPMENTS:
In general for packages/Equipment weighing greater than 20 MT Gross Weight, the delivery
point is either at the contractor’s stores or near and outside the respective building, where as
for all other packages/Equipment the delivery point shall be a designated loading point at
NPCIL stores. In no case the equipment will be delivered by NPCIL at the actual place of
erection. Contractor shall do subsequent handling and transportations where ever required.
Equipment placement on to designed location, alignment, adjustments and grouting for final
erection shall be carried out by the contractor.
4.3 STORAGE OF MATERIALS:

1. The contractor shall make his own arrangements, for constructing a covered storage
area on earmarked open space made available to the contractor at site. Attention is
drawn to the fact that the environment at KK site is corrosive and therefore proper
storage and its periodic monitoring by contractor has to be done at no extra cost.
Contractor shall make warehouse in his own arrangements to provide appropriate
storage at site (in accordance with manufacturer’s recommendation and taking into
account climatic and other relevant conditions at the warehousing site) for all NPCIL
issued FIM’s, Contractor’s Plant & Machinery and Contractor’s Equipments till the
completion of the work. All the Plant & machinery, tools & tackles, hoisting,
manpower etc required for handling the materials at contractor’s store, are in the
scope of the contractor. Watch and ward shall be the responsibility of the contractor.
2. Once materials are issued to the contractor it is the responsibility of contractor in

storing of any materials and pre-fabricated items at erection location in the building
or enclosures providing adequate protection. All storage shall be orderly and executed
in a way so as to eliminate mixing up of materials and possibility of damage prior to
their installation in the field. No material shall be stored directly on the floor.
Supports shall be provided below to ensure Gap of 100 to 150 mm from ground.
3. The Contractor shall be responsible for security of all the FIM’s stored at the
contractor’s stores till the completion of the work and acceptance by NPCIL. It is the

responsibility of the contractor to maintain complete record of the list of materials at

stores, maintain log books and entry/exit records for the material movement in and
out of the contractor’s warehouse/ store. All such records which are required for
material accounting and billing shall be prepared, recorded and maintained by the
contractor either manually or by using licensed software’s with prior approval of
ENC. NPCIL approved committee has every right to audit Contractor stores, records
and his logbooks time to time during the execution of work, for which Contractor
shall ensure and provide all such information and facilities on demand.
4.4 IDENTIFICATION, MARKING AND SEGREGATION OF MATERIALS:
1. In NPCIL stores, all MHE are identified by their KKS codes and Item no’s. It is the
responsibility of the contractor to get the details of KKS codes, package no’s, Item
no’s for such materials from NPCIL. All the FIM’s shall be stored at appropriate
locations in contractor's stores, properly tagged and identified for segregation from
other goods, properly protected and preserved as per manufacturers
recommendations, properly marked with their KKS code, system Code, Item no. and
item description like weight, material, type etc and the material locations shall be
marked properly for easy identification and retrieval of the material at stores.
2. The contractor shall visually examine all materials being erected or being used in the
fabrication and shall report any defects to the engineer. Any repair of materials shall
be as per approval of the engineer’s instructions. Any material not conforming to the
specification and subsequently rejected should be suitably identified, stocked and
disposed off as per the instructions of the engineer.
5. SEQUENCE OF ERECTION ACTIVITIES:
1. The sequence of erection shall be decided by Engineer based on availability of

erection fronts, drawings and equipments. In general the sequence of the erection
shall follow the overall project schedule of KKNPP-3&4. Generally installation of
support structures shall be taken up first followed with installation of Material
Handling Equipments, electrical and instrumentation components. The following
shall be the preferred sequence of installation.
a. Support structure installation and inspection

b. Installation and inspection of material handling equipment.
c. Installation and inspection of electrical and instrumentation components.

d. Commissioning and load testing of material handling equipment.
6. INTERFACING WITH OTHER AGENCIES:
1. The MHE contractor shall note that the construction of civil works will be continuing
by other agencies in the same building where this MHE will be erected. This type of
parallel working shall not be considered as disturbance or hindrance to erection work.
Also other mechanical/electrical agencies related to ventilation, equipment and
piping, common services, cable laying, ducting etc may also work in the same area.
Hence for carrying out the above activities the co-operation and co-ordination with
other contractors/agencies working in that area for erection of ducting, cable tray,
etc., will be required from MHE contractor.
2. All MHE erection work covered under this specification shall be planned and
executed as combined nature of civil, mechanical, electrical and instrumentation
work. The civil construction and mechanical erection works shall be done in a
sequential/combined manner. The work front for civil and MHE contractor shall be
available or released on completion of specified activities by each contractor on every
activity and both contractors shall ensure that their part of work is completed in time.
The rate quoted by bidder shall include such combination of civil, mechanical,
electrical and instrumentation work. No extra claim on account of any
misunderstanding or not understanding the nature of work shall be entertained by
NPCIL.
7. PREPARATION OF PROCEDURES & QAP:
The contractor shall prepare and submit the Erection/QAP/NDT/Testing procedures for all the
MHE erection works in his scope to ENC for approval. A sample format for guidance for
preparation of QAP is enclosed as Annexure-3 of section. The procedures shall be prepared
in line with the general Industry practice, Working Documents, acceptable codes and standards
and to the requirements of Equipment Manufacturer/Designer. The procedures shall clearly
define all the details pertaining to the type of testing, process of testing, the methodology
adopted, special requirements, sequence of steps, assembly requirements, alignment process,
quantum of testing, testing tools & consumables required, calibration requirements, testing
parameters, interpretation of results, defect rectification methodology.

Some of the major procedures to be prepared by contractor are,
1. Quality Assurance Manual

2. Welding Procedures like Welding Procedure specification (WPS), Procedure
Qualification Record (PQR).
3. Welder’s qualification Procedure
4. Qualification certificates of the personnel performing non-destructive examination
5. Assembly procedures
6. Erection procedures for MHE
7. QAP
8. NDT procedures
9. Testing procedures
10. Cleaning procedures
11. Commissioning procedures
12. Mock up procedures
13. Safety Manual
Further, where complexity of the work or safety is involved, the contractor shall submit such
work procedures when requested by the ENC. Any other procedure deemed necessary for work
shall be submitted to ENC for acceptance.
8. MANUFACTURER’S INSTRUCTION AND SUPERVISION AT SITE:
1. Manufacturer’s instructions are special/specific instructions issued by the equipment

manufacturer. Any such installation requirement specified by the Manufacturers,
such as alignment adjustments, greasing, turning of motors, mounting of particular
items on the equipment etc. is included in contractor’s scope of work. Adequate care
shall be taken during welding of MHE components. For any equipment or items
(supplied by the engineer) of proprietary nature, the Engineer will issue the
Manufacturer’s data or instructions to the Contractor. Contractor shall follow the
manufacturer’s instructions/data for equipment/items supplied by the contractor
under supply scope of contract. The manufacturer's manual should be returned to
NPCIL with deviation marked by the contractor on completion of work.
2. Wherever deemed necessary NPCIL may arrange supervisors of manufacturer

representative during erection, testing and commissioning of the equipment for pre
determined period. The contractor is required to complete the erection of such
equipment in a fixed time frame as per agreed schedule. Any delay in completion of
work by the contractor within the agreed schedule shall be considered as delay in
work. If any additional expenditure incurred by NPCIL on account of delay by the
contractor on account of supervision front, shall be deducted from the contractor.
9. ASSEMBLY, WELDING & ERECTION OF MHE:
9.1 GENERAL REQUIREMENTS:
1. The general instructions and requirements for erection are detailed in WD or

manufacturer’s documents. All the equipments shall be erected as per the equipment
installation drawings and specification and other details to be furnished to Contractor.
2. All required manpower for the erection of equipments shall be provided by the
contractor. Erection and alignment of all machineries shall be carried out by
experienced fitters and technicians. Contractor shall deploy experienced erection
supervisors and crews who have done similar type of jobs. Contractor shall ensure
performance by qualified electricians / technicians to the best industrial practice.
Proper sequence for assembly and erection / installation shall be adhered to in
accordance with drawings, catalogue and manufacturers instruction.
3. All necessary handling equipments, tools, tackles and precision instruments for
carrying out the works as specified shall be provided by the contractor at his own
cost. Contractor shall provide all tools and gauges for erection and alignment. Special
tools, if any, received as part of equipments shall be used by the contractor for
erection purposes, which shall be returned in good condition after use. While
handling, transporting or erecting the equipments, care shall be taken not to damage
any parts of the equipments.
4. Rigging procedures and erection schemes for all the heavy lifts shall be prepared by
the contractor and got approved by ENC before starting work. Approval by ENC shall
not relieve contractor of his responsibilities. The details to be submitted will include
the location of equipment from where it will be lifted, location of crane(s), details of
crane(s) (like configuration, boom length, operating radius, boom point elevation,
clearance underside the boom and the equipment, lifting capacity, counter weights
to be deployed, holds on any neighbouring foundations, structures, equipments
etc.), the load chart of the crane(s), design of the lifting tackles like spreader beam,
D-shackles, wire rope slings etc.
5. Contractor shall produce valid test certificates of the lifting tools and tackles
including slings used for erection work. However, retesting shall be done by
Contractor, as and when required for revalidation. Tested slings will be punched for
test loads and date of testing. Also, the D shackles, EYE bolts and other tackles shall
be inspected at regular intervals.
6. Before taking up the equipment for erection, the contractor shall check the readiness
of front release. Discrepancy, if any, should be brought to the notice of the ENC
before actual erection is started. Before start of erection activities contractor shall
ensure crane rail clamps are properly aligned and tightened.
7. All equipment shall be thoroughly cleaned, oiled and greased and presented for
inspection to the owner before placing in for operation. While filling lubricants and
oils, care shall be taken that they conform to manufacturer’s recommendations. The
required quantities of oils and lubricants shall be supplied by the NPCIL.
9.2 DE-PRESERVATION:
1. De-preservation shall be carried out as per manufacturer’s recommendation. After

shifting the equipment from the store to site the equipment shall be placed safely.
Steel structures/ wooden blocks used for the packing and transportation shall be
removed carefully. Equipment Manufacturer's recommendations regarding de-
preservation/preservation during storage at site store and after erection at designed
location shall be strictly followed by the contractor till the completion and handed
over to the NPCIL.
2. De-preservation of bogie pin and pin bearing surfaces shall be done by appropriate
paint remover. Before installation of bolts it is necessary to remove preservation
coating and shall be cleaned by using steel brushes. The high-strength bolts and
washers before installation shall be cleaned with petrol and wiped dry. De-
preservation of bolts, nuts and washers by immersing in boiling water for 10 minutes
and rinsing it in hot condition with mixture of 85% clear petrol and 15% of machine
oil mixture to clean them. Surface contact area and fasteners shall be de-preserved by
gas burning for removal of primer coating as instructed by the manufacturer. De-
preservation of surface of the plates wherever necessary and shall be done by gas
burning for removal of primer as instructed by the manufacturer. Necessary crates,
tank and gas burner including industrial LPG cylinder for the above activity shall be
arranged by the contractor and the quoted rate is inclusive of making such
arrangements. The thread of nuts shall be applied with mineral oil. De-preservation
of rope shall be done by wiping with brush and cleaning with cloth.

General sequence of erection procedures of major equipments are given below only for
reference. The contractor shall prepare erection procedure and QAP for erection based on
manufacturer manual and submit for approval of NPCIL before start of erection . All the
component parts of the equipments shall be shifted to the respective locations including the
erection devices.
9.3 ERECTION OF POLAR CRANE (FCA07AE071) :

A. General:
1. The Polar crane is a circular crane of lifting capacity 350/190 T with a working
range from 0o to 370o with full capacity at all ranges and located at an elevation of
+43.900 m inside the Reactor Building (UJA).
2. The polar crane is free issue material to the contractor for assembly, erection,
commissioning and testing. There are two nos. of polar cranes (one no. per unit)
under this scope of contract.
3. SOQR of this tender is for measurement and billing of polar crane work.
B. Ground assembly:
The following are the major steps involved in assembly of Polar crane.
1. Assembly of Bridge Metal Structure - L.H. & R.H.: Turn the pieces wherever they
are kept upside down. Place the bridge metal structure pieces on concrete blocks /
wooden sleepers for leveling. The straps and bridge metal structure contact surfaces
shall be prepared by shot / grit blasting to required surface finish as per the instruction
of the manufacturer. After surface preparation, match the straps and Bridge Metal
Structure as per the match marks punched on them. Matching of component or part
holes and their fixation in conformity with the working drawings shall be done with
the help of taper mandrels (assembly plugs). The taper mandrels (assembly plugs)
required for matching the holes are in the scope of the contractor. Number of
assembly plugs required shall be at least 10 % of the holes but not less than two in
one joint. The bolting area shall be cleaned and kept free from dust. During
installation of high strength bolts, make sure that nut turns easily on the bolt by hand
or replace either nut or bolt. Lubricate nut thread with mineral oil while tightening,
never lubricate bolt thread. The HSFG (High Strength Friction Grip) bolts supplied
along with the crane shall be tightened in a sequence as recommended by the
manufacturer with the help of calibrated torque wrench to the adequate torque as per
the instruction of the manufacturer. If any bolt or nut slips during tightening, it should
be replaced by a new bolt. Each bolt is installed in combination with two high-
strength washers (one of them is placed under bolt head and the other under nut).
After completion of tightening, the gap between the contact surfaces should be
checked using feeler gauge. Trolley rails are to be fixed on the Bridge Metal Structure
and the clearance between the rails should not exceed 1.5 mm.
2. Assembly of Roller Pedestal with Bridge Girder: Assembly of Roller Pedestal with
Bridge Metal Structure shall be done by Bolting joint at one end and Welding joint
at other end. After alignment, bolting and tightening of HSFG bolts shall be done as
per the same procedure followed for Bridge Metal Structure assembly. After bolting,
prior to performing welding works, each side of welding surfaces shall be ensured
for free from grease, loose scales, moisture and paint etc. The qualified welding
procedure and qualified welder shall be used. Welding shall be inspected and
accepted by the respective NDT techniques as recommended by the manufacturer.
3. Assembly of Bridge Drive Mechanism: Place one piece of drive carriage and idle
carriage on concrete blocks / wooden sleepers to the working height. Align both the
carriages to match the pin centre of the balancing beam and ensure that they are lying
on same plane. Before assembly, ensure all pins and pin housings are cleaned
properly by using appropriate Solvent recommended by the manufacturer. Place the
balance beam above the carriages and insert the pin into the pin housing with
appropriate lubrication as instructed by the manufacturer. Check the alignment of
motors and brakes. Repeat the above for the remaining three bridge drive mechanisms
assembly. Temporary locking of bridge to drive mechanism has to be done by
welding using channels for handling purposes. The welding shall be done as per the
instruction of the manufacturer.
4. Assembly of Main Hoist: Assemble the Main Hoist drive mechanism with the Main
Hoist Trolley. Installation of motor and gear box shall be carried out and alignment
of Motor to the gear box is to be done using dial gauges. Gearbox shall be de-
preserved and filled with lubricating oil. All the handrails and platforms shall be
installed with the main hoist trolley assembly.
5. Auxiliary Hoist Trolley: Alignment of Motor is done by connecting the motor with
gear box by using key and alignment is checked by means of feeler gauge. Alignment
of Brakes is done by setting manually and physical checks shall be carried out. All
the handrails and platforms shall be installed with the auxiliary hoist trolley assembly.
6. Assembly of Main Gantry: Place the two stands of the gantry on the ground. After
checking the span of stands as per drawing, horizontal piece is bolted with HSFG

bolts and tightened as per manufacturer instructions. Cantilever beam is attached with
this assembly by means of HSFG bolts and tightened as per manufacturer
instructions. Main Gantry hoist shall be installed and locked for movement during
erection activities.
7. Assembly of Auxiliary hoist Gantry with Monorail: Place the two stands of the
gantry on the ground. After checking the span of stands as per drawing, horizontal
piece is bolted with high strength friction grip (HSFG) bolts and tightened as per
manufacturer instructions. Monorail is attached with this assembly by means of
HSFG bolts and tightened as per manufacturer instructions. Auxiliary Gantry hoist
shall be installed and locked for movement during erection activities.
C. Erection sequence:
The following are the sequence of activities in erection of polar crane.
1. Before start of erection activities ensure crane rail clamps are properly aligned and
tightened.
2. Erect the assembly of Bridge Metal Structure with Roller Pedestal and Bridge Drive
mechanisms (R.H & L.H) on rail using Heavy duty crawler crane.
3. Erect the end beams, align with the respective bridge beam assemblies and bolting of
end beam by HSFG bolt is carried and tighten the bolts with Torque Wrench with
specified torque. Check the elevation and level between the two bridge metal
structures and check the span, diagonal of the crane.
4. Erect the Main hoist (MH) & Auxiliary hoist (AH) trolleys on girders separately and
connect two trolleys with main hoist carriages by pin and bolts.
5. After cleaning the bolting surface of Fixing Device, four pieces of fixing device shall
be aligned and fitted under the bridge metal structure by HSFG bolts as per
specification.
6. Grapples (four pieces) shall be erected and fixed under the trolley frame as per
drawings.
7. The assembled main gantry shall be erected over the pedestal on the Bridge metal
structure. The assembled Auxiliary hoist gantry shall be erected over the pedestal on
the Auxiliary hoist trolley.
8. Erect and align the dome maintenance platform on roller pedestal units.
9. Rope reeving of main hoist suspension and auxiliary hoist with rope drum shall be
done.

10. Fixing of permanent current supply platform is to be done after completion of dome
erection. For erection of this platform weld the erection lugs on Reactor building
dome with which the platform will be erected and fixed with dome.
11. After completion of erection lubrication at all specified points, oil filling in gear
boxes, thrusters, application of rope preservative compound shall be done.
12. Complete electrification & charging of polar crane.
9.4 ERECTION OF TRESTLE CRANE (FCJ07AE041)

A. General:
1. The trestle crane of 350/190 T is installed over the transport portal beam (UJG) at an
elevation of +52.850 m outside the Reactor Building.
2. The trestle crane is free issue material to contractor for assembly, erection,
commissioning and testing. There are two nos. of trestle cranes (one no. per unit)
under this scope of contract.
3. SOQR of this tender is for measurement and billing of trestle crane work.
B. Ground assembly:
The following are the major steps involved in assembly of Trestle crane.
1. The frame parts shall be placed on supports (concrete blocks/ wooden sleepers) with
sufficient heights accommodating bogies assembly and leveled to ensure the bolting
position.
2. The joining of frames shall be done by bolting using HSFG bolts to the adequate
torque value as instructed by the manufacturer. After completion of torque tightening
the exposed surface area shall be painted manually.
3. Fixing of Trolley hand railings, ladder and platform shall be done as ground
assembly.
4. Depot installation along with gantry and shelter shall be done in two stages as partial
ground assembly and assembly at actual place. Metal structures for above mentioned
assembly are welded / bolted joints and partial ground assemblies shall be taken up
suitably to facilitate further assembly after erection.
5. Gantry frame metal structure shall be assembled at ground with bolts and geometric
dimensions shall be checked with reference to working drawing.
6. Similarly trolley shelter with metal sheeting shall be taken up at ground assembly.
After erection of gantry & shelter at their place, necessary tie beams as per working
drawing shall be fitted for preliminary completion of Depot erection.

7. Metal structure for Shelter for Hoist shall be taken up at ground prior to erection of
gantry metal structure.
8. Above activities completes partial ground assembly of Depot. Once Depot erection
is completed necessary erection for current supply line to gantry shall be done
manually at its place.
C. Erection sequence:
The following are the sequence of activities in erection of Trestle crane.
1. Once the trolley frame is assembled at ground level along with bogies and hand
railings fitted in place shall be secured by proper welding and rope tying.
2. The Trolley frame with wheels and bogies shall be erected on to the Trestle crane
girder rail.
3. Further erection of reduction gear unit, hoist drum, sheaves, pulleys, rope reeving,
suspension block, motors ,brakes, floating shafts, load cells, security holds, fixing
devices for main hoist & aux. hoist drive assembly are to be completed.
4. Erection of cabin with top structure
5. Alignment of motor to the gear unit shall be done on the erected trolley.
6. Part assembly of the gantry and shelter shall be erected and fixed by bolting on the
crane beam.
7. Erection of balance structural assemblies, Monorail I beam, laying and termination
of power supply line to trolley.
8. Erection of the tie beams and structures including current supply line to trolley
including depot erection, cable tray & conduit fixing, foundation brackets for
electrical & instrumentation items etc., with wiring & termination and electrical
grounding work.
9. Rope reeving with Fork assembly, Fork swing mechanism and Aux. Hook.
10. In the meanwhile platform & ladders fitments with bolts & welding wherever
necessary shall be carried out.
11. Fixing of cabin structure to the crane beam by welding and the operator cabin to the
structure by bolting and fixing pins.
12. Complete electrification & charging of trestle crane.
9.5 ERECTION OF TURBINE HALL CRANE (SMM20AE001) - 180+180/32 T
A. General:
1. The turbine hall crane is an Electrical Travelling crane of load capacity 180+180/32
T. The crane is located at an elevation of +29.205 m of Turbine Building (UMA).

2. The turbine hall crane is free issue material to contractor for assembly, erection,
commissioning and testing. There are two nos. of turbine hall cranes (one no. per
unit) under this scope of contract.
3. After completion of above activities an additional mounting trolley of load lifting
capacity 180/32 T shall be mounted on each of the turbine hall crane. The scope
covers assembly, installation, inspection and combined load testing of additional
(mounting) trolley.
4. After use of the above arrangement the additional mounting trolley of load lifting
capacity 180/32 T shall be dismantled and removed from the turbine hall crane.
5. SOQR of this tender are for measurement and billing of above activities of turbine
hall crane erection, mounting of additional trolley and dismantling of additional
trolley.
B. Ground assembly:
The following are the major steps involved in assembly of Turbine hall crane.
1. The single span shall be placed on supports (concrete blocks/ wooden sleepers) with
sufficient heights to enable easy assembly of the end carriages.
2. The other single span shall be placed parallel on supports (concrete blocks/ wooden
sleepers) with required gap between the spans as per drawing.
3. The end carriages with the travel mechanism shall be fixed to the span with bolting
to form a solid bridge.
4. The crane rails shall be assembled and erected over the bridge span by welding.
5. The metal platforms and hand railing shall be assembled and erected around the
bridge by welding.
C. Erection of turbine hall crane:

The following are the sequence of activities in erection of Turbine hall crane.
1. The assembled bridge structure of the beam with travel mechanism shall be lifted and
erected over the crane rails using heavy duty crane. The erected beam structure shall
be locked temporarily in order to prevent movement of the crane over the rails during
the due course of erection activities.
2. The Erection of main trolley with travel mechanism and hoisting mechanism shall be
carried out. The erection of mounting trolley with travel mechanism and hoisting
mechanism shall be carried out. The joining together of both the trolleys shall be done
in the design position by attached arms with elements of the clutch device which
operates under convergence of trolleys.

3. The erection of seismic bracket shall be carried out after completing the trolley
erection.
4. The metal platforms and hand railings intended for the maintenance of the crane shall
be fixed in position by welding.
5. The operator cabin shall be fixed on the beam structure by welding. The welding shall
be inspected as per the manufacturer recommendations. The cabin structure shall be
fixed to the crane beam by welding and the operator cabin shall be fixed to the
structure by bolting and fixing pins.
6. Rope reeving with Fork assembly, Fork swing mechanism, Aux. Hook
7. In the meanwhile platform & ladders fitments with bolts & welding wherever
necessary shall be carried out.
8. Complete electrification & charging of turbine hall crane.
9. After the use of the turbine hall crane with additional mounting trolley in Unit-3, the
additional mounting trolley shall be de-coupled and removed from Unit-3 and shifted
to Unit – 4 for similar work. After completing the similar work in Unit-4 the
additional mounting trolley shall be returned to NPCIL stores through Contractor
Credit Voucher (CCV).
9.6 ERECTION OF ELECTRICAL OPERATED TRAVELLING CRANES:

A. General:
1. Erection of the following type of MHE is covered under this clause.
a. 20/5 T capacity crane (0SMU20AE104)
b. 32/5 T capacity crane (FCD02AE121)
c. 30/5 T capacity crane (FCD01AE071)
d. 1 to 32/5 T capacity cranes
2. The Electrical operated Travelling crane of lifting capacity of 20/5 T
(0SMU20AE104) is located at an elevation of +18.5 m inside the UKS building. The
crane is free issue material to contractor for assembly, erection, commissioning and
testing. SOQR of this tender is for measurement and billing of this crane.
3. Electrical operated Travelling crane of lifting capacity of 32/5 T (FCD02AE121) is
located at an elevation of +16.5 m inside the UFC building. The crane is free issue
material to contractor for assembly, erection, commissioning and testing. SOQR of
this tender is for measurement and billing of this crane.
4. The special Electrical travelling crane of lifting capacity of 30/5 T (FCD01AE071)
is located at an elevation of +16.5 m inside the UFC building. The crane is free issue
material to contractor for assembly, erection, commissioning and testing. SOQR of
this tender is for measurement and billing of this crane.
5. Electrical operated Travelling cranes of lifting capacity varying from 1 T to 32 T are
located in various buildings and various elevations. These cranes shall be assembled,
erected, commissioned and tested by the contractor. The following SOQR of this
tender are for measurement and billing of the cranes for assembly, erection,
commissioning and testing.
 SOQR for the electrical cranes with capacity 5 T,
 SOQR for the electrical cranes with capacity 2T,
 SOQR for the electrical cranes (contractor scope of supply) of capacity
varying from 1 T to 32 T.
B. Assembly and erection:

1. The crane span beam shall be placed on the supports (concrete block/ wooden
sleepers) with enough height for end girders assembly with travel mechanism. The
end girders are fixed to the span beam with bolted joints. The metal platforms and
hand railing shall be assembled and erected around the bridge by welding.
2. The assembled bridge structure of the beam with travel mechanism shall be lifted and
erected over the crane rails by crane with required capacity (The required crane for
lifting and erection shall be the contractor scope). The erected beam structure shall
be locked temporarily in order to prevent movement of the crane over the rails during
the due course of erection activities.
3. The Erection of trolley with travel mechanism and hoisting mechanism shall be
carried out. The operator cabin shall be fixed on the beam structure by pin and bolting.
The metal platforms and hand railings intended for the maintenance of the crane shall
be fixed in position by welding. The suspension of flexible cable is fixed on monorail
with brackets on the side wall of the span girder.
4. For double girder and single span cranes, the operator cabin shall be fixed on the
beam structure by pin and bolting. Anti-seismic restrainers shall be fixed on the
trolley and the span beam by fixing bolts.
9.7 ERECTION OF HOISTS, GRAPPLERS & MANUAL CRANES:
A. General:
1. Erection of the following type of MHE is covered under this clause.
a. Manual Stationary Gear Hoists (Capacity 0.5 T to 5 T)
b. Gear mobile hand operated hoists (Capacity 0.5 T to 5 T)
c. Hand operated Grapplers (Capacity 0.5 T to 5 T)
d. Electrical hoists (Capacity 0.25 T to 10 T)
e. Manual Cranes with capacity of up to and including 5 T

2. Manual Stationary Gear Hoists (Capacity 0.5 T to 5 T) are located in various

buildings and various elevations. These hoists shall be assembled, erected,
commissioned and tested by the contractor. The following SOQR of this tender are
for measurement and billing of the hoists for assembly, erection, commissioning and
testing.
 SOQR for the hoist (contractor scope of supply) of capacity varying from 0.5
T to 5 T.
3. Gear mobile hand operated hoists (Capacity 0.5T to 5T) are located in various
buildings and various elevations. These hoists shall be assembled, erected,
testing.
 SOQR for the hoists (contractor scope of supply) of capacity varying from
0.5 T to 5 T.
4. Hand operated Grapplers (Capacity 0.5 to 2T) are located in various buildings and
various elevations. These grapplers shall be assembled, erected, commissioned and
tested by the contractor. The following SOQR of this tender are for measurement and
billing of the grapplers for assembly, erection, commissioning and testing.
 SOQR for the grapplers (contractor scope of supply) of capacity varying from
0.5 T to 2 T.
5. Electrical hoists (Capacity 0.25T to 10T) are located in various buildings and various
elevations. These hoists shall be assembled, erected, commissioned and tested by the
contractor. The following SOQR of this tender are for measurement and billing of
the hoists for assembly, erection, commissioning and testing.
 SOQR for the hoists with capacity 5 T.
 SOQR for electrical hoists (contractor scope of supply) of capacity varying
from 0.25 T to 10 T.
6. Manual Cranes with capacity of up to and including 5 T are located in various

buildings and various elevations. These cranes shall be assembled, erected,
testing.

 SOQR for the manual cranes (contractor scope of supply) of capacity varying
from 1 T to 5 T.

1. Prior to start of the erection activities the area of erection shall be inspected for
cleanliness and availability of necessary structural arrangement for fixing the hoist in
position and the runway beam for hand operated grapplers and manual cranes. If the
structural arrangement is not available the same shall be erected at site as
recommended in the drawing. In addition, if the embedded structural part is not
available the same shall be fixed by using adequate Hilti bolts as per the drawing/ FE
recommendation. Necessary scaffolding to the height required for erection shall be
made by the contractor at site following the safety norms and requirements.
2. Necessary arrangement for lifting and erecting the support bracket, runway beam and
the hoist shall be made at location. The hoist shall be lifted and erected on its position
with the top hook of the assembly in the erection position. The runway beam shall be
lifted, aligned and erected on the brackets. The hand operated grapplers shall be lifted
and erected on the runway beams. The stopper shall be fixed on the runway beams at
both the ends on either side of the beam by welding/bolting as per the drawing
requirements. The gear operated hand hoist shall be lifted and erected on hand
operated grapplers with the top hook of the assembly in the working position.
3. The travel mechanism shall be assembled to the electrical hoisting device at ground
level. Before erection of the electrical hoist check the voltage and frequency,
indicated on the name plate.
4. The stopper shall be fixed on the runway beams at both the ends on either side of the
beam by welding/bolting as per the drawing requirements. The electrical hoist with
travel mechanism shall be lifted and erected on monorail assembly in the working
position. The current carrier from the circuit breaker to the hoist is done by electrical
cables. Pendent type control shall be used for controlling device of electrical hoist.
5. Both the end girders with travelling mechanism shall be lifted aligned and erected
over the crane runway beams. The span girder shall be lifted and erected over both
the End girders by bolting / welding as recommended by the manufacturer. The
assembled travelling hoist shall be erected under the span girder. The end stops shall
be fixed in span girder and crane runway beams by bolting or welding as specified in
the drawing.
9.8 ERECTION OF PASSENGER AND FREIGHT LIFTS

A. General:

1. Erection of Passenger and Freight lifts of lifting capacity ranging from 400 kg to 5000
kg is covered under this clause.
2. The above Passenger and Freight lifts are located in various buildings and locations.
These lifts are free issue materials to the contractor for assembly, erection,
commissioning and testing. The following SOQR of this tender are for measurement
and billing of the lifts.
 SOQR for the lifts with capacity of 400 kg,
 SOQR for the lifts with capacity of 630 kg,
 SOQR for the lifts with capacity of 5000 kg.

1. Before starting of installation the dimension, verticality and availability of EP’s for
fixing the cabin and counter balance guides of the lift shaft shall be measured and
ensured. Necessary scaffolding arrangements and temporary lifting arrangements shall
be made available in the lift shaft for the entire height of the lift shaft. The bottom of lift
shaft shall be ensured for cleanliness.
2. If EP plates are not available in their respective location the same shall be fixed with
the help of Hilti bolts. The bracket for fixing the guide shall be erected on the respective
locations over the EP plates. The guide for the cabin and the counter balance shall be
erected and aligned over the guide brackets. The lift shaft door shall be fixed starting
from the bottom floor with its mechanism. The buffer supports for the cabin and the
counter balance shall be erected at the bottom of the shaft over the concrete pedestals.
3. The counter balance frame shall be erected and the counter weights blocks shall be
added to the frame to the designed value and fixed to the frame. The cabin shall be
assembled and erected inside the lift shaft. The machine room equipments shall be
erected over the foundation pedestal of the equipment with rope driving pulley.
4. The electrical panels shall be erected inside the machine room in their respective
pedestals. The driving ropes reeving shall be done in accordance with the schematic
diagram of the erection drawing / manufacturer instruction. All the electrical and control
wiring shall be done in accordance with the instruction manual of the manufacturer.
10. ERECTION OF STRUCTURAL STEEL INCLUDING TRESTLE STRUCTURE:
10.1 Support brackets and EP plates:

1. Support brackets and EP plates shall be fixed on concrete ceiling/beam at different
locations and buildings to provide support to MHE.

2. Receipt of fabricated supports brackets and EP plates from NPCIL stores or from any
other designated place within the project premises as free issue materials, shifting to
the location and fixing of same as per the drawings and documents.
3. Arrangement of required man power, tools & tackles, plant & machinery, special
tools, consumables including NPCIL approved electrodes and filler wires, cleaning
aids etc., to complete the work as per drawings and tender specifications.
4. Arrangement of scaffolding material, preparation of staging, platforms, Installation
and de-installation of scaffolding.
5. Preparation of reports, documents required at various stages of the work.
6. Erection in general shall conform to the relevant clauses in IS: 800. In case of any
faulty erection, all such dismantling and re-erection required will be at the
contractor's cost. Any rework / rectification required on the place of erection (roof
EP’s) are to be carried out by the contractor for proper placement of fabricated plates
to the satisfaction of the Engineer by chipping and additional EPs /plate provided
with proper approval issued by ENC. This shall also include any additional inspection
requirements as decided by the Engineer.
7. All Erected structures (EP's and support brackets), assembly and welding executed
in accordance with the WD requirements are to be checked and offered for inspection
by NPCIL Engineer and recorded in a protocol.
8. The works shall be executed as per the drawings, specifications, approved procedures
and to the Instructions of Engineer In-charge.
9. The contractor shall protect all existing plants, embedded parts, all permanent and
temporary structures, piping, conduits, equipment and facilities against damage
during erection. The contractor shall perform his work in a manner, in no way
endangers the operations of any existing plant or structures or hinders other
construction activities.
10. All the support brackets and EP plates will be issued as free issue materials to the
contractor. The SOQR of this tender are for measurement and billing of structural
steel erection.
10.2 Fixing of anchor fasteners for supports:
1. The Hilti or equivalent anchor fasteners shall be fixed on ceiling at different locations
and buildings to fix the EP and provide support to MHE.
2. The scope includes receipt of bolts from NPCIL stores, marking of holes, drilling of
concrete to depth specified in drawings, cleaning the holes and fixing and tightening
of anchor fasteners to the required torque as per the manufacturer’s catalogue.

3. Extra holes may have to be drilled by the contractor if any obstruction of
reinforcement rods occurs in the location. Unused holes shall be filled with dry pack
material.
4. All consumables, machineries power supply, approach platforms, scaffoldings, tools
and tackles and works required for completion is in the scope of contactor.
5. All the anchor fasteners will be issued as free issue materials to the contractor. SOQR
is for measurements of fixing of anchor fasteners for supports.
10.3 Erection of Trestle structures:
Trestle structure in general consists of arm shaped or П-shaped columns with arms
supporting with bottom plates onto concrete base and fixed with foundation bolts.
Monorail beam is fixed on columns arms. Working area with guard for maintenance
of electric hoists is provided in one of columns bay. Shelter is provided for protection
of electric hoists from direct solar radiation and atmospheric precipitation. Electric
hoists with capacities ranging from 2T to 10T lifting capacity are mounted on the
trestle structures erected at UPU, UPX and UQX.
The details of trestle structures are as follows;

KKS Code Designation Attached implements
UPX17BQ800 Trestle L=33,0 m Electrical hoist, 5 T (SMQ24AE300)
UQX17BQ800 Trestle L=22,2 m Electrical hoist, 2 T (SMP24AE200)
UPU17BQ801 Trestle L=21,5 m Electrical hoist, 10 T (SMP24AE100)
The scope of work includes, but not limited to the following;
1. Fabrication and erection of trestle structure works like posts, beams, bracing,
monorails, stops, platforms, handrails, gratings, ladder, anchor bolts and other
structural items for Fore bay (UPU), Fish protection facility (UPX) and Siphon well
(UQX).
2. Contractor shall prepare detailed erection drawings and get approval from NPCIL
before starting the erection.
3. Unless specified in the relevant drawing and specification, all erection work shall be
carried out in accordance with the latest edition of Standard code of practice for use
of structural steel.
4. Tolerances: Standard tolerances as per relevant specifications/ drawing shall be

followed.
5. Work of fabrication & erection as per approved drawings includes, handling,
transportation, storage, drilling, bending, straightening, cutting, bolting, welding
grinding, erection, fixing and aligning in line & level and concreting/grouting of
anchor/foundation bolts.
6. The contractor shall also be responsible for drilling of holes in structures and
matching of holes.
7. Cutting may be done by shearing, sawing or machine flame cutting. All re-entrant
corners shall be shaped notch free. Sheared or gas cut edges shall be dressed to a
neat workmanlike finish and shall be free from distortion and burrs.
8. Hand flame cutting shall be undertaken only if so permitted by the Engineer and shall
only be carried out by an expert in such work. Hand flame cut edges shall be ground
smooth and straight.
9. All the fabricated structural steel members shall be inspected at all stages of
fabrication and assembly to verify that dimensions, tolerances, alignment and surface
finish in accordance with the requirements shown on the Contractor's shop drawings
approved by NPCIL.
10. In case of any faulty erection, all such dismantling and re-erection required will be at
the Contractor's cost. Erection in general shall conform to the relevant clauses in IS:
800.
11. No dragging of fabricated items is permitted.
12. After completion of erection, the contractor shall carry out in-situ touch up painting
wherever paint coating is removed or damaged trestle structures.
13. The Contractor shall protect all existing plants, embedded parts, all permanent and
temporary structures, piping, conduits, equipment and facilities against damage
during erection. The Contractor shall perform his work in a manner, in no way
endangers the operations of any existing plant or structures or hinders other
construction activities.
14. All the erected structures, assembly and welding executed in accordance with the
approved drawing requirements are to be checked and offered for inspection by
NPCIL Engineer and recorded.
15. Arrangement of required man power, tools & tackles, plant & machinery, special
tools, consumables including NPCIL approved electrodes and filler wires, cleaning
aids etc., to complete the work as per approved drawings and tender specifications.
16. Arrangement of scaffolding material, preparation of staging, platforms, installation
and de-installation of scaffolding.
17. Inspection, testing and making arrangements for the acceptance of the structures by
NPCIL.

18. Preparation of reports, documents required at various stages of the work.

19. Completion of work in all aspects, as per tender specification, drawings.
20. The contractor shall supply and install the anchor bolts by concreting/grouting at no
extra cost.
21. SOQR of this tender is for measurement and billing for erection of trestle structure.
11. WELDING REQUIREMENTS:
11.1 GENERAL
1. No welding shall be done on surfaces which are wet or exposed to rain or excessive
draft. Surfaces to be welded shall be free from paint, rust, oil, grease, dust or any
other contamination. Weld edge preparations shall be cleaned by use of approved
solvents only.
2. Welds shall be cleaned between passes to remove all traces of slag and flux before
successive beads or layers are deposited. Completed weldments shall be cleaned to
the same extent. The craters at the starting and stopping points of each individual
bead shall be carefully examined and any defects shall be removed by grinding.
3. Inspection and Quality Surveillance shall not be limited to examination of the
finished weld. All dimensions specified for welding including weld size,
reinforcement, edge preparation, fit up etc. shall be checked by gauges approved by
the Engineer. All aspects of the materials, fabrication procedures and examination
procedures used, that could affect the quality of the finished weld, shall be subjected
to the approval of the Quality Surveyor. The equipment to be used shall be suitable
for the quality of the work specified and the technique employed shall be based on
methods which are known to produce good results and which have been verified at
site by actual demonstrations. All stages of fit-up to final welding shall be checked
and cleared by qualified inspectors/engineers of contractors. Random inspection shall
be carried out by QA representative of NPCIL.
4. The welding technique and arc manipulation shall be controlled to ensure the
following:
a) Full Penetration for groove welds.
b) Full fusion into the preceding bead or layer.
c) Full fusion into the base metal without undercutting along the sides of the weld.
d) Uniformity of surface in both single run passes and beaded layers.
e) Floating all slag, oxide and gases to the surface behind the advancing arc.
f) Delay in electrode travel until base metal fusion at the starting point is assured
and until the crater is well filled at the completion of the weld.
5. Haphazard striking of the electrode on the base metal in establishing the arc shall not
be permitted. The arc should be struck either in the joint where the metal surface will
be fused into the weld or on a starting tab. Starting tabs shall be of the same material
or a material compatible with the base metal being welded. When inadvertent arc
strikes occur, the areas affected shall be ground flush and then examined by the
magnetic particle or liquid penetrant method. High frequency arc starting devices
shall be used for GTAW process.
6. Care must similarly be taken when stopping the arc to avoid an unfilled crater and
crater cracks.
7. The arc should be drawn off to the side of the joint and stopped on the beveled surface
of the joint while extending the arc length rapidly.
8. In GTAW, the machine should ideally be equipped with a foot or hand control to
permit a gradual decrease of current. It is then easier to fill the crater completely and
prevent crater cracks. Alternatively the arc shall be extinguished as mentioned above.
9. When welding carbon steel with covered electrodes, the width of the deposited pass
shall not exceed three times, the nominal core wire diameter. For vertical position
stringer bead is preferred.
10. In GTAW the electrode must be correctly shaped i.e. pointed for DC welding and a
spherical end for AC welding. The electrode extension beyond the gas cup should
be kept as short as is consistent with the joint being welded. The welding torch should
be inclined slightly in the forehand welding position and the filler metal added
carefully to avoid contact with the consequent contamination of the tungsten
electrode. If contamination does occur, the tungsten electrode shall be cleaned and
redressed. Similarly, if the tungsten electrode comes into contact with the weld pool
the operator shall break the arc and grind out the tungsten deposit.
11. Joint design: In all instances the edge preparation for welding shall be as per the
Engineer’s drawings.
12. Fit-up: Before fitting up the weld joint, the profile and dimensions of the weld edge
preparation shall be checked. If the specified tolerances are exceeded this shall be
corrected with prior approval, by grinding, machining or any other method acceptable
to Engineer. All fit-ups shall be examined by the Quality Surveyor prior to welding
the root pass.
13. Weld profile: The surface smoothness of the finished weld shall be suitable for
proper interpretation of the non-destructive examination of the weld. If grinding is
necessary, the weld shall be blended into the parent metal without thinning the basic
wall thickness of the parent or weld metal in any way. Uneven or excessive grinding
may be cause for rejection or re-work at the discretion of the Quality Surveyor. Fillet
welds shall preferably be slightly convex and shall be free from undercutting and
over-lap at the toe of the weld. Convexity shall not exceed 1.6mm Full fusion shall
be obtained at the root of the fillet and in no case shall the leg length of the fillet be

less than the nominal weld size stated in the drawings or specification.The leg length
shall not exceed the specified size by more than 1.6mm. Dimension specified in the
drawing and codes shall be adhered.
14. Tack welds: The number and size of the tack welds shall be kept as small as is
consistent with adequate strength and joint alignment. All tack welds shall be
examined visually for defects and if found defective shall be completely removed.
As the welding proceeds, tack welds shall be either removed completely or shall be
properly prepared by grinding or filling their stopping and starting ends so that they
may be satisfactorily incorporated into the final weld.
11.2 WELDING MATERIALS
1. Contractor shall supply all the welding consumables (including electrodes, welding
wire, inert gas etc.) required to execute the works of subject tender. All these shall
be procured for NPCIL approved vendors only. Copy of list of present approved
suppliers of electrode is enclosed. The following electrodes and wires shall be used:
- E7018 as per ASME section-II part C SFA-5.18
- ER70S2 as per ASME section-II part C SFA-5.9
2. The contractor shall store electrodes and filler wire in a specially developed
controlled atmosphere. The temperature of room shall be maintained not lower than
+200C and not more than 500C. The relative humidity of room should not exceed
50%.
3. The electrode of different type needs to be baked at different temperature. The
contractor shall have mother baking oven of heating capacity not lower than 400 0C.
The baked electrode shifted to site should be stored in a transfer oven at 1500C to
2000C. Electrode should be send to site only through portable oven having heating
range of 1000C and above. Electrode should never be taken to site without ovens.
11.3 WELDING TECHNOLOGY

The contractor may use following welding technologies
a. Manual arc welding with coated electrodes;
b. Manual argon-arc welding with non-consumable (tungsten) electrodes (TIG
welding);
c. Combined welding (root and hot pass by argon-arc welding; final run by manual arc
welding).
11.4 REPAIRS

1. Any weld repair shall be subject to the approval of the Quality Surveyor.
2. Unacceptable defects shall be removed by grinding, machining or chipping. Arc
gouging or flame cutting are also permitted provided gouged surfaces are ground
back at least 1.6mm below the deepest indentation.
3. If preheat is specified in the appropriate welding procedure then the same preheat
must be maintained during flame outing or arc gouging.
4. Dye penetrant examinations shall be used to check that the defect has been
completely removed prior to weld repair. In the event of any doubt regarding
complete removal of a defect, radiography may be required at the discretion of the
quality surveyor.
5. Weld repairs shall be made using qualified procedures and welders. The preparation
for the weld repair shall have the prior approval of the Quality Surveyor.
6. In the event of several unsuccessful repair attempts or if the Quality Surveyor feels
that a satisfactory repair is not feasible, the joint shall be completely remade. Due
consideration should be given to check the damage to the parent metal.
7. The re welded area shall be re-examined by the methods specified for the original
weld. Where radiography is required, a minimum amount of 50mm film overlap
beyond the repair edges must be ensured.
8. Repairs of any base material utilized in fabrication of MHE components shall not be
undertaken unless specifically permitted by the Quality Surveyor.
12. QUALITY ASSURANCE:
12.1 QUALITY CONTROL OF WELDED JOINTS:
Contractor shall prepare QAP for all the erection activities at site and submit for approval of
NPCIL. A sample format for guidance for preparation of QAP is enclosed as Annexure-3 of
this section. The operational control includes inspection of technology compliance in the
course of preparation of details, fit-up, heating, welding process etc
Notwithstanding with the quality control requirement given in referred normative document
/specification, the following shall be applicable during the quality assurance & testing:
a. Certification of inspectors;
b. Inspection of fit-up and weldment;
c. Incoming control of main materials;
d. Quality control of welding materials;
e. Operational and process control;
f. Non-destructive inspection;
g. Destructive inspection;

h. Load testing;
The contractor shall note the following:
1. The MHE erection covered by this contract shall be subjected to stage inspection and
final inspection and testing as per QAP. The Contractor shall provide all required
services and resources to establish and maintain quality of workmanship during
erection.
2. The contractor shall perform his internal inspection / NDT testing before offering the
MHE for NPCIL’s inspection. Only after ensuring that his inspection/test results are
satisfactory, contractor shall offer the MHE for NPCIL’s inspection.
3. The minimum inspection requirements for all components/equipment shall DPT, UT
and RT shall be witnessed by NPCIL as per approved QAP.
4. All MHE / structures erected shall be checked for proper alignment, orientation,
bolting/ welding, torquing etc. The inspection requirement shall be as per WD.
5. Destructive examinations such as mechanical test, inter-crystalline corrosion test,
IGC test, metallographic analysis, determination of chemical composition, and
determination of ferritic phase shall also be carried out to ascertain the quality of the
weld and base. The inspection requirements will be indicated in detail in the final
erection specification.
6. The scope of work under this contract covers erection work which demands highest
degree of quality and reliability standards. In line with these requirements, the
Contractor shall have a dedicated group of experienced and qualified inspection
engineers and inspectors responsible for assuring quality assurance and quality
surveillance program at their work. Further, persons deployed on the job shall be
subject to approval of NPCIL for their technical capabilities.
7. NPCIL shall carry out audit in all phases of the work i.e. procurement, pre-
fabrication, erection, inspection, examination and testing.
8. NPCIL or its authorized representative(s) shall carry out Quality surveillance in all
phases of the work. They will have free access to all areas where works involving the
concerned contracts/purchase orders are in progress. This includes access necessary
to verify the implementation of all aspects of the Quality Assurance Program as well
as access to Sub-contractor’s facilities.
9. Quality surveillance by NPCIL or its authorized representative includes, but is not
limited to, Witness and Hold Points.
10. ‘Witness Points’ are critical steps in examination/ inspection/testing where the
contractor is obliged to notify in sufficient advance of the start of operation/test so
that it may be witnessed. The supplier may proceed with the work past a Witness
Point if the NPCIL QS or its authorized representative is not available at the

appointed time.
11. ‘Hold Points’ are critical steps in examination/ inspection/testing where the
contractor is obliged to notify NPCIL or its authorized representative in sufficient
advance of the start of operation/test so that it may be witnessed. The contractor is
not to proceed with the work past a Hold Point except by written waiver/agreement
by NPCIL.
12. The performance (or waiver) of quality surveillance activities by NPCIL, QS or its
authorized representative does not relieve the contractor of any obligations to meet
all requirements of the drawings/specifications.
12.2 NON DESTRUCTIVE EXAMINATION (NDE):
Non Destructive Examinations of welded joints of MHE shall be performed by the methods
prescribed in working documents
The following Non Destructive Examinations shall be performed by the contractor on the MHE
as per the requirements of working documents. Contractor shall prepare procedure for each
NDE method and submit to NPCIL for approval before carrying out the examinations.
a. Visual and measuring methods;

b. DPT method;
c. Radiographic method;
d. Ultrasonic method;
e. MPT method;
1. Visual: Includes visual inspection of the weld joints and erected components of MHE
as per the approved standards and procedures by qualified and authorized QA
personnel of contractor and NPCIL.
2. DPT: Performance of Dye Penetrant Test of weld joints of MHE, supports brackets
and other structures as per working drawing and documents includes activities like
identification of the test area/joints, Pre-cleaning of joints (test area) and post
cleaning after testing, shifting of DPT consumable to location, Carryout dye penetrant
Testing by ISNT/ ASNT level-II qualified personnel as per the approved procedure,
generating reports, report analysis and submission to NPCIL for acceptance including
arrangements of equipments, manpower, tools tackles materials & consumables and

completion of work as per the tender specification, drawings and as per the
instructions of the Engineer-in-charge.
3. RT: Performance of Radiographic examination of weld joints of MHE, support

brackets and other structures as per the working drawings including providing
necessary machinery, radiographic sources, radiographic cameras, storage including
storage of source at concrete pits, handling, safety arrangements, surface cleaning of
welded joints, removal of paint, grease, slags, burrs, spatters both in CS & SS
materials, installation and dismantling of scaffolding /platforms, arranging materials,
consumables such as radiographic film, developer, fixer etc., Carryout Radiographic
Testing by ISNT/ ASNT level-II qualified personnel as per the approved procedure,
developing the films, marking, generating reports, report analysis and submission to
NPCIL for acceptance including arrangement of manpower, tools, tackles and
completion of work as per the tender specification, drawings and as per the
instructions of the Engineer-in-charge.(Radiographs shall be submitted to Engineer-
in-charge along with RT reports after interpretation).
4. UT: Performance of Ultrasonic Test of weld joints of MHE, support brackets and
other structures as indicated in working drawings and documents. includes activities
like identification of the test area/joints, Pre-cleaning of parts and components on test
area and post cleaning after testing, Sourcing and calibration of the UT machines with
calibration block, shifting of the Ultrasonic flaw detector along with probes and
accessories to location, Carryout Ultrasonic Testing by ISNT/ ASNT level-II
qualified personnel using both normal and angle probes, generating reports, report
analysis and submission to NPCIL for acceptance including arrangements of
equipments, tools tackles, materials & consumables and completion of work as per
tender specification, drawings and as per the instructions of the Engineer-in-charge.
5. MPT: Involves carrying out Magnetic Particle Testing on equipment and supports
which includes activities like identification of the test area/joints ,Pre-cleaning of
parts and components on test area and post cleaning after testing, shifting of MPT
consumables to location, Carryout Magnetic particle Testing by ISNT/ ASNT level-
II qualified personnel as per the approved procedure, generating reports, report
analysis and submission to NPCIL for acceptance and including arrangement of
plant & machinery, manpower , tools tackles & consumables and completion of work
as per the tender specification, drawings and as per the instructions of the Engineer-
in-charge.

13. COMMISSIONING AND TESTING OF EQUIPMENTS:
13.1 PRE-COMMISSIONING CHECKS AND PREPARATION FOR TESTS:
1. After completion of erection as per drawing and manuals contractor shall carry out
visual checks on the MHE as part of pre-commissioning checks to ensure that all
parts of mechanical, structural, electrical fitting, lights, limit switches including
earthings, buffers, bell/hooter, fasteners, welding, touch up painting, safety devices
or if any are in place signifying readiness of the crane for testing.
2. The temporary arrangements made for erection of MHE and inside the lift shaft shall
be removed.
3. The erected hoists grapplers shall be re-preserved and the lubrication shall be applied
on the lubrication points as per the manufacturer’s instruction.
4. All the commissioning works shall be properly documented as commissioning
reports and shall be submitted to NPCIL. Check lists, data sheets, commissioning
procedures etc., shall be prepared before the start of commissioning works and
approval shall be obtained from NPCIL.
5. The checks shall be carried out for the load testing as per the WD requirements. The
requirements of relevant Indian standard/ AERB safety guides shall also be followed.
The stringent of either of these requirements have to be met when there are variations
in the requirements of the standards. Some of the checks to be performed on the crane
subsequent to completion of work prior to load test is given below.
6. All the checks shall be recorded in a format to be agreed to the ENC and submitted
as a part of CCC.
7. The test loads shall be transported from NPCIL stores to the testing location and
contractor shall make necessary arrangement for load testing of the crane. All lifting
tools and tackles including arrangement of competent person for certifying the Load
Test shall be arranged by the contractor.
13.2 PRE-COMMISSIONING OF MECHANICAL WORKS:

1. Installation of girders for EOT cranes, fixing of rails, checking their alignment,
elevation and central line with respect to the building, clearances with respect to
building to be within the specification and recording the data.
2. Installation of I-beams and their supports for trolleys, checking their elevation,
central line, alignment and position with respect to building / equipment and
recording the same.

3. Installation of Chain pulley blocks and their supports, checking their elevation,
central line, height of travel, alignment and position with respect to building /
equipment and recording the same.
4. Installation of elevators car shaft, alignment, fixing, car cabin, landing door, gear box
machines alignment in machine room.
5. Completion of all drive elements, lubrication of gear boxes, gears, bearings,
installation of all protective guards, installation of approach platforms, etc.
13.3 PRE-COMMISSIONING OF ELECTRICAL WORKS:
Contractor shall carry out the following general checks on the electrical equipments of the
cranes as part of pre-commissioning / commissioning checks.
1. Any physical damage to the control panels, proper tag number, healthiness of the
terminal blocks used inside the panel, healthiness of the gasket, insulation resistance,
connection of two earthing terminals suitable for grounding, proper glanding, etc
shall be checked on the control panels and rectified by the contractor.
2. Any physical damage to the pendent, healthiness of the terminal blocks used inside
Pendent, healthiness of the gasket, healthiness of the push buttons, insulation,
earthling connection, etc shall be checked on the crane operating pendent and
rectified by the contractor.
3. Installation, access to motor, proper illumination at the motor location, proper
cleanliness of the motor surface, foundation bolt tightness, level of foundation,
bearing lubrication, free rotation of motor after de coupling the motor, motor frame
grounding, proper power cable support, earthing connection for continuity and
tightness, overload relay setting, healthiness of control supply fuses if any, any
physical damage to the power cable, availability of tag number for the cable,
insulation resistance of the cable, terminal box of the motor, etc shall be checked on
the motors and rectified by the contractor.
4. After completion of the erection activities the power and control cables shall be
checked for its routing and termination and continuity as per the circuit diagram.
Layout of the power and control cables shall be ensured to be in a protected route to
avoid physical damage due to movement of personnel, crane movement etc. along
with necessary support clamping and arrangement. Ends of the cables shall be
crimped with cable lugs with cable crimping tool. Proper tagging of cables shall be
done. Ferrules shall be provided for the internal wiring and identification of the wires
shall be printed in the ferrules using ferrule printer. The internal wiring of the panels

shall be checked for continuity. Shielded cables of the encoders shall be laid carefully
without any sharp bends.
5. Contractor shall ensure the continuity of control cables from equipment junction box
to individual control panels, power cables from equipment junction box to
MCC/switchgear and installation of down shop leads/ insulated bars for the electrical
supply and electrical grounding of equipments.
6. The internal components like relay, contactor and meters of the panel shall be
checked for healthiness.
7. The software for PLC & variable frequency drives of the cranes shall be installed and
necessary assistance shall be provided by the contractor to the crane manufacturer for
the same.
8. Contact resistance of DSL shall be checked by micro ohm meter.
9. All the interlocks, logic and functional tests shall be carried out by the contractor.
10. Contractor shall check the main distribution board / switch fuse unit and cable laying
from main distribution board to the local distribution board and further distribution
to the respective loads.
11. Contractor shall carry out the measurements of IR value of all the motors of driving
system and braking system, resistance and inductance measurement, the no-load
operation of the motor and measure parameters like running current, voltage, speed,
winding temperature, bearing temperature etc and corrected if necessary.
13.4 CHECKING OF CONFORMITY OF MHE:

The following should be checked for compliance to the working documents.
1. Lifting capacity of the crane
2. Lifting height of MHE
3. Hoisting speed of MHE
4. Lowering speed of MHE
5. Travelling speed of the crane (longitudinal travel and cross travel).
6. The functions of the limiting devices
7. The working characteristics of the power drive means, for example, electric current
in the electric motors under the conditions of the test loads.
13.5 VISUAL CONTROL:
The visual control is carried out to establish the conformity of the crane to passport data of the
parameters the important one are listed below.
1. Mechanism, electric equipment, safety devices, brakes, control apparatus, lightening
and signaling.

2. Metal constructions and their connections, ladders, the approach means.

3. The repair platforms must provide convenient approach to the mechanisms and
electric equipment.
4. Check the headroom available from the crane girder to roof structures to be within
requirements.
5. Protective measures – Fencing especially for current supply devices.
6. Hook or another load handling fixture and the parts for their suspension.
7. Ropes and their fixing – clamping devices are fitted properly.
8. Fixing of the rope to the drum must be done with the reliable means, which allows
substituting the rope. In case of usage of the clamp bars there must be at least two of
them. The length of the free end of the rope after the last clamp must be at least two
rope diameters.
9. Check that the rope capacity of the drum must be such, that at lowest possible position
of the load fixing device the rope shall remain rolled on the drum at least 1.5 turns of
the rope or chain, not taking into consideration the turns under the clamping device.
10. Check that the load hoists with two drives must have the rigid connections between
them, preventing the spontaneous going of the load down in case of failure of one of
the devices.
11. Cranes, running over the railways in the open must be equipped with the rail anchors.
12. Blocks, axles and the parts of their fixing.
13. Limit Deviations of the Rail Tracks (in the plan and profile).
14. Difference of the rail heads elevation in one cross section, Difference of the rail
elevations at the neighboring columns, Tapering or widening of the rail-way gauge
(deviation of the rails from the project position in the plan), Mutual displacement of
the butt ends of being connected rails in the plan and in the height, Gaps in the joints
of the rail shall be measured and recorded in mm.
13.6 CONDITIONS OF THE TESTS ON MHE:
1. For the tests, the crane must be equipped with the working equipment for the
operation with the nominal load in accordance with technical documentation.
2. Test of the crane moving over the rail way, should be conducted on the track,
executed and laid in accordance to the conditions established in the technical
documentation.
3. During the test, the speed of the wind should not exceed 8.3 m/s where ever
applicable.

13.7 FUNCTIONAL TESTS ON MHE:

1. The functional test on all MHE shall be conducted at no-load condition and adjusted
if necessary. The test must include the repeated start and stop for each movement in
the whole range of the given movement and they must continue for at least 1 hour in
the cycle of work.
2. The operational check of the hoist shall be checked as per the manufacturer
operational check list. The hoist shall be checked for free movement without load.
3. The gear mobile hand operated hoist shall be checked for free movement of rising
and lowering of hoist and the movement of grapplers along the axis of the hoist
runway beam without load. Also the movement of hand grapplers along the
longitudinal axis of runway beam shall be checked.
13.8 LOAD TESTS ON MHE:

Static load test, dynamic lest and stability test shall be conducted on MHE for its suitability
of the work. Prior to load testing the dimensions of the identified chain link shall be noted and
also the throat opening dimension of the hooks (Top & Bottom) shall be noted and recorded.
1. Static tests are executed to control the design serviceability of the crane and its
assembly units. The tests are considered successful in case during their execution;
there have been no cracks, no residual deformation, peeling of the paint or damages
and no slackening or damage of the joints. Static test should be conducted for each
MHE in the positions and execution variants such that the gradually increased test
load is elevated from the ground by 100-200 mm and kept in this position during the
period necessary for conducting the tests not less than 10 min. The test load for all
the cranes must be at least 1.25 times of the rated capacity if no higher value is to be
applied as per norms/ standard.
2. Dynamic tests are conducted to control the functioning of the crane mechanism and
brakes. The crane is considered as having successfully passed the tests in case the
elements of the crane fulfill their functions and there will not be any discovered
damages of the mechanisms or of the construction elements and no slackening of the
joints. The test load for all the cranes must be at least 1.1 times of the rated capacity
if no higher value is to be applied as per norms/ standard.
3. Stability Test: The test for the load stability is conducted to control the stability of
the crane. The crane is considered as having successfully passed the test, if it does
not overturn at the static application of the load to the hook.
4. The Load Test of polar and trestle cranes shall be performed at different stages as
detailed below.
 Safe working load at 100% (350T)

 Static load test at 125% of the rated capacity (437.5T)

 Dynamic load testing at 110% of the rated capacity (385T)
5. The Load Test of Turbine hall crane shall be performed at different stages as
detailed below.
 Static test of erection (Load) trolley at 125% (225T)
 Static test of mounting trolley at 125% (225T)
 Combined static test using the lifting beam of capacity 419 T
 Combined dynamic test using the lifting beam of capacity 369 T
6. The Load Tests of Hoists & grapplers shall be performed at different stages as
detailed below.
 Static test at 125% of the rated lifting capacity of the hoist. The load shall
be lifted to a height of 200mm to 300mm and hold it for 10 minutes.
During the static test the initial height and final height of the load from
ground level is measured and recorded. After lowering the load the
dimension of the identified chain link and the throat opening of the hooks
(Top & Bottom) shall be measured and recorded. The deflection of the
beam shall be measured and also the tightness of the fasteners of the
bracket shall be ensured. The measured dimensions shall be within the
acceptance range.
 Dynamic test at 110% of the rated lifting capacity of the hoist. The load
shall be raised and lowered to check the free movement of the hoist and
also the brake of the hoist with load shall be ensured by releasing the hand
chain at any point during raising or lowering for holding the load at any
point.
7. The Load Test of the Lifts shall be performed at different stages as detailed below.
 Safe working load at 100%

 Static load test at 200% of the rated capacity
 Dynamic load testing at 110% of the rated capacity
After completion of the load test the temporary arrangements made for erection of the MHE
shall be removed.

14. GRIT BLASTING AND PAINTING:
Grit blasting & Painting has to be performed for the various components of MHE surfaces as
mentioned in the working drawings. Material shall be inspected for any damage, lamination
etc.
Grit blasting: Grit blasting of the MHE component surfaces shall be carried out on the
surfaces wherever painting is to be removed to meet the surface finish requirements of friction
grip joints. After grit blasting the surface shall be cleaned by blowing dry air / vacuum cleaner
to remove the dust etc. Grit blasting shall be carried out to meet the surface finish requirement
of the manufacturer.
Painting: After completion of erection of MHE the contractor shall carry out touch up painting
in-situ as per the manufacturer recommendation.
15. ELECTRICAL GROUNDING OF EQUIPMENTS:
Contractor shall provide grounding connection for all the MHE to the grounding grid of the
project as part of the main erection work of MHE without any extra cost. This shall be executed
as per approved procedures and document. Procedure shall be prepared by contractor and
approved by NPCIL. The scope shall include supply of materials required for electrical
grounding of MHE and fixing of same.
16. GENERAL TECHNICAL REQUIREMENTS:
The general technical requirements are based on norms, standards and practices followed for
such jobs. The engineer shall have the right to amend the existing and to issue additional
specifications whenever the need arises. In the event that certain technical requirements are
not described in the engineer’s specification, the contractor shall request the engineer, prior to
starting any fabrication to clarify governing requirements.
16.1 Threading: The contractor shall be responsible for threading all mating components wherever
required. Prior to making a screwed joint, the threads shall be thoroughly cleaned of all foreign
matter, oil, grease etc. Any thread that has become blurred or deformed shall be repaired prior
to assembling the joint. No lubricants or sealants shall be used on threaded joints.
16.2 Tightening of bolts: All bolts shall be engaged in such a way that there is visible evidence of
complete threading through the nut or threaded attachment. At least two threads on bolt should
project beyond nut. The bolt stress in all flanged joints shall be relatively uniform. All threads
of bolts and nuts shall be cleaned by suitable means so as to be free from any foreign materials
and suitably approved lubricant whenever specified shall be used prior to tightening of bolts.
Torque Wrenches shall be used for tightening of bolts to ensure controlled tightening. Torque
values for various sizes of bolts for tightening shall be as per specification in drawings.
16.3 Removal of caps: Removal of caps and other closures from all MHE components supplied
with temporary caps is included in contractor’s scope of work. This shall be considered as part
of edge preparation and job shall be done without any extra charges. The removal of caps shall
be done by grinding or sawing off only. Any damage to the equipment during the process of
removal of the caps shall have to be made good by the contractor’s at his own cost.
17. HOUSEKEEPING & CLEANLINESS:
Project instruction for housekeeping enclosed in the tender shall be complied. The contractor
shall thoroughly check and remove the extraneous materials, if any, like electrodes, welding
rods, helmets, bolts/nuts, etc. left in the working place. Cleaning shall be done on day to day
basis. All the waste collected shall be stored in sealed container and to be removed on weekly
basis. All wastes generated like surplus earth after use/surplus construction materials to be
disposed off from time to time to the disposal locations as directed by the site Engineer In-
Charge.
Handling, Transportation & Disposal of the waste generated during construction, installation,
commissioning, etc shall be a part of the contractor’s scope of work. Contractor to collect such
waste generated within battery limit and then transport and dispose to the locations as directed
by the site Engineer In-Charge. Also, housekeeping of the area under the control of the
contractor shall be a part of the contractor’s scope of work.
Scope includes but not limited to:
a. Debris Disposal:
Involves collection of debris from various floors of buildings, transportation and disposal
to waste yard which includes activities like survey of the buildings, identification,
collection and removal of dust, electrode waste, welding waste, cutting waste, grinding
waste, packing material, cement debris, aggregate, waste sheets, cut pieces of wires/cable
etc. from working place and disposal at designated dump yard with in 2 Km distance. This
work also includes providing man power, P&M, all tools & tackles required for completion
of work, making & maintenance of reports as per tender specification and as per the
instructions of the Engineer-in-charge.
b. Surface Cleaning of MHE:

Involves cleaning of external surfaces of all MHE which includes activities like removal
of dust, unwanted sticking, foreign particles and other forms of dust, from the surface of
MHE including providing all necessary cleaning aids and appliances. This work also
includes arranging manpower, consumables and all other required tools and tackles
required for the completion of work as per tender specification and as per the instructions
of the ENC.
When work is going on it is the responsibility of the contractor to maintain clean

environment by maintaining good housekeeping. Project instruction for housekeeping
enclosed in the tender shall be complied. It is necessary to identify the person who is
responsible for the same.
18. RECORDS AND REPORTS:
18.1 Records:
The contractor shall maintain records pertaining to the storage, welding, erection, alignment,
inspection and testing work in compliance with all drawings and technical requirements. The
records shall be in a proper format as indicated by the Engineer. The contractor shall submit
the copies of such-records to the Engineer within 7 days from completion of any particular
work, and prior to submitting bill for progressive payments. The report concerning welding,
alignment of the MHE is included in this category. The Engineer shall need certain records
for verification viz. weld inspection report, consumable certificate, etc. The contractor will
have a system of record to facilitate easy traceability of all such records. These records shall
be subjected to the inspection of engineers, auditing group, AERB, Russian representatives
etc. Soft (scanned) copies for the all the reports, records shall be made and submitted to NPCIL
18.2 Reports:
The contractor shall submit on weekly basis, to the ENC three (3) copies of following reports
indicating the details of MHE erection progress, testing status, QA activities, etc.
(i) MHE erection progress report

(ii) General statement of activities
(iii)Welders performance & qualification records
(iv) Weekly report on items on critical paths
In addition to above, the following reports shall be submitted to the engineer every month:
(i) Daily, weekly, fortnightly and monthly progress reports
(ii) Monthly planning report
(iii) Three and Six months rolling schedules
All reports shall be statistical and on tabulated form indicated by the engineer.
19. COMPLETION OF WORK AND SUBMISSION OF CCC & MATERIAL

ACCOUNTING:
1. Completion of work: As far as technical requirements are concerned, the

contractor’s work shall be considered as completed when all the MHE are installed
and have passed all examination, inspection and tests requirements and painted and
complete in all respects in accordance with drawings and specifications. The
contractor shall be responsible for rectifying the defects and deficiencies revealed
during testing or commissioning of the MHE, on the joints, in consultation with the
Engineer and QS so as not to delay other works or testing.
2. Construction Completion Certificate (CCC): The contractor shall submit CCC

attaching all relevant documents needed for attesting the completion of work for each
MHE. The CCC in the approved format shall be submitted to the ENC and shall be
subject to endorsement by the ENC. The CCC for each MHE shall contain the
following.
1. MHE descriptions
2. Manufacturers instruction / literature
3. As-built drawing information
4. Important correspondence
5. List of WD (with rev. no.) including FCN, ECN & DCN certified
6. Weld inspection reports & radiographic test final results
7. Weld procedures (welding and fabrication procedures, WPS & PQR)
8. Erection procedures for mechanical components (including forming and
assembly procedures)
9. Mechanical joint inspection report [ blasting / painting ]
10. Equipment erection & alignment report
11. Commissioning and testing procedures
12. Commissioning and testing reports
Final completion certificate will be issued only after the ENC has accepted all CCC’s
and after other provisions of general contract conditions are duly met. Along with the
hard copy of final CCC the contractor shall submit scanned copy in soft form (pdf
format).
3. Material accounting: Contractor shall establish facility for soft ware based material
management system for the free issue materials, compatible with the NPCIL's
software. Contractor shall prepare material accounting taking into the consideration
of materials issued through various CIV, consumed through various erection reports,
returned back to NPCIL’s stores through CCV and tally the quantities and submit to
NPCIL for acceptance.

20. CONFIDENTIAL INFORMATION:
The drawings, specifications, proto-type, samples and such other information furnished to the
contractor relating to the supply/works/equipments etc. are to be treated as confidential, which
shall be held by the contractor in confidence and shall not be divulged to any third party without
the prior written consent of the engineer. The contractor, therefore, binds himself, his
successors, heirs, executors, administrators, employees and the permitted assignees or such
other persons or agents directly or indirectly concerned with the works/supply to the
confidential nature of the drawings, specifications, proto-type samples etc. It is a further
condition of the contract that the Contractor shall not, without prior written permission from
the Engineer, transmit, transfer, exchange, gift or communicate any such confidential
information and also the component, sub-assembly, products, by-products, non-
conforming/rejected equipment/components, etc. to any third party.
21. PATENTS AND PATENT RIGHT INDEMNIFICATION:
All specifications, drawings, patents and such other relevant information furnished to the
contractor by the engineer shall be the property of the engineer. If, during the process of
execution of the contract, any improvement, refinement or technical changes and modifications
are affected by the Contractor, such changes shall not affect the title to the property of the
engineer and the information, specifications, drawings, etc. including the
improvement/modifications effected by the Engineer. The Engineer shall also have the
absolute right to assign, transfer, sublet, use and transmit all such information and details to
the Engineer’s consultants. Contractor shall not have any claim or rights whatsoever in respect
of the Engineer’s drawings, specification, patents, proto-types etc. even where improvement
refinement, modifications etc. were affected by the contractor.
All drawings, specifications, patterns, models and prototypes furnished to the contractor by the
Engineer are intended to be complementary and to provide for and comprise everything
necessary for the completion of work/supply and are the property of the Engineer. These are
not to be used for any works or purpose other than those for which these have been provided
and shall be returned to the Engineer immediately on completion of work/supply in good
condition.

1. DISTRIBUTION
Sl. No. Copy Holder Copy No.
1 Master copy with Doc centre Original
2 All CEs / ACEs / PEs / ENCs #
# Soft copies issued through IPMIS

Annexure‐1
LIST OF SAMPLE DRAWINGS
Sl. Building No of
Drawing No Drawing Name Remarks
No KKS code sheets
Installation Drawings for whole load lifting
1 UJA R01.KK.1 UJA.0.MRR.OK.WD001 17
equipment.
Installation drawing for load lifting equipment
2 UKC R01.KK.1 UKC.SMK.MRR.OK.WD001 25
upto el. +14,000
Installation drawings for load lifting
3 UKC R01.KK.1 UKC.SMK.MRR.OK.WD002 9
equipment above to el. +14.000.
4 UKC R01.KK.1 UKC.SMK.MRR.OKU.WD003 8
equipment.
Installation drawing for whole load‐lifting
5 UMV R01.KK.1 UMV.SMM.MRR.OK.WD001 8
equipment
Installation drawings of the electrical bridge
6 UMA R01.KK.1 UMA.SMM.MRR.OK.WD001 4
crane ith a capacity of 180+180/32 ton
7 UMA R01.KK.1 UMA.SMM.MRR.OKU.WD002 equipment except cranes for load lifting 19
capacity of 180Te
1‐4 UKD Installation drawing for whole load
8 1‐4 UKD R01.KK.1 UKD.SMK.MRR.OKU.WD001 12
lifting equipment
Installation drawing for all load lifting
9 USA R01.KK.1 USA.SMS.MRR.OKU.WD001 3
equipment
10 UBA R01.KK.1 UBA.SMB.MRR.OKU.WD001 6
equipment
Installation drawing for whole load lifting
11 05 UKD R01.KK.0 5UKD.SMK.MRR.OKU.WD001 5
equipment
Installation Drawings for whole load liting
12 UFC R01.KK.0 UFC.FCD.MRR.OK.WD001 3
equipment
13 UBA R01.KK.1 UBA.SMB.MRR.OKU.WD001 6
equipment
1 UQA, UQC, UPU, UQX Installation drawing
14 UQA R28.KK.1 UQA.PA.KM.OK.WD016 for all load lifting equipment. Main pump 2
station. Superstructure
15 UQC R28.KK.1 UQC.PE.KM.OK.WD009 for all load lifting equipment. Essential loads 5
pumps houses
16 UQX R28.KK.1 1UQX.0.KM.OK.WD002 for all load lifting equipment.1 1UQX...1 4UQX 3
Siphon wells
17 UPU R28.KK.1 UPU.0.KM.OK.WD003 3
for all load lifting equipment. Forebay
1 UPC UPX Installation drawing for all load
18 UPX R28.KK.1 UPX.0.KM.OK.WD007 4
lifting equipment. Fish Protection Facilities
1 UPC UPX Installation drawing for all load
19 UPC R28.KK.1 UPC.0.KM.OK.WD006 4
lifting equipment. Water intake.
20 02UGW R01.KK.0 02UGW.SMG.MRR.OK.WD001 2
equipment
Installation drawing for whole load‐lifting
21 UKS R25.KK.0 UKS.SMU.RO.OK.WD001 10
equipment
Installation drawing for load lifting
22 UBZ R01.KK.1 UBZ.SMU.MRR.OKU.WD001 7
equipment.
23 UKZ R01.KK.1 UKZ.SMU.MRR.OKU.WD001 Installation drawing for load lifting equipment 4
1‐7UUQ Doors,manholes,ladders,gratings,
24 UUQ R37.KK.1 UUQ.PE.KZ.OK.WD001 31
hoisting gears
1‐7 UUP Doors, manholes, ladders,gratings,
25 UUP R37.KK.0 UUP.PE.KZ.OK.WD001 25
hoisting gears.
Annexure ‐ 2
LIST OF FREE ISSUE MATERIALS
KKS code of
Sl.No KKS code of MHE Description of MHE Qty Remarks
building
Crane of circular operation(Polar) with
1 UJA FCA07AE071 2
Load lifting capacity 350/190+32T
Trestle crane with Load lifting capacity
2 UJG FCJ07AE041 2
350/190/32T
3 UMA SMM20AE001 Travelling supporting electric crane 2

with Load lifting capacity 180+180/32T
Bridge support electric crane with Load
4 UKS SMU20AE104 1
lifting capacity 20/5T
Special electrical bridge crane with Load
5 UFC FCD02AE071 1
Special electrical bridge crane with Load
6 UFC FCD02AE121 1
Electrical operated travelling
7 UKS 00SMU20AE101 crane with Load lifting capacity 5 T 1
Electrical hoist with Load lifting capacity
14 UKS 00SMU24AE104 1
5 T
15 UJA UJA21AE601 Passenger lift capacity 400Kgs 2
16 UJG UJG11AE601 Passenger lift capacity 630Kgs 2
17 UKC UKC06AE602 Passenger lift capacity 400Kgs 2
18 UKC UKC06AE603 Passenger lift capacity 400Kgs 2
19 UKC UKC06AE601 Freight lift capacity 5000Kgs 2
20 UMA UMA02AE601 Passenger lift capacity 400Kgs 2
21 UMA UMA10AE601 Passenger lift capacity 400Kgs 2
22 UBA UBA02AE602 Passenger lift capacity 400Kgs 2
Annexure ‐ 2
LIST OF FREE ISSUE HILTI BOLTS
SL.No Hitli bolts & Type UOM QTY REMARKS
1 HDA T-M12X115/20 Nos. 36
2 HDA T-M12X125/30 Nos. 268
3 HDA T-M12X125/50 Nos. 80
4 HDA T-M12X190/30 Nos. 576
5 HDA T-M12X190/40 Nos. 176
6 HDA T-M16X190/40 Nos. 576

7 HSL 3G M10/20 Nos. 20
8 HSL 3G M12/15 Nos. 192

9 HSL 3G M12/25 Nos. 232
10 HSL 3G M16/25 Nos. 360

11 HST M16/140 Nos. 8
12 HST M16/25 Nos. 16

13 HST M10 Nos. 8
Annexure ‐ 2
LIST OF FREE ISSUE BRACKETS & ANCHOR PLATES
Sl.No Description of MHE Qty (MT) Remarks
1 Brackets, anchor plates etc., 130
ANNEXURE ‐3
QAP FORMAT FOR GUIDANCE

Contractor Item: Material Handling Equipment(MHE Package)
Kudankulam Nuclear Power Project Drg No:
Quality Assurance Plan (Indicative) QA category: QA2 KKS No:

1 2 3 4 5 6 7 8 9 10 11 12 13 14
Category Agency Agency Remarks
Description Attribute (Characteristic Quantum Reference Acceptance Format of Contractor NPCIL
No of Type of check / Annex.
(Component/Operation) of inspection/test) of check document norm record
Attribute Exe. QA Exe. QA
1 Incoming material & Raw Material check
As per
Identification, Marking, Un Manufacturer
1.1 Physical Major Packing list / SSIR 100% manufacturer IMIR P H W H
packing & Quantity verification document
document
Identification of welding and NDT Physical &
1.2 Major TC Review 100% MTC As per ref. standard Test report P H S H
consumables Chemical Properties
2 Qualification
Welding process Visual, NDT, PNEAG
2.1 WPS,PQR requirements parameters Major destructive 100% ‐07‐003‐89 As per ref. standard WPS & PQR P W H H
testing ASME SEC IX
PNEAG‐
2.2 Qualification of welders Skill ,performance Major Visual, NDT 100% 07‐003‐89 ASME As per ref. standard WQR P W H H
SEC IX
Procedure qualification of grit Meeting the tender TC review, trial Qualification
2.3 Major 100% Drgs & Documents As per ref. standard P W H H
blasting /drawing specification testing record
surface profile,cleaning visual,
2.4 Qualification of grit blasters Major 100% Drgs & Documents As per ref. standard BPQR P W H H
visual measurement
Performance
Qualification of Anchor bolt Visual, Performance
2.5 Skill ,performance Major 100% Certificate,Procedure As per ref. standard P W H H
installation (HILTI ) operator Measurement Report
for qualification
3 Pre assembly & Erection of MHE
Check the readiness of
Work front clearance for MHE Visual,
MHE, civil front etc, Civil front & MHE Completion
3.1 erection Major Measurement & 100% Protocol P H H H
with reference to drawings protocol
Record verification
drawing.
Identification,verification Visual, Drgs & Documents
3.2 Identification of MHE and its As per drawings
of Qty, marking, item No. Major Measurement & 100% as applicable and IMIR P H H H
components and packing list
and dimensions Record verification WP
Cleaning of MHE, Drgs & Documents As per the
Depreservation, Handling & Inspection
3.3 removal of temporary Minor Visual 100% as applicable and manufacturer’s P H W H
storage Reports
covering, degreasing etc. WP document
Checking of proper
Transportation of materials to Drg & Documents As per drawings
3.4 loading in truck,proper Minor Visual 100% MMR P H W S
erection site as applicable & WP and packing list
stacking and packing etc.
Checking of
Fit up, alignment and erection of
level,elevation,verticality, Visual,
Trestle structures, Brackets of Alignment
3.5 span & diagonals as per Major Measurement 100% Drgs & Documents As per drawings P H W H
monorail, car rail, CW rail, CT rail reports
drawing.
clamp, Lug etc.,

Assembly and erection of girders.
End carriages, Hoisting Checking of Visual and
As per drawings
mechanism and travelling level,elevation,span & dimensional Alignment
3.6 Major 100% Drgs & Documents and manufactures P H W H
mechanism of the diagonals as per drawing. measurement reports
documents
electrically/manually operated
crane
Visual and As per drawings
Assembly and erection of Checking of location and Drg & Documents Alignment
3.7 Major dimensional 100% and manufactures P H W S
electrical/manual hoists elevation as applicable & WP reports
measurement documents
Assembly and erection of car
Checking of level, Visual and As per drawings
cabin, landing doors, counter Drg & Documents Alignment
3.8 elevation, verticality, Major dimensional 100% and manufactures P H W S
weight and winch with motor of as applicable & WP reports
diagonal and alignment measurement documents
passenger/freight lifts.
Ensure required process,
Visual, Record Drg & Documents
3.9 welding process Welder & Welding Major 100% As per WPS WIR P H S H
verification as applicable & WP
Parameters.
Availablity of WPS, PQR
Record verfication,
Welding of bracket to the & WPQ
3.10 Major Visual & 100% Drgs & Documents As per drawings WIR P H W S
embedded plate(EP), Monorail, CT Ensuring welding
Measurement
rail clamp, Lug etc., parameter
Visual, Record Drg & Documents
3.11 weld root & final visual inspection weld defects Major 100% As per ref. standard WIR P H S W
verification as applicable & WP
Visual,
Erection of electrical cable and Routing of electrical
3.12 Major Measurement 100% Drgs & Documents As per drawings IR P H S W
wiring system cables as per drawing

4 NDT and Testing
Approved
4.1 RT / UT(plate, I beam butt joints) Defects Major Test *20% Approved Procedure IR P H S W
Procedure
Approved
4.2 DPT Surface defects Critical Test 100% Approved Procedure IR P H S W
Procedure
Approved
4.3 MPT Surface defects 100% Approved Procedure IR P H S W
Procedure
5 Commissioning & Load testing
As per the
Continuity check of electrical
5.1 Multi meter Major Verification 100% manufacturer’s NA Protocol P W H W
circuits
document
As per the
5.2 IR value of electrical motors Megger, Multi meter Major Measurement 100% manufacturer’s NA Test reports P W H W
document
Coupling
Visual and
5.3 Coupling of motor & gear box Alignment Major 100% Drg ,Documents As per drawings alignment P H S W
measurement
report
Verification of WD
Preparation of load testing Preparation and W.D & manufacturer Approved
5.4 Major with manufacturer 100% Test report P W H S
procedure submission documents Procedure
drawing
Record verfication,
Final acceptance clearance of load Verification of erection & Drg & Documents as Approved Alignment
5.5 Major Visual & 100% P H H H
testing alignment reports applicable & WP Procedure reports
Measurement
Checking for direction of
No load trails for electrically motors, operation of Visual, Drg & Documents as Approved
5.6 Critical 100% Test reports P H W W
operated hoist and cranes brakes, hooks approach, Measurement applicable & WP Procedure
height of lift(max & Min)
5.7 a)Manually operated Hoists (stationery & movable)/ cranes/grapplers
Checking for slippage of Visual, Drg & Documents as Approved
5.7.1 Static test (125% of SWL) Critical 100% Test reports P H W W
brakes Measurement applicable & WP Procedure
Checking for movement Visual, Drg & Documents as Approved
5.7.2 Dynamic test (110% of SWL) Critical 100% Test reports P H W W
of hoist Measurement applicable & WP Procedure
5.8 b)Electrically operated hoist / cranes
brakes and deflection Measurement applicable & WP Procedure
Checking of CT, LT
Visual, Drg & Documents as Approved
5.8.2 Dynamic test (110% of SWL) motion and hoist up and Critical 100% Test reports P H W W
Measurement applicable & WP Procedure
down motion
5.9 c)Passenger/Freight Lifts
brakes Measurement applicable & WP Procedure
Checking for operating
speed, limit switches Visual, Drg & Documents as Approved
5.9.2 Dynamic test (110% of SWL) Critical 100% Test reports P H W W
functioning and door Measurement applicable & WP Procedure
open/close at stops.
6 Final Completion
Visual, Final
As per the
Final Inspection after erection & Measurement, As per the approved Erection
6.1 Final and reporting Major 100% approved P H R H
Documentation Review of test procedures reports
procedures
Documents
Construction completion Completion of all
Document As per the approved
6.2 certificate submission Verification of records Major 100% Erection & QA CCC Format P H H H
Verification procedures
Documents
Note:
The above QAP is comprehensive covering major works of the package and is indicative only. Separate and detailed QAP shall be prepared by the contractor based on actual project requirements
and documents. The percentage of inspection may vary as per WD and specifications.

1. W‐ Witness; Contractor shall give advance information to witnessing agency of NPCIL, when this stage is reached, and proceed to next stage. Depending on the performance of task performer, NPCIL may decide to witness or
waive the witnessing.
2. H‐ Hold; Contractor shall give advance information to NPCIL, when this stage is reached, and can proceed further only after obtaining clearance from NPCIL QA.
3. R‐ Contractor shall submit all records up to this stage for review by NPCIL, not later than one week from the date of activity.
4. P‐ Perform; Ex‐ execution agency;
5. S‐ Surveillance inspection
6. IR‐ Inspection report.

TENDER No. CMM/MEQ/25-26-2-1142
SECTION – C
1. CONSTRUCTION MANAGEGMENT
REQUIREMENTS FOR CONTRACTORS
EPC-03
NUCLEAR POWER CORPORATION OF INDIA LIMITED
KUDANKULAM NUCLEAR POWER PROJECT - 3&4
CONSTRUCTION MANAGEMENT REQUIREMENTS BY PAGE NO. : Page 2 of 30

CONTRACTOR REV. NO. : R0
CONSTRUCTION MANAGEMENT REQUIREMENTS BY

CONTRACTOR
DOC NO. : I01.KK 3 4 .0.0.MP.EP.P003
REVISION NO. : R0
: 29.11.2016
DATE OF ISSUE
: 30
TOTAL NO. OF PAGES
(Including Cover
Sheet+Appendix+Annexures)
REVISION CONTROL SHEET
Rev. Description NPCIL

No. & Date of Revision Revised By Checked By Approved By
R0
November 2016

TABLE OF CONTENTS
CLAUSE NO. TITLE PAGE NO.

1.0 General 4
2.0 Execution of works 6
3.0 Construction management plan 9
4.0 Temporary Facilities 11
5.0 Records, procedures and reports 12
6.0 Schedule 13
7.0 Warehouse Management & Material Control 13
8.0 Field Engineering 22
9.0 Field Tendering 22
10.0 Field Purchase 22
11.0 Patents and patent right indemnification 22
12.0 Industrial Labour Relations 23
13.0 Construction Equipments 23
14.0 Construction Manpower 25
15.0 Interface with other CONTRACTORS 26
16.0 Colour Coding of Piping Material 26
17.0 Security Requirements 27
18.0 Approval of Erection testing & Commissioning Procedure 27
19.0 Layout and Measurement 27
20.0 Access Roads & Temporary Buildings 29
21.0 Notices 29
22.0 Pattern, samples and models 30
November 2016

1.0 GENERAL
1.1 The Contractor shall construct Plant/Facilities in accordance with the requirements of the
Technical Standards/ Specifications, with proven/good engineering practices and
procedures. Such facilities shall be safe, reliable and suitable for their intended purpose.
1.2 It is to be understood and agreed by CONTRACTOR, that the work described shall be
complete in detail, even though every item necessarily involved is not particularly
mentioned. The Contractor shall provide all supervision, labour, construction equipments,
tools & tackles, materials and consumables, temporary facilities, supply monitoring and
supply chain management etc. and render all support services necessary for the
construction. Provision of construction power and water shall be as per Special Conditions
of Contract (SCC)/ General Conditions of Contract (GCC).
1.3 The Contractor shall plan, execute, manage and control all the construction activities for
the facilities forming a part of this contract.
1.4 The Contractor to ensure mechanizing the construction activities to the maximum extent
possible.
1.5 The Contractor is deemed to have full knowledge of the applicable laws, statutory
requirements, and regulations, conditions of labour, local conditions, the SITE
conditions, environmental aspects and shall comply with the requirements thereof.
1.6 The Contractor is required to organize and mobilize Construction Management

Services in a systematic and sequential manner to ensure that the Plant installation is
carried out in accordance with the approved engineering drawings, specifications,
standards, QA/QC, safety procedures etc. and its completion is achieved within
targeted time schedule. Construction Management and Supervision is to be carried out by
the Contractor himself by deploying com pet ent persons who are on his rolls and this
activity is not to be sub- contracted in any case.
For this purpose, the Contractor shall deploy a Construction Management Team
headed by a qualified & experienced person at site. The Construction Management team
shall include engineers/ specialists in QA/QC, Project Control (Planning, scheduling,
monitoring), contract execution, material handling construction supervision, progress
measurement/billing, safety, warehousing, purchasing etc. Key personnel including the
Head should have suitable qualification/ sufficient experience and should not be
changed without concurrence from NPCIL.
Curriculum vitae (CV) of all key Construction Personnel shall be submitted to NPCIL at
least 3 months before deployment. NPCIL reserves the right to assess/ interview these
personnel before their mobilization, where ever and when ever felt necessary.
1.7 The Contractor shall ensure delegation of adequate and sufficient powers (including
financial) to the Head of his Construction Team for effective and smooth functioning of the
construction management. HO support shall be provided to the Head of Construction
Team at site during construction on all matters of project execution including the following:
- Field engineering.
- Rectification/replacement of defective supplies, if any, noticed during construction.
November 2016
NOT FOR PUBLICATION / PRESENTATION OUTSIDE NPCIL

- Expediting replacement of imported items found short/damaged.

- Required documentation for the material inspection at site
- Compilation and submission of Field Inspection documents in requisite copies
hard and soft form a s per contract
- Documentation to meet statutory requirements.
- Any support needed from HO to improve safety.
1.8 The construction supervision, co-ordination and management activities shall be carried out
by the Contractor in accordance with the construction procedures developed and
submitted by the Contractor and approved by NPCIL. Contractor shall prepare
construction schedules within the framework of overall contract schedule and submit to
NPCIL for approval. Contractor shall plan, execute, monitor and control construction
activities as per the approved construction schedule.
Contractor shall depute a project team at site during construction phase under a
project coordinator for providing above-mentioned support to the Head of Construction
Team.
1.9 In case of civil works/ requirements, most of the civil construction materials like cement,
reinforcement bars, aggregates, bricks, and structural steel are available locally. However,
the material like cement, reinforcement bars and structural steel shall be procured from
approved vendors only. The Contractor shall establish and maintain a material testing
laboratory for carrying out field tests during execution of contracts under different
disciplines at no extra cost to NPCIL. The entire test equipments deployed shall have
valid test/calibration certificates traceable to relevant national/ international standards.
Such material tests, for which testing facility at site is not established, shall be carried out
by Contractor at testing laboratories approved by NPCIL at no extra cost. Contractor
shall maintain the test records and the same shall be made available for review/
inspection of NPCIL. Further, NPCIL reserve the right to witness / inspect testing at the
laboratory at no extra cost to NPCIL.
The concrete testing lab established at site by KKNPP shall be used with NPCIL
concurrence, if provided as per the terms of the contract. However the manpower,
consumables etc for the testing shall be arranged by the contractor at his own cost.
1.10 Construction supervision and management functions to be performed by the Contractor shall
include the following as key functions for effective execution, monitoring and control:
- Planning, scheduling, monitoring & reporting.

- Construction & erection supervision discipline wise.
- Quality assurance and quality control, discipline wise.
- Shipping, custom clearances, inland transportation
- Warehouse management and material control / material handling at site.
- Field engineering/field purchase.
- Health, Safety and Environment (HSE) Management
- Statutory clearances and enforcement of statutory rules/ regulations and Labour
Laws
- Personnel/administration/Industrial Relations
- Finance and Accounts
- Security, insurance, Housekeeping & preservation
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- Transportation and material handling management

- Coordination with other contractors
- Preparation of procedures, reports and their up keeping
1.11 Whenever the hook up is to be done with the facilities under operation, efforts shall be made
by the Contractor to complete the work and restore the system expeditiously. If required
the work shall be continued round the clock.
1.12 Over Dimensional cargo (ODC) movement to the erection site is included in the scope of
the Contractor. The Contractor shall carry out the route survey and report shall be
submitted to NPCIL well in advance. All the clearances, approval from government
agencies, local bodies, private parties, police, electricity / telephone departments, Railway
authorities, PWD, Highway authorities, various departments of NPCIL etc. for moving the
ODC cargo is included in the Contractor’s scope. Before each movement, copy of the major
clearance obtained shall be forwarded to NPCIL. The cost /deposits of such approval, which
may be incurred by the Contractor, shall be included in the contract price.
1.13 Any modification, dismantling, re-routing etc. of the permanent / temporary facilities
belonging to NPCIL, private parties, public / government facilities including provision of
ramps at bridges to enable the ODC movement are in Contractor’s scope.
1.14 Restoration of the all the modified, dismantled facilities to original condition is in the scope
of the Contractor. Contractor shall obtain no claim certificates from such parties.
2.0 EXECUTION OF WORKS
The Contractor’s work during construction & erection shall include but not be limited to
the following:
i) Prepare and submit all the Plans, Procedures and documents to NPCIL as
specified in the contract.
ii) Establish requisite site organization staffed by competent and experienced
specialists, supervisors and inspectors.
iii) Supervise, Coordinate and manage the activities performed at site by him and by
his sub-contractors for execution of work and render all technical/specialist services.
iv) Plan and schedule the construction work, monitor and take timely corrective action
when required to adhere to approved execution schedule.
v) Plan, allocate and mobilize required resources, manpower, and construction
equipment/materials, commensurate with construction plan/schedule.
vi) Provide all temporary facilities required for Construction including drinking water,
lighting, office space, electronic transmission of drawings & documents, printing
facilities, rest rooms, crèches, first-aid, fire protection system, toilets, canteen
facilities, labour hutments, transport facilities for the workers and staff.
vii) Prepare & implement Quality Control and Quality Assurance plan.
viii) Prepare & implement Health, Safety & Environment (HSE) plan.
ix) Report beforehand and take approval from NPCIL regarding use of any
equipment and/or material not conforming to the contract, drawings and
specifications.
x) Execute and supervise all additional works and modification works as required or
suggested by NPCIL as a part of approved change orders.
xi) Erect and install the equipments and materials according to the approved
Specifications and procedures.
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xii) Establish required Field Inspection and Testing Laboratories at site to carryout tests
as specified in the standards/specifications of the contract.
xiii) Transferring levels and coordinates from the master benchmarks provided by NPCIL..
xiv) To organize and obtain all applicable clearances/approvals from statutory
bodies/ authorities, as required by the laws of land for the work executed at site.
xv) Obtain approval of NPCIL for Welding Procedure Specifications (WPS) /
Procedure Qualification Records (PQR) as required. Carry out inspection, non-
destructive tests and analyze and certify acceptability of all welds and materials in
accordance with specified Technical Standards. Carry out inspection and testing of
incoming materials as per agreed procedures.
xvi) Prepare detailed schemes for Heavy / Critical Equipments' movement / erection /
lifting / rigging and submit the same for review / approval to NPCIL before
undertaking such Critical/Heavy lifts/movements. Any modifications required
including dismantling and re-erection of structures/piping, etc for the existing
facilities for smooth flow of such heavy equipment shall be carried out by the
contractor at his own cost. However, prior approval for such modifications shall be
required from the NPCIL.
xvii) Organize and conduct Weekly Project Review meeting related to site construction
activities.
xviii) Provide daily work progress reports and detailed weekly and monthly progress
reports summarizing percentage completion of the work including status of
drawings, materials and effects on approved schedule, areas of concern and
corrective actions required thereof. Contractor shall also identify any foreseeable
delays in any aspect of the WORK and take corrective actions to
eliminate/minimize the effect on Overall Completion Schedule. All progress shall be
quantified.
xix) Prepare and submit records of all site meetings and any other related documents to
all parties concerned within two (2) days of the meeting.
xx) Prepare and submit safety and labour relation procedures in line with all applicable
codes, regulations and NPCIL’s requirements.
xxi) Supervise and monitor all safety and labour relation functions as per agreed
procedures and applicable laws of the land and report to NPCIL immediately for any
violations and injuries.
xxii) If any part of the facilities is completed and is under operation, while other parts of
the facilities are under construction, or work is to be carried in running Plant, it is
essential that rigid safety rules be prepared and maintained for all WORKS in
accordance with the requirements of NPCIL.
xxiii) Maintaining all the records generated during project execution up-to-date and made
available to NPCIL whenever requested. These records shall be handed over to
NPCIL on completion of the work in hard and soft form at no extra cost to NPCIL.
xxiv) Carryout warehouse management and material control in accordance with approved
procedure.
xxv) Take all necessary precautions and required actions to protect construction work
and materials from damage by local weather conditions and ongoing construction
activities in the vicinity, theft and pilferage etc. till handing over of the plant to
NPCIL.
xxvi) Take insurance policies for materials in transit and storage-cum-erection risk and
other insurance covers required for men and materials at site as per SCC/ GCC in
consultation with NPCIL.
xxvii) Undertake housekeeping including sweeping, clean up to maintain cleanliness,
sanitation, removing excess materials, temporary facilities, scaffolding, etc. on
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Regular basis till handed over to NPCIL.

xxviii) Prepare and submit to NPCIL the following reports for construction activities
covering the following:
a. Manpower deployment category wise, including attendance details.
b. Construction Equipments
c. Work Progress
d. Safety report
xxix) Ensure the control of all works with regard to its impact on the surrounding
environment.
xxx) Ensure all hot works are performed in compliance With NPCIL’s Safety Permit
System requirements wherever applicable.
xxxi) Arrange and coordinate the visits of supplier’s representatives/specialists at site.
xxxii) All material handling equipment, tools, tackles, hoisting and lifting
equipments/machineries should be subjected to required load test initially and then
periodically, to ensure safe/stable operation.
xxxiii) Organize field engineering work, wherever required and ensure timely resolution of
interface problems / site constraints in consultation with NPCIL.
xxxiv) Prepare and certify material reconciliation statement on completion of each
work to enable NPCIL to take over the surplus materials, as applicable.
xxxv) Organize the codification and handing over of surplus materials (as applicable) and
spares/ tools and tackles to the NPCIL on completion of work.
xxxvi) Provide weekly/daily activity plan for site inspection.
xxxvii) Develop a phased erection program to facilitate sequential Pre-
commissioning/Commissioning activities (Whereever applicable) in a logical
manner to meet the Overall Project Schedule.
xxxviii) Remove / demolish all temporary structures/ establishments/ facilities created by
the contractor / his sub-contractors during the execution of the work and restore
the site to its original condition.
xxxix) Estimate monthly consumption of following utilities (if provided by NPCIL):
a. Industrial water
b. Drinking water
c. Electricity
xl) Organize and conduct Positive Material Identification (PMI) of incoming materials
and of materials & welds after erection/installation, but prior to hydro testing of
facilities. Any non- conformance detected shall be removed and replaced prior to final
hydro testing.
xli) Colour coding of the pipe lines and equipments norms available with NPCIL shall be
used for painting and identification.
xlii) Carry out tightening of flange joints by using hydraulic tensioner/torque wrench as
per specifications. Contractor shall ensure that stud bolts are ordered extra long to
facilitate tensioning.
xliii) Organize safety induction programme, training programme, Housekeeping and
preservation for their manpower before deployment on work and at regular
intervals thereafter.
xliv) Develop/ deploy software based supply monitoring systems to track the supply of
materials for construction.
xlv) Execute all the civil, Mechanical, Electrical, Instrumentation and services related
construction/ erection works as per the tender requirements.
xlvi) Supply of adequate quantity of all consumables of approved brands, required for the
job, Viz., welding electrodes, welding gas, oil, grease, kerosene, cotton waste, etc,.
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xlvii) Supply and initial filling of various lubricants and control fluids of approved brands
xlviii) Hydro-test of all piping erected by him as per the piping material specifications and
piping technical specifications attached with the tender. All temporary piping hangers
and supports, fittings, strainers, valves, blanks for hydro testing of the pipelines,
valves and equipment shall be supplied by the CONTRACTOR. It is the
CONTRACTOR’s responsibility to arrange for pressuring pumps, tanks, relief valves,
instruments and other accessories that would be required for testing operations.
These are to be taken back by CONTRACTOR after successful completion of all
hydro-testing operations.
Contractor shall draw up a detailed activity list of pre shutdown activities

and shutdown activities (wherever applicable) and submit the same for the
approval of the NPCIL. All endeavours shall be made to maximize the pre-
fabrication before the planned shut down and to minimize the work during
shutdown period. All such activities shall be identified and appropriately planned
for temporary supports, scaffolding, clamping arrangements, enabling works, etc.
so that the quantum of the work during the shutdown can be minimized if
applicable.
3.0 CONSTRUCTION MANAGEMENT PLAN
Contractor shall submit Construction Management Plan to NPCIL for approval during kick-
off meeting. The Plan shall detail the management methodology to be applied during the
construction phase of the Project, along with a list of procedures to be utilized in
undertaking the work.
All reference procedures and detail work plans referred to in this document must be
submitted for review and approval by NPCIL at least (4) four weeks in advance of actual
commencement of the activity concerned.
3.1 Project Execution assurance Plan:
It shall include all the activities required for successful execution of the project as indicated in
the document Project execution assurance plan enclosed elsewhere in the tender.
Contractor shall be responsible for construction Planning, Scheduling, Monitoring and
Reporting activities at site in line with the overall master schedule and procedure shall be
submitted for approval of NPCIL and the same shall be followed after approval. Following
shall be submitted as minimum:
3.1.1 Contractor’s manpower and man-hour histogram by major section and discipline and their
manpower deployment schedule on monthly basis.
3.1.2 Major equipment mobilization plan on monthly basis with short description. Contractor shall
develop this plan with due consideration to maximize the mechanization of construction
activities.
Other plans of Contractor and procedures to be submitted at least four (4) weeks prior to
start of respective activity at site, include the following as a minimum:
a. Develop/ prepare construction/erection plan/procedures and submit to NPCIL for

approval.
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b. Temporary facilities, etc.

c. Scaffolding plan
d. Excavation and underground work plan
e. Heavy transport and heavy lifting plan (Rigging Plan), If applicable
f. Pre-fabrication plan
g. Other activity plans e.g. piping, equipment and steel structure erection plan etc.
h. Monsoon counter measures and preparation
i. Emergency Evacuation Procedure
j. Schemes to carry out works in inclement weather
Contractor shall ensure that lay down area (as applicable) given to him shall be utilized
optimally.
3.2 Sub-Contracting Plan
All Engineering Consultants, Procurement Agencies, Commissioning Agencies, Plant

Operating Agencies, Merchants, Tradesmen and others executing any work or supplying any
goods, materials or service appointed by the CONTRACTOR shall be deemed to be sub-
contractors..
If Contractor proposes to engage sub-contractor(s) for the execution of some of the

activities at site, a preliminary sub-contracting plan along with the identified scope of
work for each sub-contract shall be furnished by the Contractor to the
NPCIL at the time of bid submission. The list of Major sub contractor shall be indicated in
the bid. However for any new sub contractor the credentials of the sub contractor shall be
submitted well in advance and NPCIL acceptance shall be taken before engaging them for
this work. Contractor shall not be permitted to change the sub-contractor under any
circumstances without prior approval of NPCIL. Non-compliance of the above shall be
strictly dealt within relevant provision(s) of the contract.
The sub-contracting plan shall cover
i) Sub-contracting philosophy
ii) List and scope of work of each subcontract
iii) Subcontract administration plan
iv) Organization chart of each sub-contractor.
The list and major scope of each subcontract shall not be changed from those of the
Contractor’s plan unless specially approved by NPCIL.
In respect of the work, goods, materials or services etc. specified in the sub-contract, the sub-
contractor will undertake towards the CONTRACTOR the like obligations and liabilities as are
imposed on the CONTRACTOR towards NPCIL by the terms of the contract and will save
harmless and indemnify the CONTRACTOR from and against the same from all claims,
proceedings, damages, costs, charges and expenses whatsoever arising out of or in
connection therewith, or arising out or in connection with any failure to perform such obligations
or to fulfil such liabilities.
3.3 QUALITY ASSURANCE AND QUALITY CONTROL (QA/QC)
Contractor shall be responsible for ensuring quality of construction (including materials)

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carried out by him/his approved sub-contractors in accordance with the requirements

given in attached document “Quality Management System requirements from contractors”
attached elsewhere in the tender.
3.4 HEALTH, SAFETY AND ENVIRONMENT (HSE) MANAGEMENT
Contractor shall be responsible for Health, Safety and Environment (HSE)

Management at construction site for the construction activities to be carried out by the him/his
approved sub-contractors in accordance with the requirements mentioned in GCC/SCC
and AERB documents attached elsewhere in the tender.
All the personnel working at site shall be familiarized with the important and/or immediate
actions that may be called for e.g. the emergency announcements, siren, the emergency
shelter areas, use of prophylactics, etc. Periodic lectures and audio-visual courses, etc. shall
be organized to retrain once in a year and documented. All Contractor personnel shall be given
training on Emergency Preparedness and also a briefing shall be given before Exercise.
Personnel are to be re- trained on emergency preparedness after one year.
4.0 TEMPORARY FACILITIES
Contractor shall arrange the following temporary/ Infrastructure facilities as the minimum
(including for his sub-contractors also) in sufficient quantity to meet the quantum of contract
work:
1) Exact location of temporary work area, access and general layout inside the area.
2) Planning and Establishment of the temporary facilities:

a. Identification of borrow earth area (if required)/excess earth dumping yards
b. Site office and Fabrication yards, Open storage area and Warehouse
c. Miscellaneous workshops including maintenance area for construction
equipments. Grit blasting and Painting shops.
d. Temporary roads including access road to Plant, fencing and gates
e. Security, watch & ward, security gates, etc.
f. Utility supply systems viz. Construction power with DG Sets, construction
water, drinking water etc.
g. Area lighting
h. Fire fighting equipments
i. Drainage and Sanitation
j. Camp Accommodation
k. Field Testing Laboratory
l. Radiography Source Pit as per BARC Guidelines
m. Film processing and viewing labs
n. Communication facilities viz. Telephone, Fax, E-mail, electronic transmission of
drawings./ documents, etc.
o. Hutments, transport, Pantry and Canteen for staff and workers.
p. Vehicle parking area including construction equipments.
q. First aid arrangement/ medical and health care facilities
r. Valve testing facilities, Instruments calibration lab, Work shop for
machining etc
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Contractor shall develop the temporary facilities layout for approval of NPCIL.
Please refer Project execution assurance plan document enclosed elsewhere in the tender
for more details.
5.0 RECORDS, PROCEDURES AND REPORTS
(A) RECORDS:
The Contractor shall maintain records pertaining to the Design, engineering, drawings,
approvals, procurement, storage, fabrication, construction, welding, erection, alignment,
cabling, instrumentation, inspection and testing work in compliance with all drawings and
technical requirements. The records shall be in a proper format as indicated by the
Engineer. The Contractor shall submit the copies of such-records to the Engineer within 7
days from completion of any particular work, and prior to submitting bill for progressive
payments. For material supplied by contractor, the contractor shall forward one copy of test
certificate to the Engineer pertaining to the origin and specification of material. The
Engineer shall need certain records for verification viz. weld inspection report, stress
relieving report, consumable certificate, etc. The Contractor will have a system of record to
facilitate easy traceability of all such records.
(B) PROCEDURES:
The contractor shall submit construction procedures to the Engineer for review and
approval. Some of the major procedures are listed below:
(i) Welding Procedures

(ii) Procedure for non-destructive examination
(iii) Qualification certificates of the personnel performing non-destructive examination
(iv) Fabrication procedures)
(v) Erection procedures
(vi) Q.A. plans
(vii) Testing procedures
(viii) Mock up procedures
(ix) Cleaning, grit blasting, painting, insulation procedures
(x) Procedures and testing of various civil constructions
(xi) Procedures and testing of E&I equipments
Further, where complexity of the work or safety is involved, the contractor shall submit such
procedures when requested by the engineer. Any other procedure deemed necessary for
work shall be submitted to Engineer for acceptance.
(C ) REPORTS:
The contractor shall submit on weekly basis, to the engineer, one copy of report indicating
the details like system wise progress, fabrication/erection progress, system testing status,
QA activities, etc. Following are, indicative list of reports and other suitable reports shall be
submitted as per the instructions of engineer.
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(i) Equipment erection progress report

(ii) Piping erection progress report
(iii) General statement of activities
(iv) Welders performance & qualification records
(v) Weekly report on items on critical paths
(vi) Pipeline and support alignment and erection report
(vii) Weld joint inspection report
(viii) Grit blasting and painting report
(ix) Reports on civil construction, testing and concreting.
(x) Reports on E&I testing and erection.
All reports shall be statistical and on tabulated form indicated by the engineer.
6.0 SCHEDULE (Mile stones indicated in SCC)
The required schedule of start and completion of various activities for all facets of work of
this tender viz. procurement and supply of materials, fabrication and erection of piping and
equipment at site, are given in this tender. The contractor is required to study the schedule
and prepare a detailed activity network and should enclose the same along with the bid.
The deviation from the schedule, if any, should be brought out clearly.
7.0 WAREHOUSE MANAGEMENT & MATERIAL CONTROL
CONTRACTOR shall provide closed/semi-closed /open storage facilities with approach road
and shall ensure proper storage and maintenance of plant and equipment to be erected.
CONTRACTOR shall indicate his space requirements for provision of closed, semi-closed
and open storage areas to NPCIL. He should also indicate the space requirements for office,
workshop, canteen etc., if any. The facilities shall include proper lighting, fire protection
system, office/rest rooms/toilets for warehouse personnel.
Contractor shall obtain all statutory approvals from authorities concerned for all
warehouse equipment, instruments etc. Contractor shall comply with statutory
regulations for storage of any material covered under Explosives rules.
Contractor shall be responsible for carrying out the Warehouse Management and
Material Control in accordance with the approved warehousing procedure and material
control procedure, which is to be submitted by the Contractor during kick-off meeting. The
activities shall include but not limited to:
- Transport Liaison, both for imported materials as well as materials procured

indigenously, from the time of dispatch up to receipt at site.
- Transportation Plan (i) from source to site (ii) site to erection location.
- Filing of insurance Claims and follow up.
- Documentation for control and accounting of materials.
- Generation and upkeep of Traceability Records for materials.
- Materials Control & Issue.
- Inventory Checks.
- Field Requisition and Purchase.
- Spare & Tools including handing over of mandatory Spares/Tools to the NPCIL as per
November 2016

the terms of the contract.

- Material Appropriation and Handing Over of all items to NPCIL with NPCIL’s
Codification system.
- Security.
- Taking up with suppliers on short supplied items and placing replacement orders for
lost/damaged items.
- Intimating short/lost/damaged items received at site and further replacement action, as
applicable.
- Material handling plan and ODC movement plans.
- Preservation of the materials in storage as per manufactures’ recommendation.
- Proper up keeping of the outdoor storage area devoid of bushes, fire loads etc.
- Housekeeping of the total ware houses.
- Establishing special stores for electrode and other materials requiring heating or Air
conditioned storages.
- Material stored is to be insured. Fire fighting and ventilation facilities to be provided in
storage places
Contractor shall generate and issue following reports:

- Fortnightly statement of consignments in transit.
- Daily report of material received.
- Material receipt status and inventory status w.r.t. material delivery schedule
- Material Inspection Report with respect to materials received at site
- Report on material issue vouchers for erection works and material return vouchers
- Report on Over/Short/Reject/Damage (OSRD) receipts against each consignment on
receipt at warehouse.
- Weekly status of consignments, Material Receipt Report (MRRs)
- Monthly status of field purchase.
- Monthly status of over, short, reject & damage (OSRD) settlement.
- Monthly status of piping material MTO V/s Actual receipt.
- Log Register of Rotating Equipments maintenance
- Daily Stock Position of Cement
- Status of the purchase order and delivery schedules of the materials.
- Imported materials list and its reconciliation (with customs) status.
- Material accounting statements.
- Any other report as desired by NPCIL.
The CONTRACTOR shall submit to the NPCIL a list of equipment he proposes to use
indicating their capacities and quantities as well as the scheme of handling for approval by
NPCIL.
The various lifting / handling equipment and rigging tools proposed to be used by the
CONTRACTOR shall be tested as per statutory and safety regulations and the latest test
certificates shall be furnished to the satisfaction of NPCIL. In case NPCIL feels that the tools
and tackles are inadequate or unsuitable, the CONTRACTOR shall arrange to provide such
tools and tackles considered suitable by NPCIL in sufficient quantities acceptable to NPCIL.
The CONTRACTOR will be responsible for any damage caused due to his defective /
negligent handling of equipment and he shall make good such damages at no extra cost to
NPCIL and without affecting the project schedule. Any repairs carried out shall be with the
prior written approval from NPCIL and under CONTRACTOR supervision. A complete record
of all such repair works shall be maintained by the CONTRACTOR at all times.
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Transport of equipment by dragging, pulling, skidding on rollers etc., will require the prior
written approval from NPCIL and are generally discouraged. In all cases where major
components have to be handled, the detailed scheme shall be submitted to NPCIL for prior
approval.
It is the responsibility of the CONTRACTOR to provide adequate weather protection and

security for the equipment during the period they are transported from the unloading point to
warehouses. The safe loading of equipment as well as transport up to warehouses shall be
closely supervised by the CONTRACTOR.
7.1 STORAGE OF MECHANICAL AND ELECTRICAL EQUIPMENT AT SITE
Scope
The following specification details the general guidelines for storage of mechanical and
electrical equipment at site from the date of receipt of equipment at site by the
CONTRACTOR till the same are erected and handed over to NPCIL.
Storage Classification
The types of storage are broadly classified under the following heads :
1. Closed storage
2. Semi closed storage
3. Open storage
The equipment covered under these specifications shall be stored in the type of storage as
recommended by the MANUFACTURER / NPCIL.
7.2 CONSTRUCTION OF STORES
Normally, NPCIL makes available the space (at terms specified) for the CONTRACTOR to
construct the necessary stores as specified.
The storage areas should have adequate unloading and handling facilities with adequate
passage space for movement of material handling equipment such as cranes forklift trucks
etc. The storage of materials shall be properly planned to minimise wasteful handling during
retrieval of items required for erection.
The outdoor storage areas as well as semi closed stores shall be provided with adequate
drainage facilities to prevent water logging. The CONTRACTOR shall check the
satisfactoriness of these facilities prior to monsoon.
The storage sheds shall be built in conformity with fire safety requirements. The stores shall
be provided with adequate lights and fire extinguishers. “No smoking’ signs shall be placed
at strategic locations. Safety precautions shall be strictly enforced.
In case of storage of certain equipment / materials, it may be necessary to maintain

specified temperature ranges. In such case, it is the responsibility of the CONTRACTOR to
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provide adequate heating / air conditioning facilities on round the clock basis. The
CONTRACTOR shall check that space heaters, heating bulbs and air conditioners are kept
energised continuously as applicable. In the event there is a prolonged failure of electric
power, rendering such air conditioners / space heaters inoperative, the CONTRACTOR shall
make alternative arrangements to ensure that items under storage do not suffer any damage
/ deterioration on this account. Adequate lighting facility shall be provided by the
CONTRACTOR in storage areas and storage sheds and security personnel positioned to
ensure enforcement of security measures to prevent theft and loss of materials. The
CONTRACTOR shall carryout regular inventory of materials received, issued and erected
and inform NPCIL of any loss when noticed.
The CONTRACTOR shall provide adequate number of competent stores personnel including
store keepers, clerical staff, inspection engineers, watchmen and security staff to efficiently
store and maintain the equipment / material.
Where necessary, the CONTRACTOR shall provide necessary space heating and other
protective care to equipment in case it will take a long time to haul them to the stores. Any
equipment, left in the open under such conditions shall be, if required, covered with tarpaulin.
7.3 MAINTENANCE DURING STORAGE
The CONTRACTOR is responsible for preservation/ maintenance of the equipment /

materials in storage, during erection and until commissioning including protection of the
same against theft, elements of nature and corrosion damages. In case commissioning of
the equipment is delayed, the CONTRACTOR shall be responsible for maintenance of the
erected plant and equipment as directed by NPCIL or as per the instructions from
manufacturer. Contractor shall prepare procedure for storage of materials till erection and
preservation of equipments till handing over to NPCIL and submit the same for NPCIL
approval.
The CONTRACTOR shall repack the equipment after inspection and store the same in an
orderly manner, preserving their identification slips, tags and instruction booklets, etc.,
required during erection. The storage of materials shall be equipment wise. Loose parts
shall be stored in sheds on racks, preserving the identification marks and tags in good
condition. Contractor shall store spares received along with main equipment separately with
proper packing till handing over the same to NPCIL with Free issue material accounting. The
group codes shall be displayed on the racks.
The CONTRACTOR shall carryout frequent inspection of materials stored and also extend
necessary facilities to NPCIL to carry out such inspection, when considered necessary. The
CONTRACTOR shall implement the suggestions, if any, of NPCIL in this connection.
At no time shall any material be stored directly on ground. All materials shall be stored
minimum 200 mm above the ground by providing good wooden sleepers.
Welded and cast units shall be stored in such manner that there is no danger of distortion.
All special measures to prevent corrosion shall be taken by the CONTRACTOR.
Materials, which carry a protective coating, shall not be wrapped in paper, cloths etc, as
these are liable to absorb and retain moisture. The CONTRACTOR shall inspect the
materials and in case of signs of wear or damages to protective coating, that portion shall be
November 2016

cleaned with appropriate solution and coated with an appropriate compatible protective paint.
Complete record of all such observations and protective measures taken shall be
maintained.
The rust preventive oil or grease for application on machined / fabricated components shall
be adequate for the intended purpose and shall not cause any injury to the system, structure
and components.
Protective coatings/application of grease, oil etc shall be inspected from time to time and
reapplication/ repair shall taken at appropriate frequency.
While handling the equipment, no dragging on the ground is permitted. The CONTRACTOR
shall submit his scheme for handling major pieces of equipment for approval by NPCIL prior
to actual handling of the same. In cases where a scheme is recommended by the
MANUFACTURER, it shall be strictly adhered to.
The CONTRACTOR shall periodically inspect materials with specific reference to.
Ingress of moistures and corrosion damages.
Regular inspection and renovation of silica gel is essential.
Damage to protective coating.
Open ends in pipes, vessels and equipment.
In case any open ends are noticed, the CONTRACTOR shall get them capped.
Insulation of electrical equipment.
Regular insulation checks are essential and these values shall be properly logged.
Any damages to equipment / materials.
In case of any damages, these shall be promptly notified to NPCIL. In all cases, the repairs /
rectification shall be carried out strictly as directed by NPCIL.
In such repairs rectification is necessitated due to causes attributable to the CONTRACTOR,

such repairs / rectification shall be carried out at no extra cost to NPCIL.
In case such damages are attributable to the CONTRACTOR and if, in the opinion of NPCIL,
the CONTRACTOR is not competent to carry out necessary repairs / rectification, NPCIL
shall get this done by any other agency and recover the expenditure incurred by him from the
CONTRACTOR.
7.4 MODES OF STORAGE
Given below are the general guidelines for storage of various equipment under the broad
storage classification listed in clause 7.1 above. Wherever the specific recommendations of
the MANUFACTURER / NPCIL are at variance with what is indicated below, the former shall
prevail.
November 2016

Special Storage – Air Conditioned :
The following materials are normally stored in air-conditioned storage.
Welding ElectrodesThese deteriorate under adverse conditions of storage and are preferably
stored in air-conditioned storage. As an alternative, if approved, these can also be stored in
hot boxes / ovens.
It is essential to regularly inspect the condition of electrodes and ensure that temperature is
maintained within specified range at all times.
Ball, needle and roller bearings : These shall be stored in their original packing.Photographic
materials and films These shall be stored in their original moisture vapour proof packages.
Rubber Goods: These shall be protected against sunlight and artificial light as well as high
humidity conditions.
Electronic Instruments and Components. These shall be stored in sealed packages.
7.4.1 CLOSED STORAGE

The following materials are normally stored in closed storage.
Cement bags.
All small parts / components liable to be misplaced / lost. These shall include the following :
a) Small structural cleats, bolts, nuts, washers etc.

High tensile bolts and nuts shall be stored in separate sealed boxes with proper
identification to avoid mix up with other items
b) Pipe hangers, spring hangers etc.

The identification numbers on spring hangers shall be carefully preserved during storage.
c) Stainless steel and copper tubes, pipe fittings, etc
d) Electrical clamps, cable boxes, cable glands, ferrules, fuses, control cables, copper cable
and grounding strips, push button switches etc.
e) Pilot valves, pull rods, keys, control valves. These shall be greased, wrapped in paraffin
paper and stored in packing boxes.
All loose parts, packing plates, bolts and studs.
All indoor switchgear equipment.
All instrument parts such as measuring instruments, controllers and regulators, interlock
system, control drive units, gauges, instrument valves, thermocouples and leads
Synthetic Paints. Normally in separate stores
7.4.2 Semi-closed Storage
The following materials are normally stored in semi closed storage.
November 2016

Large C.I. valves, butterfly valves, stop and control valves, expansion joints.
Outdoor switchgear and panels, small transformers, cable tray parts, etc.
7.4.3 OPEN STORAGE
The following materials are normally stored in open storage.
Fabricated and un fabricated structural steel members.
Stairways and hand rails

Gallery steel
Steel members
Reinforcement steel
Coarse aggregate and sand.
Un fabricated pipes and fabricated pipe assemblies.
Large diameter conduits / pipes in boxes.
Cable drums
7.4.4 SPECIFIC GUIDELINES FOR STORAGE
Given below are guidelines for certain other major equipment / materials. These are broad
guidelines only and storage shall be strictly as directed by the MANUFACTURER / NPCIL.
a. ROTATING EQUIPMENT SUCH AS PUMPS AND COMPRESSORS
These are normally stored in assembled condition in closed / semi closed storage. When
stored in semi-closed storage, they shall be covered with tarpaulin and bedplates shall rest
fully on sleepers.
The CONTRACTOR is responsible for proper lubrication of these equipments as directed.
The gearboxes and oil sumps shall be kept filled with recommended lubricating gear oil. The
couplings and bearings shall be covered with approved grease and nozzle flanges screwed
with caps or suitably plugged.
The shaft and internals shall be, if so directed, given a fresh coat of approved protective
paint.
Pump, if delivered in disassembled condition, shall be stored with the parts properly greased
on wrapped in paraffin paper. Smaller parts are to be stored on racks whereas larger parts
on sleepers in closed storage. Occasional flushing with hot lubricating oil may have to be
carried out, if so directed by NPCIL.
The shafts of rotating equipment shall be turned by 90 degree every week to avoid rotor
journals from rusting and to ensure that shaft is free to rotate.
November 2016

The CONTRACTOR shall maintain record of lubrication with details of lubricants used as
well as protective measures carried out.
b. PIPING AND VALVES
All pipes shall be stored on sleeper beds with open ends securely capped. The bevelled
ends shall be protected with a coating of approved greases.
Pipes shall be neatly arranged and stacked for easy identification and retrieval.
Pipes shall be blown with air prior to installation and it shall be ensured that there is no
obstruction.
Valves shall be stored with the discs screwed down on the seat so that packing surfaces are
not exposed to dust. All machined surfaces shall be covered with grease. Preservation of
identification tags is essential to avoid installation in wrong services. Smaller valves shall be
stored in closed storage whereas large CI valves may be stored in semi closed storage.
Pipe fittings shall be stored on racks in closed storage in packed condition, with openings
suitably capped.
c. SWITCHGEAR & CONTROL PANELS
Depending on whether these are of indoor or outdoor design, these shall be stored in closed
/ semi closed storage.
The space heaters where provided, shall be kept connected with power supply irrespective
of mode of storage. Where space heaters are not provided, use of adequate number of
heating bulbs is recommended.
Insulation resistance shall be measured at regular intervals and megger values properly
logged.
d. CABLES
Cable drums if stored indoors shall be in dry ventilated stores. Cables are normally supplied
with ends sealed. When a length is cut, the end should be resealed. The drums shall be
stored with adequate spacing between them for better air circulation.
e. MOTORS
Motors shall be stored, preserved, inspected for IR and other checks as instructed in
manufacturers recommendations.
f. INSTRUMENTS
These are stored on racks in closed storage and in air-conditioned storage if so
recommended. These shall be stored in their packages in dry condition and shall be handled
with extreme care.
November 2016

Instrument flanges and nozzles, if directed, shall be coated with technical Vaseline.
In the case of fragile instruments, the storage shall be in a separate zone away from where
heavy materials are stored to minimise danger of damage.
g. STRUCTURAL STEEL
Structural steel could safely be stored in open storage but with sufficient space in between
for handling and crane movement. All steel shall be stored 300 mm above ground on suitable
packing to avoid damage. It should be stored according to sizes and sections preferably in
the order required for erection. The area for open storage should be properly graded to avoid
water logging in the storage area. Steel shall not be stored in the vicinity of areas where
excavation or grading will be done. Scratched or abraded steel shall be given a coat of
primer for protection after unloading and handling prior to erection. All milled and machined
surfaces shall be properly protected from rust / corrosion by suitable coating.
h. CEMENT
Cement shall be stored in bags in a separate closed shed away from where mechanical and
electrical equipment are stored to minimise the possibility of cement dust settling on the
equipment.
The Contractor shall make necessary arrangements for the storage of cement to prevent
deterioration due to moisture and/ or intrusion of foreign matter. If the storage arrangement is
not to the satisfaction purchaser may direct the Contractor to make such arrangements as
consider necessary, and in the event of non-compliance, purchaser would reserve the right
to make proper arrangements at the Contractor’s risk and cost. The Contractor shall have
adequate, weatherproof storage capacity for storing of cement as required.
The storage shed where cement is stored shall be absolutely watertight. The ground shall be
such that water shall drain away from the shed to prevent accumulation of water in its
vicinity.
The bags shall be neatly stacked with adequate passage in between for easy retrieval. The
cement shall be issued on ‘First in-first out” basis.
In case different grades of cement are stored in the same shed, each grade shall be stacked
separately to avoid mix up and clear indication boards shall be provided to identify different
grades.
i. PAINTS
These have limited life and as a safeguard against possible deterioration, the drums shall be
inverted at regular intervals as specified to minimise risk of hard settling of pigments.
j. SLINGS & WIRE ROPES

All slings and wire ropes shall be coated with approved grease and hung from racks in rolled
condition.
November 2016

k. DOCUMENTATION
The CONTRACTOR’S store–keeping function will include maintaining various records as

required by NPCIL. These records shall include but not be limited to the following.
Supplier wise record of equipment / material received, stored and issued for erection as well
as stock position.
Record of inspection and repairs carried out, protective measure and lubrication of
equipment in storage as well as erected until the same is taken over by NPCIL.
8.0 FIELD ENGINEERING
Where engineering is in the scope, contractor shall be responsible for controlling and
issue of technical drawings and documents, preparation of field sketches, field
modifications, checking/preparation of as-built drawings, etc. Contractor should have
adequate facilities for incorporating field changes, preparation of As-built drawings,
Printing machines and Drawing & Document Control System. Contractor shall establish
Field engineering group at site for speedy resolution of field problems.
9.0 FIELD TENDERING
Contractor shall be responsible for carrying out field tendering activities, as required from
the site itself. NPCIL- KKNPP registered sub contractors from the local area shall also be
considered for tendering and award of work.
10.0 FIELD PURCHASE
Contractor shall be responsible for carrying out field purchase activities, as required. Field
Purchase items are restricted to those required for running and maintenance of the
field offices, items required to expedite construction work and items found short, missing or
damaged against the main order when received at the site. Any material purchased from
field for usage in the plant should have proper inspection certificate and should be
purchased from NPCIL approved suppliers. If required by NPCIL, check testing of the
material samples selected by NPCIL shall be carried out by Contractor without any extra
commercial implication.
11.0 PATENTS AND PATENT RIGHTS IDENTIFICATION
All specifications, drawings, patents and such other relevant information furnished to the
contractor by the engineer shall be the property of the engineer. If, during the process of
execution of the contract, any improvement, refinement or technical changes and
modifications are implemented by the Contractor, such changes shall not affect the title to
the property of the engineer and the information, specifications, drawings, etc. including the
improvement/modifications effected by the Engineer. The Engineer shall also have the
absolute right to assign, transfer, sublet, use and transmit all such information and details to
the Engineer’s consultants. Contractor shall not have any claim or rights whatsoever in
respect of the Engineer’s drawings, specification, patents, proto-types etc. even where
improvement refinement, modifications etc. were implemented by the contractor
November 2016

12.0 INDUSTRIAL LABOUR RELATIONS
Contractor shall be responsible for industrial relation functions and implementation of

labour laws at site. Contractor’s staff shall be suitably trained and experienced in
Labour Relation functions so as to ensure a good relationship with labour and to prevent
the occurrence of industrial disputes resulting in subsequent delays or work stoppages. In
particular, Contractor shall maintain close liaison with NPCIL.
Contractor shall maintain proper liaison with Statutory Authorities and local bodies and shall
be responsible to implement and observe all statutory laws at site. Contractor must have
in his staff; a well experienced Labour Relation Officer.
Contractor shall maintain the records of wages paid in a wage register, PF, etc. as per
statutory regulations.
Contractor shall report immediately to NPCIL any problems including labour disputes,
fight, and work stoppages. A written report shall be submitted to NPCIL within 24 hours of
the incident.
Contractor must submit a Labour Relation Plan including their sub-contractor(s) prior to
the start of the work/within one month of award of the contract, whichever is earlier,
mentioning as a minimum:
a. A detailed estimate of the number of labour, indirect and direct..

b. Outline recruiting plans for all manpower requirements.
c. Identify personnel involved with labour relations and outline procedures to mitigate
labour disputes & problems.
d. Labour welfare plan
13.0 CONSTRUCTION EQUIPMENTS
Contractor is required to organize and mobilize the construction equipments and other
tools/tackles in a sequential manner and ensure that plant installation is carried out in a
mechanized manner to the extent possible and its mechanical completion is achieved
within targeted time schedule.
Contractor shall ensure deployment of the following construction equipment as a

minimum as per requirement to the maximum extent –
i Cranes of different capacities

ii. Tractor trailers of different capacities
iii. Grinding machines
v Portable Alloy Analyzers with print out facility
vi X-ray and Radiography sources
vii Stress Relieving Equipments with Recording facility
x. Welding machines
xi. DG sets
xii. Electrical and Instrumentation equipments/measuring devices etc.
xiv. Bevel Cutting Machines
xv. Test Pumps
November 2016

xvi. Compressors
xvii. Gas and Mechanical cutting devices
xviii. Various inspection / measuring devices
In order to minimize fabrication at site, all (major) fabricated equipment like

Columns/Towers, Vessels shall be transported preferably in single piece due to limitation of
space at site. Deviation to this shall be specified at the bidding stage itself. Contractor shall
carry out the route survey for transportation of 'Over Dimensioned Consignments'
including waterways from source of manufacture/supply to site well in advance of
placement of order to ensure unhindered transportation of the same to construction site.
Contractor shall arrange Cranes of suitable capacities to match with the erection
requirements and inform the source and NPCIL of the same.
Crane movement roads are to be clearly identified and marked on the plot plan before
planning of such movement. Construction of hard stands for positioning of crane in the
fabrication yard and at erection site/locations including approach roads to the hard stands
from the plant roads shall be Contractor’s responsibility. The hard stands shall be
suitable for the crane loads (self load + equipment load) to facilitate erection works and to
be tested for any settlement.
For the purpose of Equipment Erection, the Contractor shall deploy a Rigging team
headed by a Rigging Foreman/Engineer reporting to concerned Area Engineer. Area
Engineer should be well conversant with various erection techniques and shall be
responsible for preparing erection schemes in accordance with the approved procedures
and based on crane manuals and suiting to plant layout. Area Engineer shall have to
foresee various other construction activities in the surroundings areas while planning
erection schemes including safety aspects of man and machinery also.
Contractor shall prepare erection schedule in line with the overall project schedule of the
Plant in phased manner with erection schemes of various equipments, vessels and
submit to NPCIL for approval, Monitoring and control of erection schedule and erection
activities shall be carried out by the contractor as per the approved construction
procedures.
For efficient working and maintenance of construction aids, Contractor shall establish and
maintain crane yard / workshop equipped with regular maintenance facilities for various
construction aids for carrying out routine field maintenance during performance of the
contract. Temporary approach road and hard stands, wherever required for the movement
of the Cranes and other vehicles for equipment erection and transportation of material shall
be properly planned and made by the C o n t r a c t o r . Weekly/fortnightly maintenance
shall be planned in such a way that the same does not hamper the erection schedule.
During performances of the work, Contractor must ensure that structures, materials and
equipments are adequately braced with Guys, Struts or any other means as deemed fit&
approved by NPCIL. Such means shall be supplied and installed by the Contractors as
required till the erection works is satisfactorily completed. Such guys, shoring, bracing,
strutting, planking supports etc. shall not interfere with the work of other agencies and shall
not damage or cause distortion to works executed by other agencies. All lifting tools,
tackles and cranes shall be tested periodically by statutory/ competent authorities for their
load carrying capacity. Such relevant valid/test certificates shall be submitted to NPCIL
for review before actual use of the tools, tackles and cranes.
November 2016

Contractor shall submit the construction equipment deployment schedule. Contractor shall
ensure the timely augmentation of the men, equipments and machinery depending
upon the exigencies of the work to meet the overall project schedule and as per
instructions of NPCIL.
14.0 CONSTRUCTION MANPOWER
Contractor is required to organize and mobilize construction staff/ manpower in a

sequential manner to ensure that the work is carried out in accordance with the
construction schedule. Mobilization of construction staff should be such that the progress
achieved in phased manner should match with the overall Project Schedule.
For this purpose, the Contractor shall clearly indicate in his construction methodology
whether work shall be done departmentally or by engaging sub-contractor or the
combination of both. Contractor shall prepare detailed methodology for the work to be
carried out departmentally as well as through sub-contractors clearly, defining the scope
and responsibility of Contractor and his sub-contractors. Approval of NPCIL shall be
obtained for engaging the sub contractors.
The works of all sub-contractors shall be managed by the construction staff of the main
Contractor who shall perform the duties of construction management and shall
administer, coordinate, and inspect the works of the sub-contractor(s) and be responsible
for the Quality and timely completion of respective works. Contractor shall establish the
pre-requisites for successful completion of sub-contractor (s) work. However, deploying the
sub-contractor (s), as approved by NPCIL for any discipline, does not absolve the
Contractor of his total responsibility under the subject contract.
Contractor must note that in case of any sub-contractors' failure to execute the works as
per standards/specifications/drawings and/or negligence & disobedience in carrying out
any order or instruction of NPCIL, the same shall be viewed very seriously and any action
as deemed fit in accordance with provision(s) of the contract shall be taken by NPCIL.
Contractor must submit the construction manpower deployment schedule along with the
bid. Daily construction manpower deployment report shall also be submitted by the
Contractor to NPCIL on approved format. Any additional manpower of any category
required to be deployed during the actual execution of the work to meet the Project
time schedule and as instructed by NPCIL, shall be mobilized by the Contractor within a
reasonable time. Mobilization of such additional manpower by the Contractor shall not
entitle him for any additional compensation at all.
All construction supervision, coordination and management activities shall be carried out by
the Contractor in accordance with the construction procedures approved by NPCIL.
Contractor shall prepare construction schedules based on the Overall Project Schedule of
the PLANT and submit the same to NPCIL for approval. Monitoring and control of the
construction activities shall be carried out as per the approved construction schedule &
procedures.
During the execution of works at site, if the Contractor engages sub-contractor (s) for
execution of works at site as per approval obtained from NPCIL in line with contract
November 2016

provision(s) and in the event sub-contractor complains in writing to the NPCIL with regard
to the non-payment of their dues from the Contractor for the works executed by them
(excluding final payments and payments due after termination of sub-contractors' services
by the main Contractor), NPCIL reserves the right to make such payment to the sub-
contractors directly based on approved measurements with due notice to the
Contractor. NPCIL shall release such payments to sub-contractor at the cost and risk of the
Contractor in order to ensure smooth execution of work at site. All such payments
made by NPCIL to the sub-contractor(s) shall be deducted from the running account
bills or any other payments due to the Contractor.
The above provisions shall also be applicable in case of construction materials procured at
site by the Contractor from the suppliers.
15.0 INTERFACE WITH OTHER CONTRACTORS
Contractor shall ensure that his interface with other Contractors is smooth and cordial. In
case of any dispute, NPCIL decision shall be binding.
NPCIL may arrange weekly/fortnightly/monthly interface meetings. The Contractor shall

depute concerned personnel to attend these meetings.
Generally, the following interfaces may be present:
Contractor shall allow movement of persons/ material/ equipment/ vehicles

belonging to other Contractors or NPCIL through the roads constructed by him.
Contractor shall coordinate with ‘neighbouring’ contractors for maintaining

elevations/ levels of various interconnecting services.
Contractor shall not dump his earth, scrap or any material in other Contractors’ area.
He shall cooperate with NPCIL in maintaining good housekeeping throughout the
complex.
Contractor shall ensure proper drainage and no water logging in his area/other
areas.
If requested by the NPCIL, Contractor shall allow testing of materials of other

Contractors in his laboratory, in case of emergency.
Contractor shall clearly define in the interface meeting with other contractors their
erection / construction interface at their Battery limits.
16.0 COLOUR CODING OF PIPING MATERIAL
Colour coding of the pipe lines and equipments already available for KKNPP 1 &2 shall be
used for painting and identification.
November 2016

17.0 SECURITY REQUIREMENTS
For security procedures, Clause 13. 6 of the GCC and clause of SCC shall be followed. The
security procedures introduced at site from time to time shall be followed by the contractor
without failure.
18 .0 APPROVAL OF ERECTION TESTING & COMMISSIONING PROCEDURES
The CONTRACTOR shall submit to NPCIL for approval within a reasonable period a
programme of works which proposes to carry out like erection, testing and commissioning
activities. The programme shall also indicate the time by which the CONTRACTOR requires
NPCIL to have obtained any consents, approvals, etc necessary for the purpose of the
works if any. The submission to and approval by NPCIL of such programme shall not relieve
the CONTRACTOR of any of his duties or responsibilities under the contract.
Detailed procedure for carrying out handling of equipment and erection, WPS, PQR & WQR,
ND examinations, calibration of instruments, testing and commissioning, trial operation,
performance testing & handing over for all systems, structures and equipment shall be
submitted by CONTRACTOR for NPCIL’s approval prior to start of these activities, in a
format and contents to be approved by NPCIL. Detailed procedure for carrying out erection,
testing and commissioning, trial operation, performance testing & handing over for all
systems, structures and equipment as applicable shall be submitted by CONTRACTOR as
per the system description and scope document.
After submission to and approval by NPCIL of such programme the CONTRACTOR shall
adhere to the order of procedure and method stated therein unless he obtains the written
permission of NPCIL to vary such method or order.
If at any time it should appear to NPCIL that the actual progress of the works does not
conform to the programme, the CONTRACTOR shall produce, at the written request of
NPCIL, a revised programme showing modifications to the approved programme
necessary to ensure completion of the works within the time for completion.
The CONTRACTOR shall submit well in advance, his scheme for movement / lifting /
handling of heavy equipment / components also indicating the tools, tackles and equipment
he proposes to employ for the same, for approval by NPCIL prior to actual undertaking of
such work. This is essential as such activities may call for measures such as additional
reinforcements to avoid overloading of structures.
The CONTRACTOR shall submit a detailed write-up on performance test procedure along
with sample calculations for NPCIL’s approval and the same shall be finalised prior to
actual performance testing.
19.0 LAYOUT AND MEASUREMENT

All the works shall be performed to the lines, grades and elevations indicated on the
drawings. CONTRACTOR shall set out the works and shall be responsible for the true and
perfect setting out of the same and also for the correctness of the positions, levels,
dimensions and alignment of all parts thereof.
November 2016

Basic horizontal and vertical control points will be established and marked by NPCIL at
site at suitable points. These points shall be used as datum for the works under the
contract.
The CONTRACTOR shall inform NPCIL well in advance of the times and places at which
he wishes to do work in the area allotted to him, so that suitable datum points may be
established and checked by NPCIL to enable the CONTRACTOR to proceed with his
works.
If at any time any error shall appear during the progress of any part of the work,
CONTRACTOR shall, at his own expense, rectify such error, if called upon to do so, to the
satisfaction of NPCIL.
CONTRACTOR shall maintain base lines and bench marks adjacent to various sections of
work. In case of their unnecessary destruction by him or any of his employees, these shall
be re-established by CONTRACTOR at his own expense.
The CONTRACTOR shall level and adjust the plant on its foundations preparatory to
grouting and shall furnish all packing and shims required for the adjustment.
The CONTRACTOR shall check the electrical and mechanical connections to plant
supplied under the contract before such plant is commissioned and shall be responsible
for the correctness of such connections in accordance with the contract drawings and
specifications.
MEASUREMENT OF WORK
NPCIL may, from time to time, intimate CONTRACTOR that he requires the works to be
measured and CONTRACTOR shall attend or send a quality agent to assist NPCIL or his
representative in taking such measurements and calculations and to furnish all particulars
as may be required by him.
Where the erection of equipment, vessels and structural steel platforms are involved, the
basis of such measurements and progress evaluation shall be weights specified in the
shipping documents or invoices or drawings, manufacturers document as decided by
NPCIL.
Should CONTRACTOR not attend or neglect or omit to send such agents, then, the
measurement taken by NPCIL shall be taken to be the correct measurements of the work.
CONTRACTOR or his agent may at the time of measurement, take such notes of
measurements as he may require.
The measurements so taken and certified correct by NPCIL shall be the basis for the
progress payment to the CONTRACTOR. Where the breakup of contract value on unit
basis is difficult to arrive at NPCIL and CONTRACTOR shall work out at the
commencement of the CONTRACT, the weightages or the cost of breakups to arrive at a
mutually agreeable basis for computation of this progress estimates.
As per clause of General Conditions of Contract, regarding the terms of payment for
erection and commissioning, a portion of the payment will be given on pro-rata basis
against satisfactory completion of identified milestone.
November 2016

20.0 Access Roads & Temporary Buildings
The CONTRACTOR shall make the necessary temporary access roads, footways, guards
as may be necessary by reason of his work, for the protection and accommodation of foot
passengers or other traffic of the site personnel/ NPCIL’s personnel. CONTRACTOR shall
at all times provide sufficient temporary barriers, notice boards and lights to protect and
warn the public and post necessary watchman to guard the site and equipment. He shall
take all precautions necessary and shall be responsible for the safety of the work to be
performed by him. CONTRACTOR shall observe and display ‘SAFETY FIRST’ signs and
shall have proper safety and fire protection equipment.
CONTRACTOR shall construct necessary temporary buildings viz., warehouses, tool

sheds, fabrication shops, enclosures, etc. for storing his equipment, tools and tackles, etc.
at the site and at the place allotted by NPCIL.
The responsibility and cost of erecting such buildings shall be borne by the CONTRACTOR
including the cost of removing such structure after the completion of the work. The
CONTRACTOR shall obtain NPCIL’s approval prior to their removal in the event NPCIL
may wish to retain any for his own purpose.
Adequate lighting such as flood lights, hand lights and area lighting and near all the
storages, handling, fabrication, pre-assembly at erection sites for properly carrying out the
work and for safety and security shall be provided by the CONTRACTOR at his own cost.
His work area shall be adequately lighted during night time also. In any case,
CONTRACTOR shall be liable for all damages and consequence arising out of his
negligence in this regard. The CONTRACTOR shall obtain approval of NPCIL to lighting
scheme prior to its installation.
21.0 NOTICES
NOTICE OF DEFECTS
During the guarantee period, if any defect shall appear or damage occur due to the defective
materials, workmanship or on design by contractor or from any act or omission of the
CONTRACTOR, NPCIL shall forthwith inform the CONTRACTOR thereof stating in writing
the nature of the defect or damage. The CONTRACTOR shall remedy all defects/damages
or replacements or renewals to the satisfaction of NPCIL.
NOTICE FOR DELIVERY
The CONTRACTOR shall give to NPCIL advance notice in writing of the delivery date.
NOTICE OF TESTS
The CONTRACTOR shall give to NPCIL advance notice in writing of the date after which he
will be ready to make the Tests on completion. Unless otherwise agreed the tests shall take
place within 10 days after the said date or days as NPCIL shall notify the CONTRACTOR in
writing.
November 2016

NOTICE TO CONTRACTOR
All notices, written orders etc. to be given to the CONTRACTOR by NPCIL under any of the
provisions of the contract shall without limitations be conclusively deemed to have been
received by the CONTRACTOR if delivered or mailed to the CONTRACTOR at the
CONTRACTOR’s address mentioned in the work order or to the CONTRACTOR’s last
known place of business or residence or to his Resident Engineer.
NOTICE TO NPCIL
Any notice to be given to NPCIL under the terms of the contract shall be served by sending
the same by post, or leaving the same at the addresses nominated by NPCIL.
NOTICE ON CHANGE OF ADDRESS

Either party to the contract may change its nominated address by prior written notice to the
others.
22.0 PATTERNS, SAMPLES AND MODELS
All drawings, specifications, patterns, models and prototypes furnished to the contractor by
the Engineer are intended to be complementary and to provide for and comprise everything
necessary for the completion of work/supply and are the property of the Engineer. These
are not to be used for any works or purpose other than those for which these have been
provided and shall be returned to the Engineer immediately on completion of work/supply in
good condition.
November 2016

Tender 1142 Section C2

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TENDER No.

SECTION-C CONSIST OF:-

1. SECTION C-2: TECHNICAL SPECIFICATION

TECHNICAL SPECIFICATION FOR

REVISION CONTROL SHEET

I01 KK34 0 0 MRR TS P001

Sr.No. Revision Date of issue No.of

SOQR item numbers and Annexure-2

Date of issue Revision No Page Number

TECHNICAL SPECIFICATION FOR

Annexure-1--- List of sample drawings

Date of issue Revision No Page Number

TECHNICAL SPECIFICATION FOR

The scope of work includes “Handling, transportation, pre-fabrication, pre-assembly,

2.1 NPCIL SCOPE OF WORK:

NPCIL scope of work is limited to the following:

Date of issue Revision No Page Number

7. Release of test loads for load testing as identified by the contractor.

2.2 CONTRACTOR’S SCOPE OF WORK:

Contractor’s scope of work comprises but not limited to the following:

Date of issue Revision No Page Number

9. Preparation, submission of welding procedure specification (WPS) & conducting

Date of issue Revision No Page Number

3. REFERENCE DRAWINGS, DOCUMENTS & SPECIFICATIONS:

1. The KKNPP-3&4 units are designed by Russian Federation. Accordingly assembly,

Date of issue Revision No Page Number

Sl. Specification Description

4. RECEIPT, TRANSPORATATION & STORAGE OF FREE ISSUE MATERIALS:

4.1 RECEIPT OF MATERIAL FROM NPCIL STORES AND TRANSPORTATION:

Date of issue Revision No Page Number

Date of issue Revision No Page Number

5. Loading and unloading of materials and equipment shall be hoisted or skidded so as

7. The FIM shall be issued in a lot, in packed/as received condition. No piecemeal

9. Briefly the scope of material transportation covers identification of material,

Date of issue Revision No Page Number

4.2 TRANSPORTATION OF HEAVY AND CRITICAL EQUIPMENTS:

4.3 STORAGE OF MATERIALS:

2. Once materials are issued to the contractor it is the responsibility of contractor in

Date of issue Revision No Page Number

responsibility of the contractor to maintain complete record of the list of materials at

4.4 IDENTIFICATION, MARKING AND SEGREGATION OF MATERIALS:

5. SEQUENCE OF ERECTION ACTIVITIES:

1. The sequence of erection shall be decided by Engineer based on availability of

a. Support structure installation and inspection

c. Installation and inspection of electrical and instrumentation components.

6. INTERFACING WITH OTHER AGENCIES:

7. PREPARATION OF PROCEDURES & QAP:

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Some of the major procedures to be prepared by contractor are,

1. Quality Assurance Manual

8. MANUFACTURER’S INSTRUCTION AND SUPERVISION AT SITE:

1. Manufacturer’s instructions are special/specific instructions issued by the equipment

2. Wherever deemed necessary NPCIL may arrange supervisors of manufacturer

9. ASSEMBLY, WELDING & ERECTION OF MHE:

9.1 GENERAL REQUIREMENTS:

1. The general instructions and requirements for erection are detailed in WD or

1. De-preservation shall be carried out as per manufacturer’s recommendation. After

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9.3 ERECTION OF POLAR CRANE (FCA07AE071) :

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9.4 ERECTION OF TRESTLE CRANE (FCJ07AE041)