Upgrade Storage Web Brochure

CONSTRUCTION OF PETROLEUM OIL STORAGE TANKS AT PARADEEP
HINDUSTAN PETROLEUM CORPORATION LIMITED

ENGINEERING & PROJECTS
GRESHAM ASSURANCE HOUSE, 2ND FLOOR,
A-1595(3) 1-A, SIR P M ROAD, FORT
MUMBAI-400 001
TENDER DOCUMENT
FOR
CONSTRUCTION OF
PETROLEUM OIL STORAGE TANKS
AT
PARADEEP POL TERMINAL

PARADEEP
ORISSA
Page 1 of 1
INDEX
Sr. DESCRIPTION PAGES
No.
FROM TO
TENDER COVER PAGE

1 1 1
INDEX
2 1 3
PROJECT DESCRIPTION, SCOPE OF WORK & SCHEDULE OF

3 1 34
QUANTITIES
4 UNPRICED BID 1 5
5 TIME SCHEDULE 1 2
6 SPECIAL CONDITIONS OF CONTRACT 1 24
7 TENDER TECHNICAL SPECIFICATIONS
7.1 TECHNICAL SPECIFICATION
7.1-A GENERAL SCOPE OF WORK FOR TANKS 1 27

7.1-B TECHNICAL SPECIFICATION FOR FLOATING ROOF TANK 1 32
7.1-C TECHNICAL SPECIFICATION FOR FIXED CONE ROOF TANK 1 22
7.1-D STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING 1 10
7.1-E STANDARD INSPECTION TEST PLAN FOR TANK FABRICATION 1 7
7.1-F STANDARD SPECIFICATION FOR FIRE PROTECTION SYSTEM FOR 1 15
FLOATING ROOF TANKS
7.1-G STANDARD INSPECTION TEST PLAN FOR PIPELINE JOBS 1 4
7.1-H TECHNICAL SPECIFICATIONS FOR CONCRETE AND REINFORCEMENT 1 15
WORKS
7.1-I SPECIFICATION OF MECHANICAL SHOE SEAL & SECONDARY SEALS 1 5
7.1-J SPECIFICATION OF GAUGE POLE SLEEVE 1 2
7.1-K SPECIFICATION FOR FLEXIBLE PIPE 1 3
Page 1 of 3
7.1- SPECIFICATION FOR STAINLESS STEEL ARMOURED HOSE 1 3

K.1
7.1-L TECHNICAL SPECIFICATION FOR PIPES 1 4
7.1-M SPECIFICATION FOR STRUCTURAL STEEL WORKS 1 58
7.1-N STANDARD SPECIFICATION FOR WELDING OF PIPELINES 1 31
7.1-O STANDARD SPECIFICATION FOR WELDING 1 8
7.2 QC FORMATS
7.2-A ANNULAR PLATE COAL TAR EPOXY PAINTING REPORT 1 1
7.2-B ANNULAR PLATE PAINTING REPORT 1 1
7.2-C API NAME PLATE 1 1
7.2-D BLASTING PAINTING REPORT 1 1
7.2-E BOTTOM PLATE SOIL SIDE BLASTING PAINTING REPORT 1 1
7.2-F CALIBRATION CHART 1 12
7.2-G FABRICATION REPORT 1 1
7.2-H FITUP INSPECTION REPORT 1 2
7.2-I IMIR 1 1
7.2-J Paint Consumption Statement 1 1
7.2-K Post welding Inspection reading for shell 1 1
7.2-L Pre welding Inspection reading for shell 1 1
7.2-M WELD VISUAL REPORT 1 1
7.2-N FABRICATION-1 1 1
7.2-O FABRICATION-2 1 1
7.2-P FABRICATION-3 1 1
7.2-Q FABRICATION-4 1 1
7.2-R fabrication document 1 1
7.2-S Grit Blasting 1 1
7.2-T Painting DFT 1 1
7.2-U PAINTING 1 1
7.2-V QAP FORMAT 1 1
7.2-W WPS FORMAT 1 31
7.3 Job Procedures
7.3.0 JOB PROCEDURES INDEX FOR TANKAGE JOB 1 2
7.3.1. PROCEDURE FOR FABRICATION AND ERECTION OF TANKAGE BY 1 15
JACKING UP METHOD
7.3.2. RADIOGRAPHY EXAMINATION PROCEDURE 1 15
7.3.3. PROCEDURE FOR VACUUM BOX TEST 1 3
7.3.4. PROCEDURE FOR LIQUID PENETRANT EXAMINATION 1 3
7.3.5. PROCEDURE FOR OIL CHALK TEST 1 2
7.3.6. PROCEDURE FOR PNEUMATIC TEST 1 3
7.3.7. HYDRO TEST 1 3
7.3.8. PROCEDURE FOR SURFACE PREPARATION AND PAINTING 1 5
7.3.9. PROCEDURE FOR ANTI CORROSIVE LAYER 1 2
Page 2 of 3
7.3.10. INSPECTION TEST PLAN FOR TANK FABRICATION 1 6

7.3.11. WELD DETAILS 1 1
7.3.12. RCC 1 7
7.3.13 POST WELD HEAT TREATMENT 1 4
7.3.14 FLOATATION & PUNCTURE TEST 1 4
7.3.15 QAP DOCUMENT DETAILS 1 8
7.3.16 TYPICAL QAP FOR TANK FABRICATION 1 5
8 TENDER DRAWINGS 39 nos
9 SAFETY, HEALTH & ENVIRONMENT(SHE) POLICY 1 8
10 PARADEEP TERMINAL LAYOUT 1 1
Page 3 of 3
PROJECT DESCRIPTION,
SCOPE OF WORK&
SCHEDULE OF QUANTITIES
Page 1 of 34
PROJECT DESCRIPTION/ SITE INFORMATION

Hindustan Petroleum Corporation Limited proposes to Augument storage capacities as a part
of revamping facilities of the Terminal at Paradeep, Orissa and has decided to invite eligible
parties to take-up the project as per the detailed job schedule enclosed. This tender
envisages Fabrication, erection, welding, testing, painting and calibration of above ground
Petroleum Oil storage tanks on the existing Pile Foundation. Details of Tanks to be
constructed are as under:
S. No. Size of Tank Product Capacity No. of Type

Tanks
1 30.0M Dia x 10.0M Ht HSD 6716 KL 2 Cone Roof
Vertical
2 28.0M Dia x 10.0M Ht MS 5000 KL 2 Floating Roof
Vertical
The bidder is advised to visit and examine the site of works and their surrounding and
obtain for himself and on his own responsibility all information that may be necessary for
preparing of the bid and entering into the contract. The cost of visiting the sites shall be at
bidder’s own expenses. No extra claim on account of non-familiarity of site conditions shall
be entertained during execution of works.
The prospective bidders are requested to thoroughly read and comprehend the various
sections of this tender document and visit the sites before quoting for the tender and offer
their most competitive rates for the job.
The site addresses is as below:
Hindustan Petroleum Corporation Ltd
Paradeep Terminal
Opposite Paradeep Railway Station,
Paradeep- 754145
Orissa
Ph : (06722) 229225/ 229226
Page 2 of 34
SCOPE OF WORK
Scope of the job involves but not limited to the following:
1. Design, Construction and testing of above ground steel storage tanks.
IMPORTANT NOTES
1. Entire Cement concrete job need to be carried out thru Ready mix concrete only. The scope of
mix design is included in the scope of bidder and the same to be vetted by reputed
engineering institute like IIT, Kharagpur or any other reputed Engineering Institutes/
Consultant duly approved by HPCL. Party has to submit vetted design calculations to EIC and
obtain approval of the same before commencement of the job. RMC plants shall be of repute
like ACC, L&T etc. Alternatively, party can also set up a batching plant at the site and make
design mix as per provision including vetting by the reputed engineering institute like IIT,
Kharagpur or any other reputed Engineering Institutes/ Consultant duly approved by HPCL.
Party has to submit vetted design calculations to EIC and obtain approval of the HPCL before
commencement of the job.The batching plant need to be certified by third party for
robustness of performance and equipments associated with it.
2. Design of storage tank is also in the scope of the bidder. Tank design along with all
components shall be vetted by IIT, Kharagpur or any reputed institute/consultant as approved
by HPCL. However, the design data sheet is to be approved by HPCL prior to commencement
of design process and subsequent vetting by IIT Kharagpur or any reputed institute/
consultant. Party has to submit vetted design calculations to EIC and obtain approval of the
HPCL before commencement of the job.Rate to include the same in respective items and No
separate payment shall be made to the party on this account.
3. Scope also includes shifting of all types of materials including scrap materials, if any lying at
the constructional area to the designated place inside the depot premises at no extra cost. Job
also includes site clearing from any debris, vegetation, bushes and trees, etc and make the site
free for construction at no extra cost.
4. Any cables / piping encountered during excavation and other construction activities, the same
shall be separated using Sand Bed and Tiles or to be re-routed, if necessary as directed by the
Engineer in charge at no extra cost to HPCL.
5. The complete requirements shall be executed comprehensively with single point

responsibility. The prospective bidders are requested to thoroughly read and comprehend the
various sections of this tender document and visit the sites before quoting for the tender.
6. If any deviation is found during execution between the specification and the drawings, it is to be
explicitly noted that the specification will hold good and supersede the drawings.
7. The bidder is required to peruse carefully all parts of tender documents and drawings and if any
difference / inconsistency is noticed, he shall bring it to attention of HPCL before submission of
Page 3 of 34
tender and shall get the clarification(s) required. Failure to do so will not entitle the successful
bidder for any extra claims on account of such discrepancies/inconsistencies.
8. All jobs shall be executed as per technical specifications, relevant codal provisions, sound
engineering practices and as directed by EIC.
Drawings required to be submitted by the Party:
1. Preparation of all detailed and working drawing for storage tanks and obtaining approval of
HPCL/ TPI/ Consultant.
2. Submission of 4 copies of all the above drawings (As built) shall be submitted along with CD
containing soft copy in AutoCAD latest version after job completion.
The prospective bidders are requested to thoroughly read and comprehend the various sections of this
tender document and visit the sites before quoting for the tender.
SITE INFORMATION
The job needs to be carried out in the working Terminal premises. Works to be commenced only after
having obtained necessary work permit on a daily basis & all safety precautions to be taken by the
party for carrying out the above jobs as directed by Engineer In Charge/ Terminal Manager.The party
will also have to arrange for all necessary safety and fire fightingequipments like fire extinguishers,
foam trolley, localised fire screen etc at no extra cost. The party will have to abide by all instructions
and directions by Engineer In Charge/ Terminal Manager while working inside the premises.
All conditions of work permit to be followed religiously by the party. The explosive meter readings and
check for presence of flammable vapour shall be checked by contractor’s supervisor along with HPCL’s
representative before undertaking hot work. Full time supervisor to be provided at work spot and job
shall be carried out only after complying with all safety norms of the depot. A full Time Qualified
Engineer who is technically competent and having sufficient Site experience to be available at site for
supervising and carrying out all the Jobs as per the Scope.
All the safety precautions including supplying & providing localised fire screens etc shall be arranged by
the Contractors as per the directions of Engineer in charge at no extra cost to HPCL. The contractor has
to take necessary precaution for the safe transportation of the material. Before quoting for the said job
the contractor is required to visit the site and make himself acquainted with the scope of the job and
quote accordingly.
The tenderers are required to go through the tender document thoroughly and carefully and offer their
most competitive rates for the job. All sets of this tender document are to be read in conjunction with
each other and accordingly quote in the priced bid.
In case of any clarifications contractor may contact Shri B. S. GOPALA KRISHNA, Senior Manager-E&P,
Engg& Projects Dept., Gresham Assurance House, 2ND Floor, A-1595 (3), 1-A, Sir P M Road, 132, Shahid B
Singh Road, Fort, Mumbai- 400 001 on 022-22608507 regarding any queries. Party may also contact
ShriR. C. Panna, Senior Manager on 06722-229225 or 09437573955regarding any queries.
Page 4 of 34
SITE VISIT
1. The bidder is advised to visit and examine the site of works at all locations and their surrounding
and obtain for himself on his own responsibility all information that may be necessary for preparing
of the bid and entering into the contract. The cost of visiting the sites shall be at bidder’s own
expenses. No extra claim on account of non-familiarity of site conditions shall be entertained during
execution of works.
2.The bidder and any of his personnel or agents will be granted permission by the Owner to enter
upon his premises and lands for the purpose of such inspection, but only upon the explicit condition
that the bidder, his personnel or agents will release and indemnify the Owner and his personnel and
agents from and against all liability in respect thereof and will be responsible for personnel injury
(whether fatal or otherwise), loss of or damage and expenses incurred as a result hereof.
The prospective bidders are requested to thoroughly read and comprehend the various sections of this
tender document and visit the sites before quoting for the tender.
Page 5 of 34
SCHEDULE
OF
QUANTITIES
Page 6 of 34
IMPORTANT NOTES TO SCHEDULE OF QUANTITIES
1. These notes to be read in conjunction with the schedule of quantities and is integral part
of the same.
2. Scope of Work , Supply of Material, Technical Specifications, QAP, ITP( Inspection Test
Plan) Requirement of relevant Codes , SCC( Special Conditions to Contract), GTC (General
Terms & Conditions) , Schedule of Rates ,Statutory Rules & Guide Lines as applicable,
Minimum Equipment / Machineries Deployment and any other requirement to complete
the Job / Work as per this Tender Document shall be deemed to be included in SOR items.
3. For all Items preparation of Design and Construction Drawing as per relevant code &
Tech. Specifications of this Tender & vetting after review by HPCL through Third Party
approved by HPCL, Quality Control , Inspection & Job procedure, Project Scheduling &
Monitoring Document as per SCC , Submission of all these documents to HPCL for
approval deemed to be included in quoted rates.
4. Design of storage tank is also in the scope of the bidder. Tank design along with all
components shall be vetted by IIT, Kharagpur or any reputed institute/consultant as
approved by HPCL. However, the design data sheet is to be approved by HPCL prior to
commencement of design process and subsequent vetting by IIT Kharagpur or any reputed
institute/ consultant. Party has to submit vetted design calculations to EIC and obtain
approval of the HPCL before commencement of the job. Rate to include the same in
respective items and No separate payment shall be made to the party on this account.
5. The Water and Electrical power required for constructional activity shall be in the Scope of
Contractor & shall be deemed to be included in SOR Items.
6. All the Testing and Third Party Charges for Items as per tender documents elicited in
various sections shall be borne by contractor and deemed to be included in quoted rates.
7. All Tools & Tackles, Equipments, and items brought to site by contractor will be permitted
to be taken out only after completion of work & fulfillment of necessary formalities.
8. Rate for all items to include deployment of qualified Quality Control & Safety Engineer at
site from the date of LOI till completion of job as per PO. QC Engineer & Safety Engineer
deployed as per above will report to HPCL site-in-charge on daily basis for complying all
the QC/safety jobs mentioned in the PO.
9. The Drawings/QAP/ITP /Job procedures attached along with tender document are for
guidance/ tender purpose only. The successful bidder to submit the above for HPCL
approval as per the job requirements during the execution of the job.
Page 7 of 34
ITEM DESCRIPTION OF ITEM UNIT QTY

NO
CONSTRUCTION OF PETROLEUM OIL STORAGE TANKS

1.0 Excavation up to 2.0 meter Cubic 250
Meters
Staking out, marking the outline for excavation, excavation in any type of soil
including soft rock (except hard rock) for general site grading and tank pad
foundations/Ring beams/Foundations of underground tank etc. either by
machinery or manually up to 2.0m below NGL including removal of stumps and
roots to full extent, removal of all vegetation including bushes and grass,
dewatering, taking spot levels @ 5 m C/C in grid pattern, leveling, dressing and
rolling the excavated surface, loading, transportation of surplus earth to an
unobjectionable place inside the site premises, spreading, leveling, compaction
etc as per instructions of the engineer in charge. The job to be executed as per
attached technical specifications, job procedures etc complete and as directed by
EIC.
2.0 Murrum Filling Cubic 2000

Meters
Supplying and filling murrum of approved quality with PI of 7-17(Medium

plastic)containing not more than 20% cohesive fines namely clay, 20mm and
down size grading and Max. dry density of material not less than 1.80 gms/cc,
including excavation at borrow pits outside site premises, payment of all
royalties, taxes, etc to Statutory Authority for operating the borrow pit, loading at
borrow pit end, transportation from borrow pit to HPCL project site, removing
debris, organic matter, etc spreading in layers not exceeding 200mm loose depth,
watering, compaction with Vibratory Roller to obtain 95% of standard proctor
maximum laboratory dry density and finishing to slopes and grades as per
drawings all complete as per specifications and instructions of HPCL Engineer-in-
Charge. Rate shall be applicable for all depths below NGL and upto 3m above
NGL. The job to be executed as per attached technical specifications, job
procedures etc complete and as directed by EIC.
3.0 Rubble Soling Cubic 75

meters
Page 8 of 34
Providing and laying 230mm thick or specified thickness dry trap rubble stone
(granite/basalt)soling at all depths including hand packing, filling the interstices
with chips, spalls and binding with grit and selected murrum, watering,
compaction by hand ramming & rolling with 1 MT hand roller etc complete as per
attached job procedures, technical specification and as per direction of EIC.
4.0 Plain Cement Concrete 1:2:4 Cubic 50

Meters
Providing and laying Plain Cement Concrete of nominal volumetric mix 1:2:4(1
Cement; 2 Sand: 4Crushed stone aggregates) with 40mm and down size graded
aggregates for bed block for foundations& any other work as per HPCL
requirement including any required shuttering, machine mixing, tamping,
ramming, curing, etc all complete as per Specifications,Drawings, job procedures
etc and instructions of HPCL Engineer-in-Charge.
5.0 RCC M 20 - Tank Apron Cubic 135

Meters
Designing of mix, Providing, mixing and placing in position M20 mix concrete with
20 mm and down size well graded crushed aggregate including fixing form work,
compacting and curing etc complete as per specifications but excluding the cost
of supply and placing in position steel reinforcement which will be paid under
separateitem. Mobile weigh batcher or Ready Mix Concrete shall be adopted.
Mix Design shall be for Normal exposure. .Concrete ingredients shall conform to
IS 456- 2000. Rate also to include necessary Polythene sheets of approved quality
to be placed before laying the concrete. The job to be executed as per attached
technical specifications, job procedures etc complete and as directed by EIC.
6.0 RCC M 20 - Ring Beam for above ground tanks Cubic 75

meters
Designing of Mix, Providing and laying Reinforced Cement Concrete of M-20

Grade with 20mm and down size graded crushed stone aggregates for RCC Toe
beam around Morrum tank pads, supply of all required materials like cement,
stone aggregates, water, sand, labour, equipments, carrying out vibrating,
tamping, finishing, curing, testing all complete as per specifications including
shuttering required to hold the RCC in place all complete. Quoted rates to exclude
the cost of supplying and providing Reinforcement Steel. Mobile weigh batcher or
Page 9 of 34
Ready Mix Concrete shall be adopted. Mix Design shall be for Normal exposure.
NOTE: Rate also to include necessary brickwork in CM 1:5 required for shuttering
on the inside face of the plinth beam to match the slope and thickness of the tank
apron. The job to be executed as per attached technical specifications, job
procedures etc complete and as directed by EIC.
REINFORCEMENT STEEL Metric 12.5

7.0
ton
Supply, fabrication and laying in position steel reinforcement conforming to

IS:1786 at all depths including cutting, cold bending, tying and placing in position
the rods, with necessary 18 SWG black annealed binding wire including cost of
binding wire and any other incidental charges etc., complete as per standard
specification. Laps, chairs and spacer bars shall not be considered for
measurement and payment. The job to be executed as per attached technical
specifications, job procedures etc complete and as directed by EIC.
ANTI CORROSIVE LAYER Square 3000

8.0
meters
Providing and laying 100mm thick (compacted thickness) anti-corrosive layer

under the tank bottom mixed using sand mixes with 80/100 grade bitumen (8% to
10% by volume) including supplying all materials, transportation, machine mixing,
laying, tamping, rolling with 10 MT roller and finishing to required slope including
all labour required to complete the job as per specifications and instruction of
Engineer In Charge.
FABRICATION, ERECTION & WELDING – BOTTOM, SHELL, PONTOON

ROOF/DECK ETC. FOR A/G TANKS (PLATES SUPPLIED BY HPCL).
SCHEDULE OF TANKS
(1) HSD TANKS - 30.0MDia x 10.0 M Ht- Self-supporting Fixed cone roof – 2 No.
(2) MS TANKS - 28.0 M Dia x 10.0 MHt – External Floating Roof – 2 No.
Plate work for above scheduled Tanks(For Annular bottom and sketch, shell
and roof/deck plates): Taking over and Transportation of Free issue Plates
Page 10 of 34
from HPCL Storage yard to Work site/ Contractor's fabrication yard,

preparation of fabrication drawings and obtain HPCL approval, fabrication
and erection of Shell plates by Jacking-up method, Bottom Sketch and
annular plates with backing strip, plate fabricated wind girders, bearing
plates for Pipe supports, pads for structural bracings/ supports provided to
wind girders, datum plates, shell manhole necks, bolting and cover flanges
for Shell manholes, reinforcing pads for shell manholes, Nozzle reinforcing
pads, pads for all Shell appurtenances and attachments ,sprinkler deflector
plates, fabrication and installation of all items as per drawings, provision of
Hydraulic jacks, supply and fabrication of cleats and wedges and clamps,
supply of all materials as per Scope of work of supply, welding and other
consumables, bolts, nuts and gaskets, labour, equipment, machinery, tools,
tackles, etc to complete the work in all respects as per approved drawings,
tech specifications, job procedures, QAP/ITP, Codes, standards, Scope of
work complete and instructions of HPCL Engineer-in-Charge .After
completion of work, the Contractor has to carry out reconciliation of free
Issue steel plates, returning Surplus Full Plates/Off cuts/ Accountable scrap to
HPCL storage yard.Rate to include radiographic inspection of weld jointsas
detailed in SECTION 8 OF API 650. Job to include copper slag blasting of
required profile to the underside of bottom/ sketch/ annular plates (soil
side) along with 2 coats of High Build Coal Tar Epoxy of min DFT 100 micron
per coat and one primer coat of inorganic zinc silicate of minimum 65
micron (Total DFT 265mm minimum).
The Tank design along with all components shall be vetted by IIT, Kharagpur
or any reputed institute/consultant as approved by HPCL.However, the
design data sheet is to be approved by HPCL prior to commencement of
design process and subsequent vetting by the bidder.
All the Testing/Design/Third party inspection/vetting requirements as per
attached technical specifications/job procedures shall be included in the
quoted rate. No separate payment will be made for the same.
9.0 Annular/Sketch plates of the tanks with 8 mm to 12 mm thick plates Metric 310
including bearing plates. Ton
10.0 Shell strakes of thickness varying from 6 mm to 22 mm including extension Metric 400
plates. Ton
11.0 Roof plates including foam dam plates including design of floating roof. Metric 250
ton
Page 11 of 34
NOTE : (for Item Nos9 to11)

1) For fabrication details reference shall be made to technical specifications/
applicable codes and standards.
2) Quantity of steel given is approximate. Payment shall be made for actual
quantities of plates laid/ erected duly certified by the Engineer at site. The
payment and reconciliation will be made on theoretical weight only
3) MS plates in sizes available will be supplied to the contractor at site and
contractor shall prepare fabrication drawings for approval, prior to
commencement of fabrication work.
4) Design and drawing for entire fabrication and welding sequence to be
submitted to HPCL for approval and design to be approved by HPCL before
commencement of fabrication.
5) Method of inventory and recovery of steel plates issued by HPCL shall be
as per relevant clause of SPECIAL TERMS AND CONDITIONS attached.
6) Fabrication work of Tanks shall be carried out by Jacking up Method only.
7) Vendor to note that for welding of tanks, the following electrodes only
should be used. E-6013 of brands like ESAB or approved equivalent for
plate thk less than 12 mm.
E-7018 of brands like ESAB/D&H or approved equivalent for plate thk equal
to and more than 12 mm and for shell to annual plate joint from inside
and outside.
8)Scope of the job includes carrying out radiography of shell joints using
gamma ray as detailed in API650 & Appendix A / technical specs.
9) Rate for the above plate work items should be offered after thoroughly
comprehending all the sections of the bid document.
10) The underside of all floating roofs and fixed roof shall be seal welded
and the rate to include the same.
Important Note:- If the Gamma ray source needs to be kept inside the
location on a continuous basis, all precautions as stipulated by BARC needs
to be strictly followed and approval shall be obtained from them before
keeping the source inside the location.
STRUCTURAL STEEL WORK USING STRUCTURAL STEEL SUPPLIED BY
CONTRACTOR.REFERENCE SHALL BE MADE TO THE SPECIAL TERMS AND
CONDITIONS FOR SCOPE OF SUPPLY AND OTHER DETAILED SPECIFICATIONS
OF MATERIAL.
(For item nos. 12 to 20)
Page 12 of 34
STRUCTURAL/PLATE WORK
Structural/ Plate work: Supply, fabrication, erection, inspection and testing of
steel structures as per approved drawings and designs such as rolled
sections, gratings and flats for curb angles, spiral stairways, landings, top
platform, earthing connections cleats, wind girder supports & pad plates,
stiffeners/ gussets for wind girder, deflector plate for wind girders, stiffeners/
catwalks for interconnecting tanks, supply of all materials, consumables,
labour, equipments/ machinery, tools & tackles required to complete the
work as per drawings, Scope of work, technical specifications, job
procedures, QAP/ITP complete and instructions of HPCL Engineer-in-Charge.
Rate to include supply, fabrication, erection & welding, straightening, cutting
to required length supply and fixing all nuts and bolts washers wherever
required for following items. Separate measurements will not be taken for
nuts, bolts, washers etc for payment purpose.
All structural designs shall be vetted by IIT, Kharagpur or any reputed
institute/consultant as approved by HPCL.However, the design data sheet is
to be approved by HPCL prior to commencement of design process and
subsequent vetting by the bidder.
All the Testing/Design/Third party inspection/vetting requirements as per

quoted rate. No separate payment will be made for the same.
12.0 Supply, fabrication, welding and erection of all floating roof structural, rim Metric 30
and frame angles, pontoon stiffening rafters, curb angles, cleats, support Ton
structural for sprinkler system and foam system, and all angles, gusset
plates, wind girders etc complete as per specifications.
13.0 Supply, fabrication, welding and erection of all self-supporting fixed cone roof Metric 40
structural trusses, rafters, cleats, gussets etc complete as per attached Ton
technical specifications, drawings, job procedures, QAP/ITP and as directed
by EIC.
Job also to include copper slag blasting of the structural members followed
by one coat of 65 micron inorganic zinc silicate primer. The primer shall be
followed with one coat of 100 micron HBMIO followed by two coats of
each of 40 micron polyurethane paint of approved make and shade.
14.0 Structural steel for the hand rail of the stringer type spiral stairway, landing Metric 6
Page 13 of 34
platforms and roof top railing like angles, flats and connecting cleat angles. Ton
Note:- Hand rails will be pipe hand rails and will be paid though separate
item.
The stairway step gratings, landing platform gratings, MS square rods will be
paid through a separate item.
15.0 Structural steel for ladder, track, rollers, axle and connecting flat of the self- Metric 6
leveling steps made out of MS gratings only Rate to include supply and Ton
bracing of brass strip over wheels of rolling ladder in floating roof tanks.
Note: Hand rails will be pipe hand rails and will be paid though separate
item. The stairway step gratings will be paid through a separate item.
16.0 Supply, fabrication, welding and erection of pipe hand rails for the staircase Metric 3
made out of 40 mm diaSch 80 seamless pipe conforming to ASTM A106. Ton
17.0 MS square bars of 20 mm size for stairway and ladder as per attached Metric 2
drawings and technical specifications and as directed by EIC. Ton
MS GRATINGS
Supply, fabrication, welding and erection of the following size MS gratings
with MS flat in honey comb pattern as shown in the drawing. The Gratings
shall be fabricated out of 25x6 MS flats(Outer frame, Straight flats) and 25x 3
MS Bent flats. Rate includes grit blasting thoroughly to S.A 2.5 of Swedish
Ivonsk Standard SIS 055900-Latest edition and applying one coat (DFT 65
microns) of inorganic zinc silicate (Zinc anode 304) primer of Berger or
approved equivalent. (For items 56 to 58) followed by 100 micron HBMIO.
18.0 800 x 250 mm size gratings for all stairways with honeycomb pattern. Square 65
meter
19.0 800 x 1000 mm size grating for the top and mid landing platforms with honey Square 55
comb pattern. meter
20.0 800 x 200 mm size gratings for all rolling ladder stairways with honeycomb Square 25
pattern. meter
TANK APPURTENANCES
REFERENCE SHALL BE MADE TO THE SPECIAL TERMS AND CONDITIONS FOR
SCOPE OF SUPPLY AND OTHER DETAILED SPECIFICATIONS OF MATERIAL.
Page 14 of 34
All appurtenances to be fabricated in line with requirements of API 650.

SHELL APPURTENANCES(For items 21 to 24)
Appurtenances: Preparation of Drawings and obtaining approval from HPCL,
Supply, Fabrication, installation, welding, inspection and testing required for
the following nozzles( Reinforcing pads covered under plate work) including
supply of pipes, Nozzle flanges and Blind/ companion/ matching flanges
wherever required as per approved drawings and standards along with
gaskets and bolting, conducting air pressure test for Reinforcing pads, supply
of all required materials, consumables and labour to complete the work as
per attached drawings, technical specifications, standards, codes, Scope of
work and as per instructions of HPCL engineer. Nozzle neck lengths shall be
as per drawings/ data sheets/specs.
21.0 SHELL MANHOLES Each 8
600 mm nominal dia shell manhole with neck ring, manhole cover plate with
handle, bolting flange, MS reinforcement pad plate,3 mm thk oil permeate
gasket, stud bolts and nuts. Only plates for reinforcement pad will be
supplied by HPCL. Quoted rates are deemed to include supply and fabrication
of neck ring, testing including radiography, bolting flange, cover plate, gasket,
stud bolts and nuts.
SHELL NOZZLE
Shell nozzles of the following sizes with reinforcement pad plate, using
seamless pipes conforming to ASTM A 106 Grade XS, for nozzle sizes upto
and including 300mm. The nozzle sizes above 300 mm shall be fabricated
form MS plate of IS 2062: grade A/B of thickness as per the provision laid
down in API- 650. The nozzle shall be with ASA class 150 forged steel slip on
flanges with holes drilled as per ANSI-B-16.5 inside as well as outside, 350
mm dia x 600 mm length semi circular anti splash trough inside the tank, 2
mm thk oil permeate gasket, stud bolts, flanges including fixing of HPCL
supplied valve complete as per specifications. Only plates for reinforcement
pad will be supplied by HPCL. Quoted rates are deemed to include supply and
fabrication of nozzle, trough, slip-on flanges, gasket and stud bolts and nuts.
The job shall also include DP testing of the root and radiography of the seam
joint in case of nozzle being fabricated from plates.
22.0 450 mm DIA using MS plate conforming to IS 2062 Gr.A/B Each 8
23.0 250mm DIA using seamless pipes conforming to ASTM A 106 Grade XS Each 4
24.0 WATER DRAW OFF NOZZLE Each 16
Page 15 of 34
Water draw off nozzles of 80 mm dia with reinforcement pad plate,

seamless pipe of A 106 XS Grade, ASA class 150 forged steel slip on flanges
with holes drilled as per ANSI-B-16.5 inside as well as outside, 2 mm thk oil
permeate gasket, stud bolts, flanges including fixing of HPCL supplied valves
(2 Nos) with blind flange with a spool piece in between of approx.200 mm
length. The rate shall include supply, fabrication, erection, welding and
testing of the above including flanges and pipe. Only plates for reinforcement
pad will be supplied by HPCL. Job also to include supply and provision of bend
inside the tank with anti-vortex plate at the tip as per attached drawings,
technical specifications etc and as directed by EIC.
25.0 SUPPLY & FIXING FOAM POURER & MAKER WITH NOZZLES Each 16
Foam pourer nozzles of 150 mm dia with reinforcement pad plate, seamless
pipe, ASA class 150 slip on flanges with holes as per ANSI-B 16.5, foam
deflector, gasket, nuts, bolts, washers, flanges including fixing of foam maker
&foam pourer for floating roof and fixed cone roof as per design/tech
specifications/standards/codes complete. Job also includes supplying and
fixing of approved foam maker & pourers as per technical specs attached at
required elevation with gasket, stud bolts, etc complete. All the
Testing/Design/Third party inspection/vetting requirements as per attached
technical specifications/job procedures shall be included in the quoted rate.
No separate payment will be made for the same. The job to be executed as
per attached technical specifications, job procedures etc complete and as
directed by EIC.
26.0 PRESSURE TRANSMITTER NOZZLE Each 4
Pressure transmitter nozzles of 80 mm dia with reinforcement pad plate,

seamless pipe of A 106 XS Grade, ASA class 150 forged steel slip on flanges
with holes drilled as per ANSI-B-16.5, gasket, stud bolts, flanges including
fixing of HPCL supplied valve with blind flange. Only plates for reinforcement
pad will be supplied by HPCL. The job to be executed as per attached
technical specifications, job procedures etc complete and as directed by EIC
FLOATING ROOF APPURTENANCES

Supply fabrication erection and welding of the following roof appurtenances.
Rate to include supply, fabrication and welding of the neck rings, MS
ERW/Seamless pipes, bolting flanges, MS plate slip on flanges, manhole
covers with handle, all gaskets ,stud bolts and fabrication and welding of all
Page 16 of 34
reinforcement pad plates as per drawing complete as per specifications. For

all roof appurtenances only plates for reinforcement pad will be supplied by
HPCL. All the Testing/Design/Third party inspection/vetting requirements as
per attached technical specifications/job procedures shall be included in the
quoted rate. No separate payment will be made for the same.The job to be
executed as per attached technical specifications, job procedures etc
complete and as directed by EIC (For items 27 to 43 )
27.0 DECK THROUGH MANHOLES-600mm NB Each 2
600 mm NB deck through manhole with 6 mm sleeve, manhole cover, bolting

flange, reinforcement pad plate and cat ladder with ISA 65 x 65 x 8 and 25
mm plain rods @ 250 c-c. Structural steel work for cat ladders will be paid
separately under item no 17. The job to be executed as per attached
technical specifications, job procedures, drawings etc complete and as
directed by EIC
28.0 DECK THROUGH MANHOLES- 750mm NB Each 2
750 mm NB deck through manhole with 6 mm sleeve, manhole cover, bolting

flange, reinforcement pad plate and cat ladder with ISA 65 x 65 x 8 and 25
mm plain rods @ 250 c-c. Structural steel work for cat ladders will be paid
separately under item no 17. The job to be executed as per attached
technical specifications, job procedures, drawings etc complete and as
directed by EIC.
29.0 GAUGEWELL SLEEVE FOR AUTOLEVEL GAUGE AND MANUAL GAUGE PIPE. EACH 4
Fabrication and erection of 500 NB and 1.5 mt long MS ERW sleeve

(fabrication) of thickness 6 mm for auto level gauge float. Rate to include
welding the pipe to the pontoon bottom and top plates with reinforcement
plates, welding suitable flange (to be supplied by the party) conforming to
ASA class 150 and holes drilled as per ANSI-B-16.5, fabrication ,welding and
fixing of cover plate with necessary sockets for gauge float string/ guides
including necessary stud bolts and gaskets. Job also to include supply and
fixing of 20mm thick brass flange and 20mm thick neoprene sheet to suit the
above. The job to be executed as per attached technical specifications, job
procedures, drawings etc complete and as directed by EIC
Page 17 of 34
30.0 PONTOON MANHOLES Each 56
500 mm nominal diameter manholes with cover plates and handles. Suitable
Neoprene rubber beading / lining of 5/6 mm shall be provided on the neck of
pontoon manhole with proper fixing arrangement to prevent any sparking.
Manhole cover shall be provided with proper locking/venting arrangement.
The job to be executed as per attached technical specifications, job
31.0 AUTO BLEEDER VENT Each 4
Supply, fabrication, erection of 300 mm dia pipe conforming to ASTM A 105

Gr.BSch 40 for auto bleeder vent as per drawing. All materials including
brazing of pipes is in the scope of vendor. The job to be executed as per
attached technical specifications, job procedures, drawings etc complete and
as directed by EIC
32.0 RIM VENT Each 4
Supply, fabrication, erection of 150 mm nominal dia rim vent, including fixing
of vendor supplied Aluminium pressure vacuum (PV) vent as per attached
specs and approved makes. Rate to include supply, fabrication, erection of
pipe, flanges and PV vent.
33.0 EMERGENCY DRAIN Each 2
Supply, fabrication, erection of 150 mm nominal dia emergency drain with

water trough and water seal with Sch 40 seamless pipe all accessories
complete as per approved drawings.
CENTRAL ARTICULATED ROOF DRAIN ASSEMBLY
Roof Drain: Design, sizing, Preparation of drawings, submission of design

calculations and obtaining HPCL approval, supply, fabrication and erection of
primary Roof Drain Flexible (make) roof drain system made from unbonded
flexible pipe conforming to API17j of make Co flexip or MESA or HPCL
approved equivalent as detailed specification attached (Annexure II) with
Cast steel Non-return Valve including Supply, fabrication and installation of
suitable Shell nozzle for Roof Drain ,Supply, fabrication and welding for inlet
piping from Roof Drain sump to Inlet side of Selected system and Outlet
piping from Outlet side of Selected system to shell nozzle with required
Page 18 of 34
shoes, guides and guards, if any as per Manufacturer's instructions; Supply,

fabrication and erection of Roof drain Extension piping along with cast steel
Gate valve, supports and foundation for Roof drain extension, etc, Testing
and completing the work in all respects as per specifications, drawings and
instructions of HPCL Engineer-in-Charge, providing Performance Guarantee
for the entire System for 3 years from the date of Commissioning. The drain
shall be so designed that the entire rain water (125 mm/hr – to be
considered for design of roof drain) is immediately drained off. Bolts
used inside the tank should be of stainless steel.(for item 34)
Complete layout of Primary Roof Drain shall be provided by the supplier and
installed by the Contractor. Contractor shall supply all required materials.
34.0 28 M DIA X 10.0 Mt HT TANK – External Floating Roof EACH 2
FLOATING ROOF LEGS
35.0 100 mm NB (actual length to be as per site conditions) seamless pipes of Meters 100
schedule 40 thickness for sleeves of legs.
36.0 80 mm NB( actual length to be as per site conditions)seamless pipes of Meters 180
schedule 80 thickness for leg supports with holes drilled as specified in the
drawing for two operating levels one at 1.8 mt and the other at 1.2 mt
respectively and MS rod and cotter pin of specified size.
NOTE: (Note: for items 35 & 36)
1. Reference shall be made to specifications for materials in contractor’s

scope of supply for scope of supply and details of specifications of pipes.
2. The 80 mm dia leg support shall have 36mm dia sleeve at locations where
holes are drilled.
3. Bearing plate under each pipe supports (legs) shall be welded around.
4. 100 mm Sleeve shall be brass brazed at the top and bottom for length. of
50 mm measured along the pipe.
5. The leg pins shall be stainless steel and 32 mm in diameter.
6. The rates to include supply and fixing of neoprene between sleeve and leg
Page 19 of 34
supports as per details provided in attached drawing.
37.0 COMBINED STILL WELL PIPES 400 MM NB Meters 26
Supply, fabrication, erection and welding of the 400 mm NB gauge well using
seamless pipes conforming to ASTM A 106 Gr B of schedule 40 thickness with
holes drilled as per drawing. Rate to include supply, fabrication and welding
of the neck rings, seamless pipes, bolting flanges, supplying and fixing of all
gaskets ,stud bolts and fabrication and connecting the well pipes with party
supplied Al gauge hatches complete along with welding of 600 x 600 x 8 mm
datum plate as per specifications. Rate also to include providing and fixing
guide pole cover/housing of approved design and make to minimize
evaporation of MS/HSD and other volatile organic compound (VOC).
Necessary structural supports shall be paid vide item no 12. Job to be
executed as per attached technical specifications, job procedures, drawings
etc complete and as directed by EIC
Note: One no. 200 mm NB & one no. 80mm NB pipes shall be placed inside
400mm NB pipes erected against this item. However, the same shall be paid
separately against item nos. 39&40 respectively. Party shall quote only for
400 mm NB Combined still well pipes.
38.0 GUAGE WELL PIPES 300 MM NB Meters 26
seamless pipes conforming to ASTM A 106 Gr B of schedule 40 thickness with
holes drilled as per drawing. Rate to include supply, fabrication and welding
of the neck rings, seamless pipes, bolting flanges, supplying and fixing of all
gaskets ,stud bolts and fabrication and connecting the well pipes with party
supplied Al gauge hatches complete along with welding of 600 x 600 x 8 mm
datum plate as per specifications. Rate also to include providing and fixing
guide pole cover/housing of approved design and make to minimize
evaporation of MS/HSD and other volatile organic compound (VOC).
Necessary structural supports shall be paid vide item no 13.0. Job to be
executed as per attached technical specifications, job procedures, drawings
etc complete and as directed by EIC.
Page 20 of 34
seamless pipes conforming to ASTM A 106 Gr B of schedule 40 thickness

with holes drilled as per drawing. Rate to include supply, fabrication and
welding of the neck rings, seamless pipes, bolting flanges, supplying and
fixing of all gaskets ,stud bolts and fabrication and connecting the well
pipes complete along with welding of 600 x 600 x 8 mm datum plate as
per specifications. Necessary structural supports shall be paid vide item
no 12.0. Job to be executed as per attached technical specifications, job
Note: 200 mm NB pipes shall be placed inside 400mm NB pipes erected

against this item for floating roof tank.
40.0 AVERAGE TEMP. SENSOR PIPE. Meters 26
Supply, fabrication, erection and welding of the slotted pipes (80 mm NB x

5.5 mm thick) conforming to IS: 1978 YST 210 grade inside manual gauge well
pipe of floating roof tanks and standalone arrangement in cone roof tanks for
installation of average temp. sensor. Rate to include supply, fabrication and
welding of the neck rings, MS ERW pipes, bolting flanges, fixing arrangements
if any, supplying and fixing of all gaskets stud bolts and fabrication as per
technical specifications and instructions of the engineer in charge.
Note: The above 80mm NB pipes shall be placed inside 400mm NB pipes
erected against this item for floating roof tank.
41.0 SHUNT SPRINGS EACH 75
Providing and fixing suitable stainless steel flats of size 300mm x 50 mm x

3.15mm at the bottom of the pontoon @ 2.5 m c/c around the periphery.
Rate to include supply of SS bolts, nuts, washers etc complete as per attached
drawings, technical specifications complete and as directed by EIC.
42.0 ROOF STOPPER: supply , fabrication/welding of roof stoppers made EACH 10

out of 100 mm NB pipe sch 40 of length 75mm brazed on outside the
surface of the pipe and as per details provided in the std drawing for
roof stopper for floating roof tanks
MECHANICAL SHOE SEAL
Primary Mechanical Shoe Seal with Secondary seal: Design, Preparation of
Page 21 of 34
all drawings and obtaining HPCL approval. Supply of all materials and
installation of primary mechanical shoe seal using SS metallic shoe of dept
1.2mm (for sliding contact along with primary seal fabric) and rim mounted
Secondary Seal along with all fixtures, inspection and testing of all materials
and sealing device namely Pusher Mechanism of SS 304 grade, Hanger, dip
curtain of PTFE, SS shunt, shoe, Secondary seal. Providing Two Year
performance Guarantee for the Primary and Secondary seals from the date of
commissioning all complete as per specifications, standards and instructions
of HPCL Engineer-in-Charge. Contractor shall furnish the name of the supplier
and Model quoted in the tender along with relevant catalogues in Unpriced
Bid.
43.0 28 M DIA TANK Each 2
Design, Supply, fabrication, erection, welding of circulation vents as per

attached drawings, technical specifications and as directed by EIC etc
complete.
FIXED CONE ROOF APPURTENANCES(item No: 44 to 47)
Supply fabrication erection and welding of the following roof appurtenances.
Rate to include supply, fabrication and welding of the neck rings, MS ERW
pipes, bolting flanges, MS plate slip on flanges, manhole covers with handle,
all gaskets ,stud bolts and fabrication and welding of all reinforcement pad
plates as per drawing complete as per specifications. For all roof
appurtenances only plates for reinforcement pad will be supplied by HPCL. All
the Testing/Design/Third party inspection/vetting requirements as per
quoted rate. No separate payment will be made for the same. The job to be
executed as per attached technical specifications, job procedures etc
complete and as directed by EIC
44.0 ROOF MANHOLES – Fixed Cone Roof Each 4
600 mm nominal dia roof manhole with neck ring, manhole cover plate with
handle, bolting flange, MS reinforcement pad plate and suitable dia stud
bolts etc complete.
45.0 ROOF NOZZLES (VENT) with PRV – Fixed Cone Roof Each 4
Page 22 of 34
Supply and fixing of 200 mm dia. Roof nozzles With PRV as per attached
specifications with reinforcement pad plate, MS ERW pipe of suitable
thickness,180 degree forged steel bend of sch 40, ASA class 150 slip on
flanges with holes drilled as per ANSI-B-16.5, stud bolts, washers etc
complete. Rate to include fixing of vendor supplied Aluminium pressure
relief valve.
seamless pipes conforming to ASTM A 106 Gr B of schedule 40 thickness
with holes drilled as per drawing. Rate to include supply, fabrication and
welding of the neck rings, seamless pipes, bolting flanges, supplying and
fixing of all gaskets ,stud bolts and fabrication and connecting the well
pipes with party supplied Al gauge hatches complete along with welding
of 600 x 600 x 8 mm datum plate as per specifications. Necessary
structural supports shall be paid vide item no 13.0.Job to be executed as
per attached technical specifications, job procedures, drawings etc
47.0 AVERAGE TEMP. SENSOR PIPE. Meters 26
Supply, fabrication, erection and welding of the slotted pipes (80 mm NB x

5.5 mm thick) conforming to IS: 1978 YST 210 grade. Rate to include supply,
fabrication and welding of the neck rings, MS ERW pipes, bolting flanges,
screwable cap, fixing arrangements if any, supplying and fixing of all gaskets
stud bolts and fabrication as per technical specifications and instructions of
the engineer in charge.
TESTING OF TANKS:( for items 48 to 53)

Conducting tests such as Vacuum box test, Dye penetration test, Pneumatic
test, diesel chalk test and hydro test as outlined in API 650 and the job to be
executedas per attached technical specifications, job procedures etc
complete and as directed by EIC.
BOTTOM TESTING. (Note: For items 48 & 49)

Testing of the welding joints of the tank bottom with vacuum box method up
to a vacuum of 5 psi (absolute). Rate to include arrangement of all equipment
like glass box, compressor rubber tubes, torch lights and mud packing
complete as per attached technical specifications, job procedures
Page 23 of 34
etccomplete and as directed by EIC.
48.0 30.0 M Dia x 10.0 M HtSelf-supporting Fixed cone roof Tank EACH 2
49.0 28.0 M Dia x 10.0 M Ht External Floating roof Tank EACH 2
SHELL TESTING (Note: For item nos50&51)

Hydrostatic testing of tank shell by filling water upto curb angle including
supply and filling water. Rate to include supply and filling of water up to max.
liquid level, observing for weld joint leaks or plate leaks if any, hammering
the joints as per the directions of Engineer-in-charge, decanting water after
successful completion of testing, cleaning the bottom, shell and roof and
drying it completely etc. as per attached technical specifications, job
procedures etc complete and as directed by EIC specifications including diesel
chalk test for the shell to bottom joint prior to hydrotest.
50.0 30.0 M Dia x 10.0 M Ht Self-supporting Fixed cone roof Tank EACH 2
NOTE: In case of any leaks observed during any of the above tests contractor
shall decant the water up to 300 mm below the leak, repair the leak and
again test the tank by filling the water to the satisfaction of the Engineer-in-
charge. Contractor shall repeat the process till all the leaks are rectified.
ROOF TESTING (Note: For items 52&53)

Testing of the welding joints of the long & short seam of cone roof and
pontoons of Floating roof & deck of IFR with pneumatic pressure method.
The rate to include arrangement of all the equipments, accessories etc and as
per technical specifications, job procedures etc complete and including
diesel chalk test/vacuum box test where ever necessary for pontoons and as
directed by EIC complete.
52.0 30.0 M Dia x 10.0 M HtSelf-supporting Fixed cone roof Tank 2

EACH
Page 24 of 34
TANK CALIBRATION
CALIBRATION OF TANK BOTTOM(Note: For Item Nos 54 & 55)
Physical calibration of the following dia tank bottom by calibrated flow meter
up to the datum plate. Rate to include arrangement of equipment necessary
pumping water, taking readings as per technical specifications, job
procedures etc complete and as directed by EICand presenting the same etc.
complete including certification by proper statutory authorities.
CALIBRATION OF TANK SHELL(Note: For item Nos 56 & 57)

Calibration of tank shell using strapping tape when the tank is full with water.
Rate to include supply and erection of necessary scaffolding, platforms,
taking readings at top, middle and bottom of each shell strake after applying
sufficient pull by spring balance and presenting results as per technical
specifications, job procedures etc complete and as directed by EIC including
certification by proper statutory authorities.
(Note: For item nos 54 to 57)

1) The calibrated strapping tape (100 Rmt) shall be supplied by Contractor.
2) Contractor shall carry out both bottoms by flow meter up to crown and
shell calibration in the presence of the representatives of W&M and HPCL.
The calibration charts shall be prepared by contractor and get the same
certified by W&M. The contractor shall make all necessary arrangements for
Page 25 of 34
the visit of representatives from W&M. All statutory fees and any other
expenses in this regard shall be borne by the contractor. Rate quoted in the
above 4 items shall include certification by W&M. Certificates to be handed
over to HPCL.
MISCELLANEOUS ITEMS (ITEM NOS 58 to 61)
58.0 PRESSURE RELIEF LINE Meters 250
Supply, fabrication and fixing of 25 mm dia MS heavy duty Sch 80 thickness

seamless pipeline from receipt/delivery line up to the top most
shell/roof/nozzle of the fixed roof tank and shell manhole/Nozzle/free drop
pipe at top in the floating roof tank. Rate to include supply and fixing of
necessary MS forged slip on flanges, tees, elbows, U clamps and supply and
fixing of ISA 50 x 50 x 6 angles for supports (of required nos) per tank to the
shell. Job to be executed as per technical specifications, drawings, job
procedures etc complete and as directed by EIC (MS angles will be paid
separately in the structural steel item )
59.0 GATE VALVE 25MM DIA Each 40

Supply and fixing of 25 mm dia forged steel gate valves class 1500 with
flanged ends of approved make. Job to be executed as per technical
specifications, drawings, job procedures etc complete and as directed by EIC.
60.0 NON RETURN VALVE 25 MM DIA Each 18

Supply and fixing of 25 mm dia forged steel horizontal non-return valve class
1500 with flanged ends of approved make. Job to be executed as per
technical specifications, drawings, job procedures etc complete and as
directed by EIC.
61.0 THERMAL SAFETY VALVE Each 18
Supply ,fixing of thermal safety valve for a differential pressure of range 6.5-
7.5 kg/cm2 as per attached technical specifications, drawings and as directed
by EIC complete. The TSV shall be designed for back pressure of max 1.5
2
kg/cm . The Make of the TSV shall be “Tyco” or equivalent as approved by
HPCL. The design calculations for selection for a particular tanks regarding set
pressure shall be submitted by the vendor and the same shall be approved by
HPCL before procurement.
Page 26 of 34
TANK EARTHING
EARTHING PITS
Providing and constructing plate electrode type earthing pits conforming to

IS- 3043 latest edition as per drawing enclosed, with all GI parts. Rate to
include supply of all material necessary for earthing pit, supply and welding
MS earthing boss to the tank shell at 500 mm above the bottom plate and
connecting the boss with pit and pipe electrode by 50 x 6 mm thk MS
galvanised strip. Rate also to include carrying out megger testing of pits and
issuing test certificate from licensed electrical contractor. Job to be executed
as per technical specifications, drawings, job procedures etc complete and as
directed by EIC. The size of manhole cover for earthing pits with GI plate
shall be 600 x 600 mm & minimum weight of cover with frame shall be 42 kg.
62.0 Earth Pits with GI Plates using 600 x 600 x 6.3mm GI plates Each 20
63.0 50x6mm GI FLAT Running 1000

Meter
Supply and fabrication of 50 x 6mm GI flats strips required for earthing. The
strips shall be bolted with brass nuts on one side of equipment and other
with the electrode. The pieces of flat in between the ends shall be welded
and coated with one coat of bitumen.
64.0 COPPER CABLE Meters 40
Supply and fixing of 25 sq. mm braided copper cables between rolling ladder
and track & rolling ladder and platform at the top. Rate to include supply and
fixing of Copper lugs, bolts etc. complete. Job to be executed as per technical
specifications, drawings, job procedures etc complete and as directed by EIC
65.0 CHAIN BARRIER Each 10
Supply fabrication and fixing of 12 mm dia 750 mm long barriers at a height

of 1.0 M and 0.5 M each at the entrance of staircase platforms of tanks along
with 6 mm dia MS hooks openable type as detailed in the drawing.Job to be
executed as per technical specifications, drawings, job procedures etc
complete and as directed by EIC.
SPRINKLER /FOAM SYSTEM(Note: For items 66 to 70)
Page 27 of 34
Design, supply, fabrication, erection and testing of following size pipes for
sprinkler system conforming to IS 1239/3589 as per attached specs in the
specified curvature and installing with necessary GI ‘U’ clamps supplied by
the party on the periphery of floating roof tanks on angle support welded on
the shell of the tanks. Job includes supply, fabrication, welding of necessary
half couplings to MS pipe for fixing m sprinkler nozzles, fabrication and
welding of angle supports (shall be paid separately under the item no. 20).
The curved pipe to have flange joints every 6 m for ease of removal and
replacement at a later date. Supplying and fixing necessary flanges, gaskets,
stud bolts as per HPCL specs attached to this tender are in the scope of the
vendor. Rate to include all the Testing/Design/Third party
inspection/vetting requirements as per attached technical
specifications/job procedures shall be included in the quoted rate. No
separate payment will be made for the same.Job to be executed as per
technical specifications, drawings, job procedures etc complete and as
directed by EIC.
66.0 75 mm dia Meters 400
Design, supply, fabrication, erection and testing of following size pipes for
sprinkler/foam system conforming to IS 1239/3589 as per attached specs for
the vertical tap-off / connection for sprinkler lines / foam makers including
installing necessary ‘U’ clamps/ stopper rods on the periphery of floating roof
tanks and on support angles (shall be paid separately under the item no. 55)
welded on the shell of the tanks. Battery limit flange also to be supplied and
welded by the party. (Note: For items 68 & 69)
70.0 SPRINKLER NOZZLES EACH 500
Design, supply and installation of water sprinkler nozzles as per attached

specs on the above installed water sprinkler line.
Note:- For the items 66 to 70, party to submit the design from a reputed fire
fighting equipment manufacturer/ consultant for sprinkler / foam line
sizing and selection of numbers & K value of the sprinkler nozzles provided
Page 28 of 34
at each level, based on tender specs ,TPI vetted, for HPCL approval before
proceeding with the procurement activities.
EXTERNAL PAINTING OF TANKS
71.0 COPPER SLAG BLASTING : Square 14000

Preparation of surfaces of tank shell, roof / deck and roof top railings, Meters
staircases, landing platforms, shell, roof/deck appurtenances, nozzles, tank
body valves, walkway cum wind girder & its railing, stiffener rings/sprinkler/
foam lines, roof top railings, staircases, landing platforms, stiffener rings/
wind girders, wind girder cum walkway and its railings, Gauge Well & Foam
pourer platforms, structural supports/ brackets/ ribs, curb angles, bottom
plate projections, spiral staircases including steps from walkway to Guage
Well Pipes for Floating roof tanks, Rolling ladder including track for FR tanks,
expansion, sprinkler & foam pipelines etc of all the tanks on the tank etc. by
copper slag blasting with approved quality copper slag, thoroughly to S.A 2.5
of Swedish Ivonsk Standard SIS 055900- 1967 to bare metal to ensure
thorough cleaning of surfaces to receive paints as per specifications. Rate to
include for providing and fixing DOUBLE PIPE scaffolding with working
platforms, inspection ladders/steps/walkways etc in an approved/safe
manner and cleaning of Tank Farm area after shot blasting is completed. Job
to be executed as per technical specifications, drawings, job procedures etc
Note: Contractor to arrange and keep at site relevant Swedish photographic
standards, calibrated profile gauges, calibrated digital Elco meter for
inspection by HPCL Site In charge failing which permission to proceed with
the work will not be granted. Please refer the Special terms & Conditions of
the contract also.
72.0 PRIMING COAT-EXTERNAL Square 11000

Supply and application of one coat 65 micron DFT zinc anode 304 primer of Meters
Berger or approved equivalent by HPCL, to shell, roof, roof top railings,
staircase, landing platforms, all shell/roof /deck appurtenances, nozzles and
tank body valves, stiffener / wind girder, stiffener rings/ wind girders, wind
girder cum walkway and its railings, Gauge Well & Foam Pourer platforms,
structural supports/ brackets/ ribs, curb angles, bottom plate projections,
spiral staircases including steps from walkway to Gauge Well Pipes for
Floating roof tanks, Rolling ladder including track for FR tanks, expansion,
sprinkler & foam pipelines etc of all the tanks. Rate to include wastages,
Page 29 of 34
mixing the paint properly as per manufacturer's specifications, applying with

air less spray gun till 65 micron DFT of paint thickness is obtained, testing for
thickness, providing pipe DOUBLE scaffolding etc. complete. Job to be
executed as per technical specifications, drawings, job procedures etc
73.0 INTERMEDIATE COAT Square 11000

Supply and painting One coat of 100 micron of Epilux 155 HB MIO of Berger Meters
or approved Make to shell and roof including all appurtenances, roof top
railings, staircase, landing platforms, all shell/roof /deck appurtenances,
nozzles and tank body valves, stiffener / wind girder cum walkway and its
railings, gauge well & Foam pourer platforms, structural supports/ brackets/
ribs, curb angles, bottom plate projections, spiral staircases including steps
from walkway to Guage Well Pipes for Floating roof tanks, rolling ladder
including tracks for FR tanks, expansion, sprinkler & foam pipelines etc. Rate
to include wastages, mixing as per manufacture's specifications, providing
necessary DOUBLE pipe scaffolding, testing for thickness etc complete and
applying with air less spray gun till 100 micron DFT of paint thickness is
obtained, testing for thickness , providing pipe scaffolding etc. complete.
Job to be executed as per technical specifications, drawings, job
procedures etc complete and as directed by EIC
Note: - Payment for item no 71 to 73 will be made on actual surface area of
tank shell and roof measured only once. No separate measurement will be
taken for nozzles, shell/deck/roof appurtenance, tank body valves, roof top
railings, staircases, landing platforms, stiffener rings/ wind girders, wind
girder cum walkway and its railings, gauge well & Foam pourer platforms,
structural supports/ brackets/ ribs, curb angles, bottom plate projections,
spiral staircases including steps from walkway to Gauge Well Pipes for
Floating roof tanks, Rolling ladder including track for FR tanks, expansion,
sprinkler & foam pipelines etc of all the tanks for payment purposes.
However, floor area of walkway cum wind girders / stiffener rings will be
measured for payment purpose and will be paid through this item only.
74.0 FINISH COAT -EXTERNAL Square 11000

Supply and painting with Bergerthane Enamel or approved equivalent as Meters
approved by HPCL, in not less than two coats to shell and roof of approved
shade including all appurtenances nozzles and tank body valves, Gauge well
& Foam pourer platforms, structural supports/ brackets/ ribs, curb angles,
Page 30 of 34
bottom plate projections, expansion, sprinkler & foam pipelines with

appropriate colour shade etc. Rate to include wastages, mixing as per
manufacturers specifications, providing necessary pipe scaffolding, applying
in two or more coats to achieve 80 micron DFT (40 micron in each coat) ,
using conventional spray/air less spray gun till the required DFT of paint
thickness is obtained, testing for thickness , providing pipe scaffolding etc.
complete.
Painting shall be applied to tank shell, roof, deck, shell and roof
appurtenances, nozzles and tank body valves etc.
Note: - Payment for this item will be made on actual surface area of tank
shell and roof measured only once. Also, floor area of walkway cum wind
girders catwalk will be measured for payment purpose and will be paid
through this item only. No separate measurement will be taken for nozzles,
shell/deck / roof appurtenance, tank body valves. Stiffener rings/ wind
girders, gauge well & Foam pourer platforms, structural supports/
brackets/ ribs, curb angles, bottom plate projections, expansion, sprinkler
& foam pipelines etc of all the tanks for payment purposes. However roof
top railings, walkway cum wind girder railing, staircases, landing platforms,
etc will be paid through separate items.
INTERNAL PAINTING
75.0 PRIMING COAT -INTERNAL Square 3500

Supply and application of one coat 65 micron DFT zinc anode 304 primer of Meters
Berger or approved equivalent make to total bottom, shell and under side of
the deck. Rate to include wastages, mixing the paint properly as per
manufacturer's specifications, applying with air less spray gun till 65 micron
DFT of paint thickness is obtained, testing for thickness , providing pipe
scaffolding etc. complete.
76.0 FINISH COAT-INTERNAL Square 3500

Supply and application of two coats 100 micron DFT each Epilux 78 HB TL of Meters
Berger or approved equivalent make to total bottom, shell and underside of
floating roof deck. Rate to include wastages, mixing the paint properly as per
manufacturer's specifications, applying with air less spray gun till 200 micron
DFT of paint thickness is obtained, testing for thickness , providing pipe
scaffolding etc. Complete.
Page 31 of 34
Note: - Payment for this item will be made on actual surface area of tank
shell and roof measured only once.
PU PAINTING OF WALK WAY CUM WIND GIRDER RAILING OF FLOATING

ROOF TANKS AND ROOF TOP RAILINGS OF FIXED CONE ROOF TANKS :
Supply and painting with Bergethane enamel or approved equivalent and

approved shade by HPCL, of approved shade, mixing as per manufacture's
specifications, providing necessary pipe scaffolding, applying in two or more
coats to achieve 60 micron DFT , testing for thickness etc complete. Painting
shall be applied to roof top railings , walk ways cum wind girders, including
vertical posts, mid and bottom flats, angle support etc. and other exposed
steel structure on the following above ground tanks.
EACH
77.0 30.0 M Dia x 10.0 M Ht Self-supporting Fixed cone roof Tank 2
78.0 28.0 M Dia x 10.0 M Ht External Floating/Open roof Tank EACH 2
PU PAINTING( STAIRWAY) :
Supply and painting with Bergerthane enamel or approved equivalent by

HPCL, of approved shade, mixing as per manufacture's specifications,
applying in two or more coats with conventional spray / air less spray gun to
achieve 60 micron DFT , testing for thickness etc complete. Painting shall be
applied to stairway including all landing platforms, roof top platforms, all
gratings, flats, square rods, vertical posts and other exposed steel structure
on the following above ground tanks including providing necessary pipe
scaffolding etc complete.
80.0 28.0 M Dia x 10.0 M Ht External Floating roof/open roof Tank EACH 2
PU PAINTING OF ROLLING LADDER
Page 32 of 34
Supply and painting with Bergerthane enamel or approved equivalent by

HPCL, mixing as per manufacture's specifications, applying in two or more
coats to achieve 60 micron DFT, testing for thickness etc complete. Painting
shall be applied to rolling ladder of MS tank including all gratings, flats,
square rods, vertical posts and other exposed steel structure on the following
above ground tanks including providing necessary pipe scaffolding etc
complete.
82.0 HEADINGS EACH 4

Supply and painting of Corporations name in HINDI / ENGLISH in 600 mm size
letters in the middle of the top shell of the tank as directed by EIC in Black
enamel paint.
83.0 LETTERING EACH 4

Supply and painting the following on the second shell of the tanks in black
enamel paint.
Tank number : 230 mm ht
Name of product : 150 mm ht
Tank capacity : 80 mm ht
Size of tank : 80 mm ht
Safe filling height : 80 mm ht
Date painted : 80 mm ht
Date Commissioned.: 80 mm ht
Date of Calibration : 80 mm ht
Date of Hydro testing : 80 mm ht
Due Date of Cleaning : 80 mm ht
If any additional details are required to be painted, the same shall be painted
at no extra cost.
84.0 LOGO EACH 4
Supply and painting the logo sign of the 2.4 M x 3.0 M size for the above
ground tanks on the top or penultimate shell or as directed by Engineer-In-
Charge. Rate to include for supply of required shade of enamel paints of
approved make, supply and erection of pipe scaffolding and painting the logo
Page 33 of 34
as per standard drawing complete. Logo should be painted as per required

colour code.
85.0 COPPER SLAG BLASTING AND PRIMER COAT INSIDE PONTOONS EACH 56
Preparation of internal surfaces of the floating roof pontoons by Cu slag

blasting (during fabrication itself) thoroughly to S.A 2.5 of Swedish Ivonsk
Standard SIS 055900-Latest edition to bare metal and applying with one coat
(DFT-60microns) of Zinc Anode 304 primer of Berger or approved equivalent
followed by 100 micron HBMIO as per attached technical specifications, job
procedures complete and as directed by EIC.
Page 34 of 34
UNPRICED BID
Page 1 of 5
SR.
DESCRIPTION UNIT QUANTITY
NO
Excavation up to 2.0 meter Cubic Meters 250
1
Murrum Filling Cubic Meters 2000
2
Rubble Soling Cubic meters 75
3
Plain Cement Concrete 1:2:4 Cubic Meters 50
4
RCC M 20 Tank Apron Cubic Meters 135
5
RCC M 20 Ring Beam Cubic Meters 75
6
REINFORCEMENT STEEL Metric ton 12.5
7
ANTI CORROSIVE LAYER Square meters 3000
8
F & L BOTTOM PLATES Underside painting
Metric Ton 310
9 incl.
F& L SHELL PLATES Metric Ton 400

10
F & L ROOF/DECK PLATE Metric ton 250
11
S & I ROOF STRUTURALS- FR Metric Ton 30
12
S & I ROOF STRUTURALS- CR-
Metric Ton 40
13 Blasting/painting incl.
S& I HAND RAILS- Structurals Metric Ton 6

14
S& I ROLLING LADDER Metric Ton 6
15
S& I HAND RAILS- Pipes Metric Ton 3
16
S & I MS SQUARE BAR Metric Ton 2
17
S&I MS GRATNG 800 x 250 MM Square meter 65
18
S& I MS GRATNG 800 x 1000 MM Square meter 55
19
S&I MS GRATING 800 X 200 MM Square meter 25
20
SHELL MANHOLES Each 8
21
SHELL NOZZLE 450mm Each 8
22
SHELL NOZZLE 250mm Each 4
23
Page 2 of 5
WATER DRAW OFF NOZZLE Each 16

24
S& I FOAM POURER/MAKER Each 16
25
PRESSURE TRANSMITTER NOZZLE Each 4
26
DECK THROUGH MANHOLES-600mm NB Each 2
27
DECK THROUGH MANHOLES- 750mm NB Each 2
28
GAUGEWELL SLEEVE EACH 4
29
PONTOON MANHOLES Each 56
30
AUTO BLEEDER VENT Each 4
31
RIM VENT Each 4
32
EMERGENCY DRAIN Each 2
33
CENTRAL ROOF DRAIN ASSEMBLY EACH 2

34
S&I 100 MM NB (SCH 40) SLEEVE Meters 100

35
S & I 80 MM NB(SCH 80) LEGS Meters 180

36
COMBINED STILL WELL PIPES 400 MM NB Meters 26

37
GUAGE WELL PIPES 300 MM NB Meters 26

38
GUAGE WELL PIPES 200 MM NB Meters 26

39
AVERAGE TEMP. SENSOR PIPE. Meters 26
40
SHUNT SPRINGS EACH 75
41
ROOF STOPPER EACH 10
42
MECH SEAL WITH SECONDARY SEAL-28 M
Each 2
43 DIA TANK
ROOF MANHOLE-CR Each 4

44
ROOF NOZZLE WITH PRV-CR Each 4
45
GAUGE WELL PIPES 200MM –CR Meters 52
46
TEMP. SENSOR PIPE- CR Meters 26
47
BOTTOM TESTING 30.0M Diax10.0M Ht Each 2

48
Page 3 of 5
CR TANK
BOTTOM TESTING 28.0MDiax10.0M Ht FR

Each 2
49 TANK
SHELL TESTING 30.0M Diax10.0M Ht CR

Each 2
50 TANK
SHELL TESTING 28.0MDiax10.0MHt FR

Each 2
51 TANK
ROOF TESTING 30.0M Diax10.0M Ht CR

Each 2
52 TANK
ROOF TESTING 28.0MDiax10.0M Ht FR

Each 2
53 TANK
BOTTOM CALIBRATION 30.0M Diax10.0M

Each 2
54 Ht CR TANK
BOTTOM CALIBRATION 28.0MDiax10.0M

Each 2
55 Ht FR TANK
SHELL CALIBRATION 30.0M Diax10.0M Ht

Each 2
56 CR TANK
SHELL CALIBRATION 28.0MDiax10.0M Ht

Each 2
57 FR TANK
PRESSURE RELIEF LINE Meters 250

58
25 MM DIA GATE VALVE Each 40
59
NON RETURN VALVE 25 MM DIA Each 18
60
THERMAL SAFETY VALVES Each 18
61
EARTHING PITS Each 20
62
50x6 mm GI Flat Each 1000
63
COPPER CABLE Meters 40
64
CHAIN BARRIER Each 10
65
S&L 75MM DIA CIRC SPRNKLR Meters 400
66
S&L 100 MM DIA CIRC SPRNKLR Meters 800
67
S& L 150 MM DIA VERT. HEADR Meters 120
68
Page 4 of 5
S& L 100 MM DIA VERT. HEADR Meters 200

69
S& F SPRINKLER NOZZLES EACH 500
70
COPPER SLAG BLASTING Square Meters 14000
71
PRIMING COAT-EXTERNAL Square Meters 11000
72
INTERMEDIATE COAT Square Meters 11000

73
FINISH COAT –EXTERNAL Square Meters 11000

74
PRIMING COAT -INTERNAL Square Meters 3500
75
FINISH COAT-INTERNAL Square Meters 3500
76
PU PAINT OF ROOF RAILING 30 M DIA Each 2

77
PU PAINT OF WG & RAILING 28 M DIA Each 2

78
PU PAINT-STR.WAY 30 M DIA CR TANK Each 2

79
PU PAINT-STR.WAY 28 M DIA FR TANK Each 2

80
PU PAINT OF ROLLING LADDER Each 2

81
HEADINGS Each 4
82
LETTERING Each 4
83
LOGO Each 4
84
PAINTING OF PONTOONS Each 56

85
Page 5 of 5
TIME SCHEDULE
Page 1 of 2
TIME SCHEDULE
DESCRIPTION OF WORK:
CONSTRUCTION OF PETROLEUM OIL STORAGE TANKS AT

PARADEEP POL TERMINAL, ORISSA
PART COMPLETION PERIOD
A CONSTRUCTION OF PRODUCT STORAGE TANKS 6 MONTHS
(FROM THE DATE OF HANDING OVER OF THE SITE)
LOCATION: PARADEEPPOL TERMINAL
PARADEEP
ORISSA
NOTE:
1) Time for completion shall be reckoned from the date of issue of Fax/ Letter of
Intent/Purchase Order by HPCL.
2) Time for completion shall include the time required for mobilization, design,
QAP, fabrication, erection, Testing, calibration, handing over, demobilization,
carrying out the works as per requirements of Contract Document and
instructions of HPCL Engineer-in-Charge.
Page 2 of 2
SPECIAL CONDITIONS
OF
CONTRACT
Page 1 of 24
1.0 GENERAL
1.1 Special Conditions of Contract (SCC) shall be read in conjunction with the
General Conditions of Contract (GCC) also referred to as General Terms &
Conditions of Works Contract, Schedule of Quantities, specifications of
work, drawings and any other document forming part of this Contract
wherever the context so requires.
1.2 Notwithstanding the sub-division of the document into these separate

sections and volumes, every part of each shall be deemed to be
supplementary of every other part and shall be read with and into the
Contract so far as it may be practicable to do so.
1.3 Where any portion of the GCC is repugnant to or at variance with any
provisions of the Special Conditions of Contract, then unless a different
intention appears, the provision(s) of the Special Conditions of Contract
shall be deemed to override the provision(s) of GCC only to the extent
that such repugnancy or variations in the Special Conditions of Contract
are not possible of being reconciled with the provisions of GCC.
1.4 Wherever it is stated in this Bidding Document that such and such a
supply is to be affected or such and such a work is to be carried out, it
shall be understood that the same shall be affected and /or carried out by
the Contractor at his own cost, unless a different intention is specifically
and expressly stated herein or otherwise explicit from the context.
Contract Price shall be deemed to have included such cost.
1.5 The materials, design & workmanship shall satisfy the applicable relevant
Indian Standards, the job specifications contained herein & codes referred
to. Where the job specifications stipulate requirements in addition to those
contained in the standard codes and specifications, these additional
requirements shall also be satisfied. In the absence of any Standard /
Specifications / Codes of practice for detailed specifications covering any
part of the work covered in this bidding document, the instructions /
directions of Engineer-in-Charge will be binding upon the Contractor.
Page 2 of 24
1.6 In case of contradiction between relevant Indian standards, GCC, Special

Conditions of Contract, Specifications, Drawings and Schedule of Rates, the
following shall prevail in order of precedence.
i) Detailed Purchase Order along with Statement of Agreed Variations, if any,

and its enclosures .
ii) Fax of Intent (FOI)/Letter of Intent(LOI)
iii) Schedule of Quantities AND Technical specifications
iv) Special Conditions of Contract
v) Drawings/data sheets/job procedures
vi) Instructions to Bidders
vii) General Conditions of Contract
viii) Relevant Indian Standards.
1.7 SAFETY, FIRE FIGHTING AND SPECIFIC REQUIREMENTS OF HPCL
1.7.1 Contractor shall provide adequate number of standard lengths of IS Stamped Fire
hoses, IS Stamped DCP Fire extinguishers, fire buckets with sand and nozzles.
These items can be taken back by the Contractor after completion of work. Sand
shall also be maintained dry by the Contractor with fresh supply, whenever
required. Work permit may not be issued by HPCL in the absence of above items.
1.7.2 Safety Helmets shall be provided to all the employees of Contractor including
that of his labour contractors.
1.7.3 Safety Belts and Harnesses shall be provided by the Contractor in adequate
number for the workers working at heights.
1.7.4 Proper earthing shall be provided for all equipments and generators.
2.0 THE WORK
2.1 Scope of Work & Scope of Supply
2.1.1 The scope of work and Scope of Supply covered in this Contract
will be as described in Scope of work provided in the Instructions
Page 3 of 24
to bidders, Schedule of Quantities, Technical Specifications,

Drawings, etc.
2.2 Time Schedule
The Completion period for Construction of Petroleum Oil storage tanks on existing
pile foundation shall be 6(SIX) Months from the date of handing over the site.
2.2.1 Time is the essence of this Contract. The period of completion given includes
the time required for mobilization as well as testing, rectifications, if any,
retesting, demobilization and completion in all respects to the satisfaction
of the Engineer-in-Charge.
2.2.2 A joint program of execution of work will be prepared by the Engineer-in-

Charge and Contractor. This program will take into account the time of
completion period of the Contract.
2.2.3 Monthly execution program will be drawn up by the Engineer-in-Charge

jointly with the Contractor based on availability of materials, work fronts
and the joint program of execution as referred to above. The Contractor
shall scrupulously adhere to the Targets / Program by deploying adequate
personnel, Construction Equipment, Tools and Tackles and also by Timely
Supply of required materials coming within his scope of supply as per
Contract. In all matters concerning the extent of target set out in the
monthly program and the degree of achievement, the decision of the
Engineer-in-Charge will be final and binding upon the Contractor.
2.2.4 Contractor shall give every day category-wise labour and equipment
deployment report along with the progress of work done on previous day
in the proforma prescribed by the Engineer-in-Charge.
2.3 Measurement of Works
2.3.1 Mode of measurement will be as specified in Specifications or SOR.
2.4 Payment Terms
2.4.1 Payment will be released within 15 days of submission of duly certified Running
Account Bills at Disbursement section at Mumbai after deduction of
Page 4 of 24
WCST(Works Contract Sales Tax) or VAT whichever is applicable, IT(Income Tax)

and any other statutory deduction as applicable from time to time, Any
MRR(Materials Received Report- An internal document forwarded by HPCL Site –
in-Charge/ Engineer to Disbursement Section along with Contractor’s Bill and
duly certified measurement sheets for release of payment) Deductions, LD, etc.
In case of Final Bill, Payment will be released within 45 days of submission of
duly certified Final Bill along with all requisite documents, drawings, etc.
Payment break up for various items covered in SOR/PRICED BID is as indicated as
Appendix 1 to SCC. No further alteration is permitted in approved payment
break up.
2.5 Temporary Works
2.5.1 All temporary works, enabling works, including dewatering of surface and
subsoil water, preparation and maintenance of temporary drains at the
work site, preparation and maintenance of approaches to working areas,
adequate lighting, wherever required, for execution of the work, shall be
the responsibility of the Contractor and all costs towards the same shall be
deemed to have been included in the quoted prices.
2.6 Quality Assurance
2.6.1 Detailed quality assurance programme to be followed for the execution of

Contract under various divisions of works will be mutually discussed and
agreed to.
2.6.2 The Contractor shall establish, document and maintain an effective

quality assurance system as outlined in the specifications and various codes
and standards.
2.6.4 The Owner/Consultant or their representative shall reserve the right to

inspect/witness, review any or all stages of work at shop/site as deemed
necessary for quality assurance and / or timely completion of the work.
2.6.5 In case Contractor fails to follow the instructions of Engineer-in-Charge
with respect to above clauses, next payment due to him shall not be
released unless and until he complies with the instructions to the full
satisfaction of Engineer-in-Charge
Page 5 of 24
2.7 Leads
2.7.1 For the various works, in case of contradiction, leads mentioned in the
Schedule of Quantities shall prevail over those indicated in the Technical
specifications.
3.0 ROYALTY, INCOME TAX, SERVICE TAX AND PRICES
3.1 Royalty
3.1.1 All royalties etc., as may be required for any Borrow Areas, including right
of way etc., to be arranged by Contractor shall be deemed to have been
included in the quoted prices.
3.1.2 Contractor’s quoted rates should include the royalty on different applicable
items as per the prevailing State Government rates. In case, Owner is able
to obtain the exemption of royalty from the State Government the
Contractor shall pass on the same to Owner for all the items involving
royalty. Any increase in prevailing rate of royalty shall be borne by the
Contractor at no extra cost to the Owner.
3.2 Income Tax
3.2.1 Income Tax at the prevailing rate as applicable from time to time shall be deducted
from Contractor’s Bills as per Income Tax Act and quoted rates shall be inclusive
of this. Owner will issue the TDS (Tax Deduction at Source) Certificate.
3.3 Firm Prices
3.3.1 The contract price shall remain firm and fixed till the completion of work in
all respects and no escalation in prices on any account shall be admissible
to the Contractor except for statutory variations as per General Terms and
Conditions (GTC).
Page 6 of 24
4 PROVIDENT FUND,LABOUR, LABOUR LAWS AND SITE REQUIREMENTS
4.1 Provident Fund
4.1.1 The Contractor shall strictly comply with the provisions of Employees
Provident Fund Act and register himself with Regional Provident Fund
Commissioner (RPFC) before commencing work. The Contractor shall deposit
Employees and Employers contributions to the RPFC every month. The
Contractor shall furnish along with each Running bill, the challan / receipt
for the payment made to the RPFC for the preceding month. The
Contractor shall furnish the code number allotted by the RPFC Authority to
the Engineer-in-Charge before commencing the work.
4.1.2 In case the RPFC challan / receipt, as above, is not furnished, Owner shall
deduct 16% (sixteen percent) of the payable amount from Contractor’s
running bill and retain the same as a deposit. Such retained amounts shall
be refunded to Contractor on production of RPFC Challan / receipt for the
period covered by the related running bill.
4.2 Labour License
4.2.1 Before starting of work, Contractor shall obtain a license from concerned
authorities under the Contract Labour (Abolition and Regulation) Act 1970,
and furnish copy of the same to Owner.
4.3 Labour Relations
4.3.1 In case of labour unrest/labour dispute arising out of non-implementation

of any law, the responsibility shall solely lie with the Contractor and they
shall remove/resolve the same satisfactorily at his cost and risk.
4.3.2 The Contractor shall at all times take all reasonable precautions to prevent
any unlawful, riotous or disorderly conduct by or amongst his staff and
labour and to preserve peace and protection of persons and property in
the neighbourhoods of the Works against such conduct.
Page 7 of 24
4.4 Employment of Local Labour
4.4.1 The Contractor shall ensure that local labour skilled and / or unskilled, to
the extent available shall be employed in this work. In case of non –
availability of suitable labour in any category out of the above persons,
labour from outside may be employed.
4.4.2 The Contractor shall not recruit personnel of any category from among
those who are already employed by other agencies working at site but
shall make maximum use of local labour available.
4.5 Site Cleaning
4.5.1 The Contractor shall clean and keep clean the work site from time to time
to the satisfaction of the Engineer-in-Charge for easy access to work site
and to ensure safe passage, movement and working.
4.5.2 The Contractor shall dispose off the unserviceable materials, debris etc., to
the earmarked area within the premises or any other location outside the
premises as decided by the Engineer-in-Charge. No extra payment shall be paid
on this account.
4.5.3 Review/Approval of Drawings, Design and other documents submitted by

Contractor
4.5.3.1 HPCL/consultant will normally require and utilize a maximum time frame of seven
(07) working days from the date of Receipt for Review/Approval of Drawings,
Design and other documents submitted by Contractor. Upon Review of the
submitted documents, HPCL may give their comments and ask for redesign/
resubmission after necessary rectifications/ modifications and the time frame of
7 working days will be applicable for same.
4.6 Protection of Existing Facilities
4.6.1 Contractor shall obtain all clearance (work permit) from the Owner, as may
be required from time to time, prior to start of work. Work without
permit shall not be carried out within the existing premises.
Page 8 of 24
4.6.2 Contractor shall obtain plans and full details of all existing and planned
facilities/services/utilities from the Owner and shall follow these plans
closely at all times during the performance of work. Contractor shall be
responsible for location and protection of all facilities/utilities and
structures at his own cost.
4.6.3 Despite all precautions, should any damage to any structure / utility etc. occur,
the Contractor shall contact the Owner / authority concerned and
Contractor shall forthwith carry out repair at his expenses under the
direction and to the satisfaction of Engineer-in-Charge and the
Owner/concerned authority.
4.6.4 Contractor shall take all precautions to ensure that no damage is caused
to the existing facilities etc., during construction. Existing
structures/facilities/utilities damaged / disturbed during construction shall be
repaired and restored to their original condition by Contractor after
completion of construction to the complete satisfaction of Owner.
4.7 Work Front
4.7.1 The work involved under this Contract may include such works as
have to be taken up and completed after other agencies have completed
their jobs. The Contractor will be required and bound to take up as and
when the fronts are available for the same and no claim of any sort
whatsoever shall be admissible to the Contractor on this account. Only
extension of time limit shall be admissible, if the availabilities of work
fronts to the Contractor are delayed due to any reason not attributable to
the Contractor and the same is clearly recorded.
4.8 Site Facilities
4.8.1 The Contractor shall arrange for the following facilities at site, for workmen
deployed/engaged by him / his sub-contractor, at his own cost:
i) Arrangement for First Aid.

ii) Arrangement for clean & potable drinking water.
iii) A crèche where 10 or more women workers are having children below
the age of 6 years.
iv) Any other facility/utility as may be required under the Contract as per the
existing legislation/regulations.
Page 9 of 24
4.9 Contractor’s Site Office and Stores
4.9.1 Owner shall provide land only for contractor’s site office and stores and
fabrication yard, if any at site. However, same shall be dismantled prior to
submission of Final Bill.
4.9.2 The Contractor shall remove all temporary buildings / facilities etc., before
leaving the site after completion of works in all respect.
4.10 Construction Power and Water

4.10.1 Owner shall not provide power and the Contractor shall be exclusively
responsible to make his own arrangements for supply of power, without
any extra cost to the Owner.
4.10.2 Water required for the works shall be arranged by the Contractor. The
contractor has to make all necessary arrangement for drawing water
including making temporary storage, pumping etc.
4.10.3 CEMENT:
Cement required for execution of the job under the entire scope of work (other
than for Ready Mix Concrete where the cement is from the RMC manufacturer
scope) contained in this tender shall be supplied at provided at site by the
contractor at his own cost. Contractor to include the cost of cement required
for execution of various items included in this tender in their quoted rates.
Cement shall be of 43 / 53 Grade OPC as specified in the technical specifications
of Ultra Tech Cement/ Gujarat Ambuja / ACC / Birla / Lafarge Makes only and
shall conform to IS relevent standards of latest edition. Contractor to produce
Invoice Copy of every batch of cement procured at site to EIC. However, HPCL’s
decision with regard to the specific brand of cement to be procured for the
execution of the work shall be final and binding on the contractor.
Cement shall be procured and brought to site atleast 15 days in advance.

Sample from every batch of cement brought to site shall be tested for standard
test as per the specification of relevant IS standards in approved Laboratory and
Test Certificate shall be submitted to EIC for verification. Only after obtaining
approval of EIC, cement shall be put into use. Manufacturer’s Batch Test
Certificates backed by Factory’s Invoice for the batch will also be acceptable for
approval of cement. Contractor shall bring cement well in advance before full
Page 10 of 24
consumption of previous lot. No claims for extension of completion period for

stoppage of work on account of non-availability of cement / delays is testing
procedures will be entertained/accepted by HPCL.
For all computation purposes, the theoretical cement consumption shall be

considered as per CPWD standards. Cement cost shall be recovered for under-
consumption at the penal rate of Rs.7000/- per MT. Empty cement bag shall be
the property of the contractor. Theoretical weight of cement in a bag will be
considered as 50 Kgs. Bags weighing upto 4% less shall be accepted by HPCL.
Any shortage in weight of any cement bag by more than 4% will be to
contractor’s account. Contractor shall maintain necessary weighing scale at site
for the purpose of random checking of the weight of cement bags by
representative of HPCL.
The contractor will be required to maintain a stock register for receipt, issuance
and daily consumption of cement at site. Cement shall be regulated on the basis
of 1st receipt to go as 1st issue. Cement not consumed within 3 months after
bringing to site shall not be used and shall be removed from site with prior
written permission of EIC.
All RA bills including the final bills will be accompanied by Cement Consumption
Statements giving the detailed working of cement used.
Contractor shall construct suitable temporary godown at site for storage of

cement under his lock and key. The contractor will be fully responsible for safe
custody of cement.
HPCL will not entertain any claims by the Contractor for theft, loss or damages to
cement. Contractor shall not remove from the site any cement bags at any time.
Permissible wastage shall be total 3% of the theoretical consumption. However,

these wastage shall be considered in excess of the theoretical quantity required
for the various items of work. No extra payment will be made towards this
wastage and the same will be in the contractor’s account. The contractor shall
be penalised for any under-consumption of cement at the rate of Rs7000/- per
MT.
4.10.4 STEEL:
Entire quantity of reinforcement / structural steel required for the project shall
be supplied and provided at site by the contractor at his own cost. Contractor
to include the cost of steel reinforcement / structural steel required to be used
against various items of this scope of work in their quoted rates. HPCL shall not
supply any reinforcement / structural steel. The contractor shall make necessary
Page 11 of 24
arrangement at his own cost for unloading, storage of steel in the open duly
fenced under locking arrangement. The reinforcement steel shall be procured
from Tata/SAIL/Vizag Steel/Jindal and will produce invoice for the same to EIC
for every batch of procurement alongwith Manufacturer’s Test Certificate.
In the case of steel reinforcement or structural steel the theoretical quantity of

steel shall be taken as the quantity required as per design or as authorised by
Architect/Consultant /HPCL’s Engineer including authorised lap lengths/chairs
etc. No further claim towards additional wastage due to lap length / full length
bars or other consideration including rolling margin will be entertained. No
payment will be made or measurement recorded for binding wires which shall
be of 18 SWG gauge and shall be provided by the contractor.
For the purpose of dealing and accounting, only linear measurements will be
taken and any difference in weight based on linear measurement and actual
weight shall be to contractor’s account. Quoted rate shall be deemed to include
the above and the wastage mentioned below. No claim whatsoever shall be
entertained on account of wastage and difference in weight as referred to
above.
All binding wires required for tying the reinforcement in position etc. will be
supplied by the contractor. Cost of this binding wire and labour will be included
in the item for binding and placing reinforcement in position.
It will be necessary that the contractor get the steel tested at his own cost at a
Govt. approved laboratory as per the testing schedule or as per the EIC’s advise,
for strength and other properties specified in IS – 1786 latest editioin before
using it in the work.
The contractor will be required to maintain a register for recording details of

steel receipt, steel utilised and balance at site.
Final bill will be accompanied by steel consumption statement.
In every case, it shall be the contractor’s responsibility to ensure the standard of

quality and the correctness of quantity of steel procured at site by him.
The permissible wastage (wastage defined as bars having less than 3 mt. Length)
shall be of 3% of theoretical consumption. Recovery for less consumption as per
theoretical consumption will be recovered at Rs.50,000/- per MT. All scrap
(scrap defined as pieces of steel bars measuring less than 3 mt. in length) shall be
Page 12 of 24
the property of the contractor. The wastage quantity shall not be considered to
be included within the theoretical quantity and no extra shall be payable on
account of wastage.
4.11 Construction
4.11.1 Rules and Regulations
4.11.2 Contractor shall observe in addition to Codes specified in respective

specification, all national and local laws, ordinances, rules and regulations
and requirements pertaining to the work and shall be responsible for extra
costs arising from violations of the same.
5.0 Procedures
5.1 Various procedures and method statements to be adopted by Contractor

during the construction as required as per the respective specifications
shall be submitted to Engineer-in-Charge in due time for approval.
5.2 Security
5.2.1 As the premises will be protected area, entry into the area shall be
restricted and may be governed by issue of photo gate passes. The
Contractor shall arrange to obtain through the Engineer-in-Charge, well in
advance, all necessary entry permits/gate passes for his staffs and labourers
and entry and exit of his men and materials shall be subject to vigorous
checking by the security staff. The Contractor shall not be eligible for any
claim or extension of time whatsoever on this account.
5.2.2 It shall be the responsibility of the contractor to safeguard all his

materials/owned from theft, damage etc. For this purpose the contractor shall
be allowed to keep his own security inside HPCL premises
5.3 Drawings and Documents
5.3.1 Drawings accompanying the Bidding Document are indicative of scope of

work and issued for bidding purpose only. Purpose of these drawings is to
Page 13 of 24
enable the bidder to make an offer in line with the requirements of the
owner.
5.3.2 The contractor as per ‘scope of work’ shall carry out preparation of detailed
and working drawings. Detailed construction layout drawings as needed
shall be prepared by contractor and got reviewed/approved by Engineer-in-
Charge/Architect before taking up the work.
5.4 Rounding off
5.4.1 All payments to and recoveries from the Contractor shall be rounded off to
the nearest rupee. Wherever the amount to be paid / recovered consists of
a fraction of a rupee (paise), the amount shall be rounded off to the next
higher rupee if the fraction consists of 50 (fifty) paise or more and if the
faction of a rupee is less than 50 (fifty) paise, the same shall be ignored.
5.5 Contractor’s Billing System
5.5.1 HPCL will provide an approved format for Measurement sheets, Bill Summary and
Bill Abstract. Contractor has to ensure that these data are updated for each
subsequent RA and Final Bill.
5.5.1 HPCL will utilize these data for processing and verification of the
Contractor’s bill.
5.6 Site Organization
5.6.1 The Contractor shall without prejudice to his overall responsibility to

execute and complete the works as per specifications and time schedule
progressively deploy adequate qualified and experienced personnel together
with skilled / unskilled manpower and augment the same as decided by
Engineer-in-Charge depending on the exigencies of work to suit the
construction schedule without any additional cost to Owner.
5.6.2 The Contractor shall provide all necessary superintendence during the
execution of the Works and as long thereafter as the Engineer-in-Charge
may consider necessary for the proper fulfilling of the Contractor’s
obligations under the Contract Such superintendence shall be given by
Page 14 of 24
sufficient persons having adequate knowledge of the operations to be

carried out (including the methods and techniques required, the hazards
likely to be encountered and methods of preventing accidents) for the
satisfactory and safe execution of the Work. The workmen deployed by
the Contractor should also possess the necessary license etc., if required
under the existing laws, rules and regulations.
5.7 Additional / Extra Works
Owner reserves the right to execute any additional works / extra works,
during the execution of work, either by themselves or by appointing any other
agency, even though such works are incidental to and necessary for the
completion of works awarded to the Contractor.
5.8 Responsibility of Contractor
5.8.1 It shall be the responsibility of the contractor to obtain the approval for
any revision and/or modifications decided by the contractor from the
Owner / Engineer-in-Charge before implementation. Also such revisions and /
or modifications if accepted / approved by the Owner / Engineer-in-Charge
shall be carried out at no extra cost to the owner. Any change required
during functional requirements or for efficient running of system, keeping
the basic parameters unchanged and which has not been indicated by the
contractor in the data / drawings furnished along with the offer shall be
carried out by the contractor at no extra cost to the owner.
5.8.2 All expenses towards mobilization at site and demobilization including

bringing in equipment, work force, materials, dismantling the equipment,
clearing the site etc. shall be deemed to be included in the prices quoted
and no separate payments on account of such expenses shall be
entertained.
5.8.3 It shall be entirely the contractor’s responsibility to provide, operate and

maintain all necessary construction equipment, steel scaffoldings and safety
gadgets, cranes and other lifting tackles, tools and appliances to perform
the work in a workman like and efficient manner and complete all the
jobs as per time schedule.
5.8.4 Preparing approaches and working area for the movement of his men and
machinery.
Page 15 of 24
5.8.5 The procurement and supply in sequences and at the appropriate time of
all materials, and consumables shall be entirely the contractor’s
responsibility and his rates for execution of work will be inclusive of
supply of all these items.
5.9 Coordination with other agencies
5.9.1 Contractor shall be responsible for proper coordination with other agencies
operating at the site of work so that work may be carried out
concurrently, without any hindrance to others. The Engineer – in – Charge
shall resolve disputes, if any, in this regard, and his decision shall be final
and binding on the Contractor.
5.10 Underground and overhead structures
5.10.1 The Contractor will familiarize himself with and obtain information and
details from the Owner in respect of all existing structures, and utilities
existing at the job site before commencing work. The Contractor shall
execute the work in such a manner that the said structures, utilities, etc.
are not disturbed or damaged, and shall indemnify and keep indemnified the
Owner from and against any destruction thereof or damages thereto.
5.11 Documents required with final bill
5.11.1 Statement of final bills – issue of No Claim/ No Due Certificate
5.11.2 The Contractor shall furnish a No-Claim/No-Due declaration indicating that there
are no balance dues to his sub-vendor/sub-contractors/labour contractors along
with the Final Bill.
5.12 Working hours
5.12.1 Depending upon the requirement, time schedule / drawing/ programme

and the target set to complete the job in time, the works may also have
to continue beyond normal working hours/night hours / holidays or during
such periods with out causing any inconvenience to the neighbours/others with
due permission from EIC, for which no extra claim shall be entertained.
Page 16 of 24
However for all such working contractor’s responsible representative shall be

available at site to receive the work permit to be issued by HPCL. With out
responsible representative of the contractor, no work shall be allowed inside the
premises.
6.0 TESTS, INSPECTION AND COMPLETION
6.1 Tests and Inspection
6.1.1 The Contractor shall carry out the various tests as enumerated in the
technical specifications of this Bidding Document and technical documents
that will be furnished to him during the performance of the work at no
extra cost to the Owner.
6.1.2 All the tests either on the field or at outside laboratories concerning the
execution of the work and supply of materials by the Contractor shall be
carried out by Contractor at his cost.
6.1.3 The work is subject to inspection at all times by the Engineer-in-Charge.

The Contractor shall carry out all instructions given during inspection and
shall ensure that the work is being carried out according to the technical
specifications of this bidding document, the technical documents that will
be furnished to him during performance of work and the relevant codes of
practice.
6.1.4 Compressed air for carrying out works ,if required shall be arranged by the
Contractor at his own cost.
6.1.5 For material supplied by Owner, Contractor shall carry out the tests, if
required by the Engineer-in-Charge, and the cost of such tests shall be
reimbursed by the Owner at actual to the Contractor on production of
documentary evidence.
6.1.6 All results of inspection and tests will be recorded in the inspection
reports, proforma of which will be approved by the Engineer-in-Charge.
These reports shall form part of the completion documents. Any work not
conforming to execution drawings, specifications or codes shall be rejected
and the Contractor shall carry out the rectifications at his own cost.
Page 17 of 24
6.2Final Inspection
After completion of all tests as per specification the whole work w ill be subject to a
final inspection to ensure that job has been completed as per requirement.
If any defect is noticed, the Contractor will be notified by the Engineer-in-
Charge and he shall make good the defects with utmost speed. If
however, the Contractor fails to attend to these defects within a
reasonable time (time period shall be fixed by the Engineer-in-Charge) then
Engineer-in-Charge may have defects rectified at Contractor’s cost.
6.3 Inspection of Supply Items
6.3.1 All inspection and tests on bought out items shall be made as required by
specifications forming part of this contract. Various stages of inspection
and testing shall be identified after receipt of Quality Assurance
Programme from the contractor / manufacturer.
6.3.2 Inspection calls shall be given for association of Owner , as per

mutually agreed programme in prescribed proforma , giving details of
equipment and attaching relevant test certificates and internal inspection
report of the contractor. All drawings, general arrangement and other
contract drawings, specifications, catalogues etc. pertaining to equipment
offered for inspection shall be got approved by Owner and copies shall be
made available to Owner before hand for undertaking inspection.
6.3.3 The contractor shall ensure full and free access to the inspection
engineer of Owner at the contractor’s or their sub-contractor’s premises at
any time during contract period to facilitate him to carry out inspection
and testing assignments.
6.3.4 The contractor / sub – contractor shall provide all instruments, tools,
necessary testing and other inspection facilities to inspection engineer of
Owner free of cost for carrying out inspection.
6.3.5 Where facilities for testing do not exist in the contractor’s / sub-
contractor’s laboratories, samples and test pieces shall be drawn by the
contractor / sub-contractor in presence of Inspection Engineer of Owner and
duly sealed by the later and sent for tests in Government approved test
Page 18 of 24
house or any other testing laboratories approved by the Inspection

Engineer at the contractor’s cost.
6.3.6 The contractor shall comply with the instructions of the Inspection
Engineer fully and with promptitude.
6.3.7 The contractor shall ensure that the equipment / assemblies /

component of the plant and equipment required to be inspected are not
assembled or dispatched before inspection.
6.3.8 The contractor shall not offer equipment for inspection in painted
conditions unless otherwise agreed in writing with the Owner .
6.3.9 The contractor shall ensure that the parts once rejected by the
inspection engineer are not used in the manufacture of the plant and
equipment. Where parts rejected by the inspection engineer have been
rectified or altered, such parts shall be segregated for separate inspection
and approval, before being used in the work.
6.3.10 On satisfactory completion of final inspection and testing, all accepted

part of the work and equipment shall be stamped suitably and inspection
certificate shall be stamped suitably and inspection certificate shall be
issued in requisite copies for all accepted items. For stage inspection and
for rejected items, only inspection memo shall be issued indicating therein
the details of observations and remarks.
6.3.11 All inspections and tests shall be made as required by the

specifications forming part of this contract. Contractor shall advise HPCL in
writing at least fifteen days in advance of the date of final inspection /
tests. Manufacturers inspection or testing certificate for equipment and
materials supplied may be considered for acceptance, at the discretion of
Engineer-in-Charge. All costs towards testing etc. shall be borne by the
contractor within their quoted rates.
6.4 Documentation
6.4.1 Completion Documents
The following documents shall also be submitted by the Contractor in

triplicate as part of completion documents :
Page 19 of 24
a) Test certificate for materials supplied by the Contractor.

b) Certified records of field tests on materials / equipment, as applicable.
c) Material appropriation statement as required.
d) Six sets of drawings showing therein the as built conditions of the
work duly approved by the Engineer-in-Charge along with one set of
reproducible on polyester film (drawings prepared by Contractor)
along with soft form of the same.
e) Other documents as mentioned in Technical Specification.
6.4.2 “AS BUILT” Drawings
Upon completion of work, the Contractor shall complete all drawings to

“As built” status (including all vendor / Sub – vendor’s drawings for
bought out items) and provide the Owner, the following :
a. One complete set of all original tracings / reproducible along with the
soft form of the same.
b. Six complete sets of prints.
7.0 OTHERS
7.1 Dispute Settlement between Govt. Dept. / PSU & PSE
7.1.1 In the event of any disputes or differences between the Contractor and the
Owner, if the Contractor is a Government department, a Government
company or an undertaking in the public sector, then such disputes or
differences shall be resolved amicably by mutual consultation or through
the good offices or empowered agencies of the Government. If such
resolution is not possible, then the unresolved disputes or differences shall
be referred to arbitration of an arbitrator to be nominated by the
Secretary. Department of legal affairs (Law Secretary) in terms of the
Office Memorandum No. 55 / 1 / 75 – CF dated 19th December 1975 issued
by the Cabinet Secretariat (Dept. of Cabinet Affairs) as modified from time
to time. The Arbitration Conciliation Act 1996 shall not be applicable to
the arbitrator under this clause. The award of the arbitrator shall be
binding upon parties to the dispute, provided, however any party aggrieved
by such award may make a further reference for setting aside or revision
Page 20 of 24
of the award to Law Secretary whose decision shall bind the parties finally
and conclusively.
7.2 Project Scheduling and Monitoring
7.2.1 The following schedules / documents / reports shall be prepared and

submitted by the CONTRACTOR for review / approval at various stages of
the contract.
7.2.3 After placement of Purchase Order
Upon placement of Purchase Order, Contractor has to furnish a detailed bar

chart within 15 days of issue of FOI/LOI.
7.2.4 Project Review Meetings
7.2.4.1 The CONTRACTOR shall present the programme and status at various review
meetings as required.
Monthly Review Meeting
Level of Participation:Senior Officers of Owner & Contractor.
Agenda a)Progress Status/ statistics. .

b) Completion Outlook
c) Major hold ups / slippages.
d) Assistance required.
e) Critical issues.
f) Client query / approval.
Venue : Site
7.2.5 Progress Reports
I) Monthly Progress Report
Page 21 of 24
This report shall be submitted in three copies on a monthly basis

within Ten calendar days from cut-off date as agreed upon, covering
overall scenario of the work. The report shall include but not be
limited to the following :
a) Brief introduction of the work.
b) Activities executed / achievements during the month.
c) Scheduled vs actual percentage progress and progress curves for
sub-ordering, manufacturing / delivery, sub-contracting, construction
activities and overall quantum wise status of purchase orders against
scheduled.
d) Areas of concern / problems / hold ups, impact and action plans.
e) Resource deployment status.
f) Annexure giving status summary for Material Requisitions and
deliveries, sub-contracting and construction
Distribution: OWNER Two copies & One at Site.
II) Daily Report:
Daily report in duplicate as out lined in 2.2.4 of SCC and any other additional
information/data/guideline/job procedure sought by Engineer-in-Charge shall be
submitted without fail to HPCL at site by contractor.
7.3 General Environment Requirement
The contractor has to ensure efficient use of natural resources like water,
fuel oil and lubricants. The contractor should ensure proper awareness to
workers to maintain a green and clean environment inside / outside the
building premises. The contractor must collect and dispose of all the waste
and scrap materials at the designated place only as directed by Engineer – in
– Charge.
7.4 DEFECT LIABILITY PERIOD/Warranty Period
As per clause No. 5n of GTC.
7.5 Form C/D etc will not be issued by M/s HPCL
Page 22 of 24
APPENDIX -1 TO SCC
TERMS OF PAYMENTS
1.1 The basis and terms of payment without prejudice to any other mode of
recovery available to Owner, shall be as given below :
1.2 The Contractor shall be paid monthly running account bills at stages of
completion of individual item / work, based on the joint measurement, in
the following manner after deductions of necessary dues payable by
Contractor to the Owner such as Retention money, Taxes, Duties etc. in
accordance with various provisions made elsewhere in this document.
1.3 SPECIAL PAYMENT TERMS
Following payment shall be made to the contractor against the running bills
subject to the rate awarded to him and the clause regarding retention money as
per general terms and conditions.
1. Plate Work :(Item nos9 to 11)
30 % after Fabrication
25 % after erection & welding,
10% after radiography
30 % after hydro-testing
5% after Completion and acceptance by HPCL as pr SOR
2. Structural Steel Works/Grating: (Item Nos 12 to20)
50 % after supply of material at site

15 % after fabrication
20 % after erection/welding/bolting
10% after painting
5% after Completion and acceptance by HPCL as per SOR
3. Mechanical Shoe Seal (Primary) & Secondary Seal ( item no43)

25 % after installation.
5 % aftercompletion and acceptance by HPCL as per SOR
Page 23 of 24
4. Central Roof Drain – Unbonded flexible pipe( item No:34)

25 % after installation.
5 % after Completionand acceptance by HPCL as per SOR
5. For all the remaining items
95% after completion of the job

5% after completion and acceptance by HPCL as per SOR
NOTES :
1.For Each stage, necessary testing shall be completed prior to claiming the
percentage break-up as given above
2. Partial bill will be processed only after submission of duly certified copy of
proof of payment towards royalty.
3. Final bill will be processed only after submission of “No objection certificate”
from relevant statutory authorities towards payment of royalty.
Page 24 of 24
GENERAL
SCOPE OF WORK
FOR
TANKS
Page 1 of 27
1.0 SCOPE OF WORK
1.1. Contractor’s Scope of Work :
The scope of work for Contractor shall include the following but not limited to the
same. The scope of work shall also include other items / works required to
complete the work in all respects as per specifications, standards, drawings, IS
codes/API Standards & instructions of HPCL whether specifically mentioned or
not in the tender document :
i) Design, Fabrication, Erection, Welding including welding Procedure & welder

qualifications and welding all the joints in accordance to respective WPS,
marking etc as per API 650 for the tanks as given in Annexure1 is
completely in the Contractor’s Scope of Work.
ii) Preparation of all detailed and working drawings including plate cutting
diagrams for various components of storage tanks & getting the same
reviewed and approved by HPCL prior to commencement of work. No work
will commence without HPCL’s approval on drawing by Engineer in Charge.
iii) Preparation, Submission for Review and obtaining approval from HPCL for
Detailed Quality Assurance System plans/ procedures developed by
contractor basis Std. Inspection & Test Plan furnished in this tender/ Scope
of work/SOR/GTCC/SCC & other relevant codes. The same shall be
reviewed / approved by HPCL prior to commencement of work. The required
competent man power, machinery, tools, tackles, equipments, etc required
to execute the work as per the Approved Quality assurance plan (QAP) shall
be the responsibility of contractor. Due records will be maintained by
contractor through out the work period as per instructions of Engineer-in-
Charge.
Vii) Time is the essence of this contract. Monthly/weekly Execution Plans will be
developed by Contractor in consultation with Engineer- in- Charge &
execution of work as per these plans will be the sole responsibility of
contractor. Scheduling & Monitoring of awarded work is the SOLE
RESPONSIBILITY of contractor, in this regards rates quoted shall include
following:
1. Kick off Meeting shall be planned by contractor within SEVEN DAYS
from date of LOI.
2. Contractor shall submit DETAILED BAR CHART/RESOUCE
PLAN/MICRO SCHEDULING ACTIVITY WISE giving earliest & latest
date with back up calculation of Man –Power, Machinery,
Consumables,, etc for HPCL’s approval for Tankage Work All the
queries on matter suggested by HPCL will be complied on mutual
discussion basis & Final Detailed Bar Chart will be made implemented
within Fifteen days from date of LOI.
Page 2 of 27
3. Contractor will provide his authorized nominee at site to take
participation in weekly meeting & to sign the Records of Meeting.
4. Contractor will submit on daily basis Progress Report to be generated
at site in E Form through E- Mail @ the address provided by HPCL
giving all the details including valid reasons for delay if any vis-à-vis to
commitment i.e. weekly plan /monthly plan /approved bar chart in
prescribed format approved by HPCL.
5. Contractor to submit procurement plans for various item falling under
their scope to supply under this tender along with Bar Chart vide point
Vii 2.
iv) (A) Submission of Design calculations of TANK AS PER RESPECTIVE
standards in detail for review by EIL or IIT, Kharagpur or equivalent as
approved by HPCL and thereafter, approval by HPCL. The document shall
be first submitted to HPCL and same shall be forwarded by HPCL to EIL or
IIT or any other approved institution by HPCL. The charges for vetting of
design by EIL or IIT, Kharagpur shall be borne by the Contractor. It shall be
the sole responsibility of the Contractor to prove these design calculations
details while conducting the Test to HPCL Engineer in toto. Contractor shall
also carry out design calculations as per API 650 & other relevant codes for
Shell, Bottom plates incl. annular sketch plate, wind girder, stability against
wind & seismic movement, Brackets for Top Wind Girder /Plate form,
Brackets for Sprinkler & Foam Pipe etc
v) Procurement & Supply of materials & consumables as indicated in

contractor’s scope of supply.
vi) Loading, transportation and handling of all free issue materials from Owner’s
stores to work site/ Contractor’s store and fabrication yard as applicable
including supply of all necessary tools, tackles, transportation and handling
equipments, etc.
vii) Stripping/Removal of vegetation for fabrication yard at Site.
viii) Welding procedure & Welder qualification :
1. Welding Procedure Specifications for all the Weld Joints to be made in field for
Bottom, Shell & Roof along with all other type of joints shall be prepared by
contractor as per QW-482 Suggested Format for WPS in ASME Sect.IX.
(Sample Joint design QW 402 for various joint is attached in Tender Document).
The same will be vetted/certified by HPCL approved Third Party like IRS, BV,
TUV etc. The weld joints will be made in accordance to respective approved
WPS only.
2. QW-483 i.e. Procedure Qualification records (PQR) as per ASME Sect IX to be

performed in accordance to API 650 with required lab test on test piece in
supervision of HPCL Engineer & approved Third Party like IRS,BV,TUV etc.
PQR document duly vetted / certified by Third Party shall be submitted to HPCL.
Page 3 of 27
3. QW 484 ASME Sect.IX Welding Operator Performance Qualification will be
conducted in presence of HPCL Engineer and HPCL approved Third Party like
IRS, BV, TUV etc.. at site. After due testing of Test Piece like radiography etc
WOPQ duly certified by Third party will be submitted to HPCL for all proposed
deployed welding operators.
4. Contractor shall submit proposed number of radiographs shots as per API 650
along with procedures for undertaking shots on the drawing i.e. operating with
required due safety /Health/Environment precautions and Film review norms in
accordance to API 650, ASME IX & respective other standards duly vetted by
HPCL approved Third Party to enable HPCL to direct for Shots.
5. FILMS will be reviewed & vetted by HPCL approved Third Party. HPCL will
witness the process randomly.
6. All the third party charges shall be borne by the contractor. No separate
payment will be made on this account.
ix) Supply, Fabrication and erection of various shell appurtenances and

nozzles.
x) SHELL ERECTION & DISMANTLING SHALL BE STRICTLY BY JACKING

UP METHOD. Required Load Calculation shall be submitted & prior HPCL’s
approval shall be taken. For safety reasons test certificate for fitness of
equipments & accessories shall be submitted. Min. one Jack per Three
Metre circumferentially shall be provided. Plates shall be made after
removal of Jacks to it’s original thickness to the best satisfaction of
HPCL.The Load calculations and Test certificate for fitness of the
equipments shall be vetted by approved third party agency and the charges
towards the same shall be borne by the contractor.
xi) Supply, Fabrication and erection of Inlet and outlet troughs for Inlet and
Outlet nozzles.
xii) Design, Fabrication, Erection and testing of External single deck floating roof
(EFR)and its components with foam dam and its accessories including pipe
supports & appurtenances including welding on underside.
xiii) Design, Fabrication, Erection and testing of Fixed Cone roof tanks with self
supporting(FR) truss and its components with necessary sprinkler/foam
appurtenances etc and its accessories.
xiv) Design, Fabrication, Erection and testing of Open roof tanks appurtenances
etc and its accessories.
xv) Supply, Fabrication and erection of various Roof appurtenances and

nozzles.
Page 4 of 27
xvi) Conducting Floatation test for the roof (EFR & IFR)
xvii) Procurement, Third party Inspection, supply, installation and testing of

primary roof drains of Flexible Hose Pipe type with associated rigid piping
sections, if any and brass non return valve including shell nozzles for roof
drain extension piping (from gate valve to storm water drain) along with gate
valve, support& foundation of roof drain etc including supply of all materials.
The Flexible roof drain shall be manufactured by( A) Coflexip (Flexi France)
/ ( B) Well stream Holding Plc U.K / (C) NKT Flexible Denmark.(D) Pivot
master (E) MESA
xviii) Design and its vetting/ Review and approval by HPCL, procurement, supply,
fabrication, erection, testing, & commissioning of Sprinkler/Foam system
complete in all respects, structural supports for Foam cooling system risers,
etc.
xix) Design and its vetting/ review and Approval, procurement, Third party
Inspection, supply & installation of Primary shoe seal and Secondary seals
floating roof tanks s with all components and accessories etc as per
manufacturer’s instructions.
xx) Supply & fabrication of stairways, handrails, landing platforms, curb angle,
bracing for foam dam, structural supports for primary wind girders.
xxi) Supply, fabrication, installation and testing of various roof appurtenances for
Single and Double Deck Pontoon Type for both External and internal
floating roof & Fixed Cone Roof Self supported.
xxii) Supply, fabrication & erection of Gauge hatch with still well, still wells for
level transmitters, level switch & temperature instruments etc and Gauge
socks.
xxiii) Supply, fabrication & erection of earth connection as per respective IS code.
Xxvi) Radiography / DP / Diesel chalk/ Vacuum box test/ any other test on various
components of tanks as per Specifications of this Tender document,
requirements of API standard & instructions from Engineer-in-Charge.
Additionally, all Horizontal and vertical Shell joints including extensions
above the Maximum Design Liquid Level shall be Dye Penetrant Tested after
Root Run and necessary repairs carried out as per HPCL’s instructions. All
radiography Films shall be reviewed by a HPCL approved Third Party
Inspection Agency.
xxvii) Calibration of tanks and getting approval from Weights & Measure
department using contractor’s own tape,tools ,tackles etc.
Page 5 of 27
xxviii) Carrying out hydrostatic / water fill up test in accordance to OISD 129/
Standard Specifications of this Tender & keeping the records for same,
pneumatic , vacuum & other test as specified in code/ specifications & as per
requirements of Engineer-in-Charge using contractor’s own equipment.
Fixed cone Roof leak proof test as per code/specifications.
xxix) Pontoon Leak proof test by air @ 20mm water column as directed by HPCL
& deck weld joints with Vaccum Box Methods. Floating Roof Joints like
joining of Pantoon & deck which can not be tested by Vaccum Box Method
shall undergo DP test for Root Run . Puncture Test or Satisfying design
condition by filling the quantity of water on deck / & pantoon shall be carried
out successfully to establish the design.
xxx) Accomplishment of any other item of work required to make the storage
tanks ready for commissioning and as per instruction of Engineer-in- Charge.
xxxi) Assistance to HPCL for commissioning of the tanks including supply of

manpower, supervision, labour with all required tools and spares. This
commissioning assistance shall extend upto 24 hrs beyond completion of
first Pump-in of product in to the tanks.
xxxii) Supply of all equipment, machineries, tools, tackles etc, labour and
supervision of all works at site.
xxxiii) Clean-up job at site for all surplus material, debris, scrap, construction
equipment etc as per direction of Engineer-in – charge.
xxxiii) Reconciliation of free issue steel / material and returning excess plates, off
cuts and scrap as per direction of Engineer-in – charge.
xxxiv) Supply of Power required for the job shall be the responsibility of the
Contractor & will be in his scope. HPCL will not give any connection from
their existing electrical system.
xxxv) Complying & meeting all the safety rules & regulations as per standards &
instructions of Engineer- in – Charge will be the sole responsibility of
contractor.
xxxvi) Supply of all required materials, supplying and providing /Double scaffolding
wherever required, Carrying out Grit blasting and surface preparation, primer
and finish painting.
xxxvii) Quoted rates for work to include deployment of Qualified Quality Control
Engineer/Safety Engineers at site right from starting date whose
responsibility is to prepare all the Quality control/Safety records as sought in
PO, relevant to work, relevant codes, and other requirements to ensure full
Page 6 of 27
compliance on quality/Safety during execution as guided by HPCL. The
suggested formats for QC re cords for Civil Foundation & Tankage work
attached with this section i.e scope of work.
xxxviii) The work will be performed as outlined in Standard Inspection Test Plan for
Tank Fabrication(ITP) in the tender document/ developed by contractor basis
this Tender document duly approved by HPCL. This ITP can undergo
revision at the sole discretion of HPCL Engineer- in – Charge to meet the on-
going practical scenario at site while execution and to improve the quality of
work. Job Methodology will be prepared by contractor for items as sought by
HPCL for proper execution & quality of Work.
xxxix) Material handling arrangement i.e MS Plate, Sand, Sand asphalt mix
movement etc at site has to be properly & effectively designed by contractor .
The same shall be got approved from HPCL prior to work commencement.
The rates quoted shall be inclusive of this. HPCL will not allow to change/
amend/break any other existing facilities construced/under construction.
xl) Supply of Gauge Hatch & Leg Support Sacks, Liquid mounted Mech Shoe
Seal as per attach specifications.
xli) Contractor will have to make all necessary arrangement for water requirement
for the entire job. After Hydro test & First Test water shall be disposed off by
Contractor in an un-objectionable manner to HPCL , Statutory Authorities like
PCB etc & it’s neighbors in unobjectionable manner at his cost & efforts. The
tank shall be washed with sweet water by contractor at no extra cost to HPCL
before commissioning.
SCOPE OF SUPPLY
2.1 OWNER’S SCOPE OF SUPPLY
2.1.1 Subject to the provisions mentioned elsewhere in the tender document, HPCL
will issue the following materials free of charge from Stores at Site for the Steel
plates IS2062 of regular width & Length required only for the following
components of the tanks:
- Bottom: Annular Ring & Sketch plates
- Shell
- Shell extension for stairway and foam connection
- Roof Plates for Self supported Fixed Cone Roof.
- Internal and External Floating Roof: Pontoon Bottom & Top, Deck plates,
Outer & Inner Rim , Doubler plates, Bulk Head & foam dam and
Page 7 of 27
appurtenances.
- RF Pads & bearing plates for floating roof pipe support, pontoon manhole
neck & cover plate.
- Reinforcing pads for all shell openings and manholes.
-Top wind girder including extensions for stairways and plate stiffeners as
applicable.
-Secondary wind girder as per design requirements of the tank s including
plate gussets/ plate stiffeners.
-Tertiary wind girders as per design requirements of the tanks including plate
gussets/ plate stiffeners
2.1.3)SCRAP/ CUTTING ALLOWANCES FOR OWNER’S FREE ISSUE

MATERIALS
The plates will be issued by HPCL to the Contractor on Theoretical weight

basis. At the end of the work, Reconciliation shall be also done on theoretical
weight basis only.
A Tabulated statement showing the size wise plates issued and Total
consumption will be prepared as per HPCL instructions. Based on the Total
consumption in MT as a sum of individual sizewise consumption for a
particular site, generation of maximum 2.7% Returnable accountable scrap is
allowed. The Returnable Accountable scrap includes Offcuts and plates
smaller than 2400mm perimeter. Offcut plates shall be of minimum perimeter
2400 mm generated as per approved cutting Schedules. Plates smaller than
2400mm in perimeter are also classified under Returnable Accountable Scrap.
On an overall basis, the generation of accountable scrap shall be limited to
2.7% of total net consumption taken as a sum of net consumption for various
sizes. However, the Contractor shall make an all out effort at the time of
preparation of Drawings/ BOQ to limit the generation of Returnable
Accountable Scrap to a minimum preferably less than 2.7%.It will be the
responsibility of the Contractor to load, transport the accountable scrap, weigh
at weighbridge including payment of weighbridge charges, return to HPCL
Premises, Unloading and handing over to HPCL at their Storeyard/ scrap yard
as per instructions of HPCL Engineer-in-Charge. Apart from Accountable
Scrap, the Contractor shall be allowed a maximum of 0.30% of Burnout
Losses.
In case, the actual generation of Returnable Accountable scrap on overall

basis is higher than 2.7% or burnout losses being greater than 0.30% of
Overall consumption(Theoretical tonnage), then HPCL shall effect recovery @
Rs. 60,000/= per MT for excess scrap generation and/or burnout loss. It shall
be therefore the sole responsibility of the Contractor to plan the cutting
Page 8 of 27
schedule to control his scrap generation within above limits.
2.2 CONTRACTOR’S SCOPE OF SUPPLY

The procurement and supply in sequence and at the appropriate time of all
materials and consumables including structural steel (Plates & sections)
required for completion of works as per drawings, specifications and standards
except the materials specifically listed in Cl.no 2.1 above shall entirely be the
contractor’s responsibility. The items to be supplied by the contractor are in
general but not limited to following:
A) All steel plates required for the components other than those listed in
Cl.2.1.1.
B) All consumables such as electrodes, filler wires, acetylene, grease, oil,

gases, electricity etc.
C) All structural steel sections wherever required for curb angles, Top wind
girders Supports/stiffeners/ extensions for stairways, Top wind girder
bracings, Secondary wind girders, supports for Fire water Cooling Spray
Headers/ risers, supports for Foam system risers, spiral stairways, landings ,
platforms, handrails, bracing for foam dam, Inlet and Outlet Nozzle Troughs,
Gratings(which may be fabricated by the Contractor at a workshop/ factory
outside HPCL premises), stiffeners for Shell extension and supports for top
platform, trusses for Roof ,INSULATION STUBS & RING ANGLES ETC.
D) All pontoon stiffeners for floating roof.
E) Rolling Ladder, internal ladders, hand rail for stairways, ladders,

platforms, etc.
F) All seamless pipes for nozzle necks 200mm NB and below, internal pipes,
Nozzle necks for openings more than 200mm,Materials for Inlet/ Outlet
Nozzle troughs, floating roof supports, bleeder vents, emergency drain,
extension piping for roof drain, etc.
G) All pipe fittings, valves, flanges, matching flanges and blind covers
wherever specified for all nozzles, stainless steel wire mesh for emergency
drain, brass items and brazing for Auto bleeder vents/legs
H)Repeatable lay pattern Flexible Hose Pipe type primary roof drain after Third
Party Inspection with associated rigid piping sections, if any adequately
supported on Bottom/ from deck underside, necessary shoes/ guards, etc as per
Manufacturer’s instructions including brass non return valve, gate valve,
extension piping. The Flexible roof drain shall be manufactured by ( A) Coflexip
(Flexi France) / ( B) Well stream Holding Plc U.K / (C) NKT Flexible Denmark.
Page 9 of 27
I) Bolts, nuts and gaskets for roof & shell manholes, nozzles with blind cover/
matching flange, bolts & nuts for roof structure and other structural works.
J) Seals (Primary & Secondary) and weather protector, wherever applicable of
approved make, guide rollers, roof stoppers, earthing cable, shunts etc.
Seals shall be supplied after Third Party Inspection only.
L) Gauge Hatch with cover. Gauge Pipe/ Leg Support Sleeves.
M) Pipes, fittings, flanges and bolts and nuts and spray Nozzles and orifice
plates and structural supports for Piping for Fixed water Cooling spray
system.
N) Pipes, fittings, flanges, orifice plates, Foam makers/ Pourers and deflectors
on point of spray on shell and structural supports for Piping for Foam system
O) GI Deflector plates including supporting arrangement required for cooling

system.
P) Internal Bolts & Gaskets.
Q) Strapping tapes & accessories for calibration.
R) Radiographic Films & Consumables for NDT.
S) Earth connections, support cleats for pipes, structures & cables.
T) Any Blind flanges, valves, nipples, plugs, bolts, nuts, gaskets, etc required for
conducting hydrostatic testing and any other test required by HPCL.
U) All primer materials and painting materials, scaffolding, Ferrous Grit and
related equipment for Painting.
V) Aluminum/Brass plate for still well.
W) Water required for the entire job including hydrotest
Note:
While every effort has been made to list all the supply items, it
shall be the sole responsibility of the Contractor to review the list and
seek clarifications, if any at the time of Unpriced Bid itself. HPCL
undertakes to provide only Free Issue Steel plates for Fabrication and all
the other items shall be supplied by the Contractor only. No claims/
disputes by the Bidder/ Contractor shall be entertained by HPCL at a later
date.
3.0 DOCUMENTS / FABRICATION DRAWING DETAILS

The Contractor shall submit the detail fabrication drawings/ documents in the
Page 10 of 27
following sequence:
1. Drawing Index
2. General arrangement drawing of tank showing design data, basic

dimensions, thickness, nozzle & internal parts.
3. Bottom and annular ring layout.
4. Shell plate layout showing location of nozzles & their distances from weld
seams.
5. Nozzle orientation on shell.
6. Details of wind girders.
7. Spiral stairway, ladder and platform.
8. Plate layout of Pontoon top & Bottom, Roof Deck, inner &outer rim , bulk
heads for floating roof, floating roof support details, details of appurtenances
on floating roof , detail along with design calculation.
9. Any other design calculations as per contract.
10. Orientation and details of nozzles on tank roof.
11. Details of shell & roof nozzles.
12. Details of tank internals like still wells, roof stoppers etc.
13. Details of Foam & Cooling System along with supporting calculations.
13. Details of Rim Seals (Primary & Primary/Secondary)
14. Details of Roof Drains (Primary & Emergency) along with design
calculations.
15. Plate cutting diagram for Free Issue Plates along with indicating anticipated
the oritical scrap i.e. Burn oil losses & Accountable losses.
16. Material test certificate for items supplied by contractor.
17. Welding procedures & welders qualification reports
18. Radiography test reports.
Page 11 of 27
19. Final Inspection certificate and Hydrostatic test report.
20. Calibration Charts
21. Self Support Roof
22. As - Built drawing showing details as listed in Sr. No 1 to 15 & 21 above in

HARD/ SOFT COPIES including one set of tracing of all drawings
4.0 MANDATORY SPARES
OVER AND ABOVE THE QUANTITY CONSUMED IN TESTING AND /OR

INSTALLED AFTER TESTING, CONTRACTOR SHALL SUPPLY
FOLLOWING SPARES, WHICH SHALL BE HANDED OVER TO OWNER:
A. 10% FASTENERS WITH MINIMUM OF 2 NO.S.

B. 2 SETS OF GASKETS FOR EACH SHELL AND ROOF NOZZLE
REQUIRED FOR BLIND FLANGE/ COVER/ MATCHING FLANGE AND
FOR SHELL/ ROOF NOZZLE FLANGES INCLUDING MANHOLES.
Page 12 of 27
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Page 13 of 27
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Page 14 of 27
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Page 15 of 27
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Page 16 of 27
SPECIFICATIONS
FOR
MATERIALS
IN
CONTRACTOR’S SCOPE
OF
SUPPLY
Page 17 of 27
SPECIFICATIONS FOR MATERIALS IN CONTRACTOR’S SCOPE OF
SUPPLY
1.0 SCOPE:
This specification covers the material specification requirements for the

materials to be supplied by the Contractor. All the materials covered in this
specification shall be sourced from reputed manufacturers/ vendors with API
Monogram License / ISI Mark License.
2.0 VENDORS:
In cases where ISI / API/ASTM mark may not be available on the materials,
Contractor shall obtain HPCL approval for the subject vendor on a case-to-case
basis. For rolled structural sections, materials must be sourced from SAIL,
RINL, VIZAG Steel or TISCO. LSAW/ Seamless pipes must be sourced from
Surya Roshni, SAWPIPES, Welspun, Maharashtra Seamless, Jindal, SAIL,
Indian seamless or Man Industries or any other reputed foreign vendor
approved by HPCL.
3.0 TESTING:
Contractor has to provide Batchwise Manufacturer Test/Guarantee Certificates

and the Heat No.s or Batch No.s shall be clearly identified on the materials
along with ISI/API markings, as applicable. All the Manufacturer test Certificates
shall be as per relevant Codes/ standards. Any material rejected by HPCL shall
be forthwith removed from Site. Additionally, HPCL may also select samples of
materials in accordance with relevant codes/ standards for testing at HPCL
approved laboratory such as National Testing Laboratory or any other reputed
lab. Contractor shall arrange for testing the same at his own cost. The frequency
of such testing shall be as per relevant Codes/ standards.
Page 18 of 27
4.0 LIST OF ITEMS IN CONTRACTOR’S SCOPE OF SUPPLY WITH
SPECIFICATIONS:
SL.NO. ITEM DESCRIPTION MATERIAL SPECIFICATIONS
1 COMBINED Pipes
STILL WELL 406.4 MM/ 12.7 API 5L GR. A, B OR X 42
MM WT/123.3 (LSAW)
KG/M
for WITH ASTM A

GAUGE WELL 219.1MM/SCH.40 106GR.B(SEAMLESS)
&
TEMP. ELEMENT 88.9 MM/7.6 SEAMLESS ASTM A-106
MMWT/15.24 GR.B
KG/M
&
LEVEL 300 MM/SCH.40 SEAMLESS ASTM A 106
TRANSMITTER GR.B
2 PLATE PLATES IS: 2062 GR. A OR B
FABRICATION
3 STRUCTURALS SECTIONS IS: 2062 GR.A
incldg. GRATINGS
4 NOZZLE NECKS 300 NB AND SEAMLESS ASTM A-106
BELOW- GR.B
XS SCHEDULE
5 NOZZLE NECKS ABOVE 300MM IS: 2062 GR.A
NB 14MM THK
6 NOZZLE ASTM A 105 SORF 150#

FLANGES(EXCEPT
MANWAY)
7 MANWAY NECK IS: 2062 GR.A
AND FLANGES
8 BOLTING FOR IS: 1367 CL. 4.6/4.0
NOZZLES
9 BOLTING FOR IS: 1363
STRUCTURE
10 PIPE FITTINGS ASTM A 234 WPB
11 HANDRAILS PIPES IS: 1239 MEDIUM
Page 19 of 27
12 GASKETS(CAF) SHEET CHAMPION OIL & WATER
13 PONTOON & 80 NB S80/7.6TK ASTM A-53/ IS:1978

DECK PIPE 100 NB
SUPPORTS S 40/6 TK ASTM A-53/ IS:1978
32 NB S40/3.6TK
ASTM A-53/IS:1978
14 ROOF DRAIN PIPE ASTM A 53 GR.B SCH 40
EXTENSION/RIM
VENT VALVE GATE VALVE 150#(API 600,
RF, A 216 GR. WCB, 13%
CR.TRIM)
15 COOLING WATER 2 IN TO 6 IN IS: 1239 HVY BLACK

SYSTEM PIPING
8 IN TO 16 IN
IS:3589 GR.410
SORF, SWRF
AND BLRF
ASTM A 105
FITTINGS
SW:ASTM A 105
CAPS BW: ASTM A 234 GR. WPB
SPRAY NOZZLE ASTM A 105
CU. ALLOY GR. LTB-2,

CHROMIUM PLATED
16 FOAM SYSTEM SAME AS SAME AS COOLING SYSTEM
PIPING COOLING PIPING(SPRAY NOZZLES
SYSTEM PIPING NOT APPLICABLE)
4.0 For items not listed above such as bushes, split pins, neoprene bushes, etc, for
which Manufacturer Test certificates may not be available, HPCL may approve
for incorporation in works based on visual inspection.
5.0 Shoe seal /SS leg pins to be included
Page 20 of 27
ANNEXURES
Page 21 of 27
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Page 26 of 27
Page 27 of 27
TECHNICALSPECIFICATIONS
FOR
FLOATING ROOF TANK

(EXTERNAL & INTERNAL)
Page 1 of 32
CONTENTS
1.0 SCOPE
2.0 REFERENCE
3.0 SELECTION OF MATERIALS
4.0 DRAWINGS AND DOCUMENTS
5.0 FABRICATION AND ERECTION
6.0 APPURTENANCES
7.0 INSPECTION AND TESTING
8.0 CALIBRATION
9.0 PAINTING
10.0 TOLERANCES
11.0 IDENTIFICATION,PACKING & TRANSPORTATION
12.0 GUARANTEE
13.0 INTERNAL FLOATING ROOF
Page 2 of 32
STANDARD SPECIFICATIONS FOR FABRICATION,
ERECTION AND TESTING OF ABOVE GROUND STORAGE
FLOATING ROOF TANKS
1.0 SCOPE
1.1 This specification covers the minimum requirements for

design, selection of materials, fabrication, erection,
inspection, testing, fitting of other attachments and
appurtenances, cleaning, calibration and painting of A/G
FLOATING ROOF FOR PETROLEUM PRODUCTS
storage tanks and is intended to supplement the minimum
requirements of the applicable codes.
1.2 Engineering drawings shall take precedence over

specifications/standards.
1.3 The Review/ approval of design by HPCL shall not absolve

Contractor from the responsibility of successful performance
of Floating Roof(External/Internal). It shall be the sole
responsibility of the Contractor to ensure successful
performance of Floating Roof design.
2.0 REFERENCE
2.1 Design Codes
The following codes in their latest edition shall form the

basis for design, fabrication, inspection, testing and
acceptance of storage tanks :
API Standard 650 : Welded steel tanks for oil

(Latest edition) storage
Page 3 of 32
IS : 875 (Part 3) : Code of practice for design loads,
wind loads(other than earthquake)
For building and structures.
IS: 1893 : Criteria for earthquake resistant

design of Structures.
API : 2000 : Venting atmospheric and low

pressure storage tanks.
IS : 2007 : Method for calibration of Vertical

Oil Storage tanks.
IS : 2008 : Method for computation of

capacity tables for Vertical Oil
Storage tanks
API : RP 2003 : Protection against ignitions

arising out of static, lightning and
. stray currents
ASME Sect IX : Welding
OISD-129 : Inspection of storage tanks.
OISD-117 : Fire Protection facilities for

Petroleum depots and Terminals.
OISD-118 : Layouts for Oil & Gas installations.
OISD-105 : Work permit system.
Page 4 of 32
2.2 Materials Codes
Material to be used shall conform to:

Indian Standard Specifications or ASTM standards as
applicable.
2.3 Regulations
National laws and regulations together with local bye-laws

for the country or state wherever the tanks are to be erected
must be compiled with.
3.1 All materials shall be as per applicable Codes.
3.2 Manhole necks, nozzle necks 250 mm NB and above may

be fabricated from same plate material as used for shell.
3.3 Plate material used for ring flanges shall have a minimum
UTS of 4200 Kg./cm2 . For Flange thickness over 38 mm,
plate material shall be boiler quality, fine-grained, killed, and
normalised and impact tested as per the requirements of
API Standard 650.
3.4 All clips and attachments shall be fabricated from carbon

steel plates of weldable quality.
3.5 Gaskets for manholes fitted with blind flanges shall conform
to IS: 2712. 3.0 mm thickness. All the nozzles shall be fitted
with spiral wound gasket with CS outer ring & SS inner ring
(API 601) up to24” dia.
3.6 Bolts and nuts for all nozzles fitted with blind flanges shall
conform to IS: 1367, ASTM A-307 Gr. B, A-193 Gr. B-7, or
Page 5 of 32
A-194 Gr. 2H. Bolts and nuts for all structures shall conform
to IS: 1363.
3.7 Floating roof pipe supports and pipe sleeves shall be of

carbon steel conforming to ASTM A-53 /IS: 1978.
3.8 Following classifications of electrodes are recommended for

welding. However, minimum requirements of applicable
codes and appendices should be adhered to:
a] Low hydrogen electrodes namely, E-7018 shall

be used for all manual metal-arc welds of shall
courses having a thickness of 12mm or more and
for attachment of shell courses to bottom or
annular plates.E-7018 will be used for any weld
joint(butt/fillet) having one plate thickness
equivalent or more than 12mm
b] High cellulose/rutile type electrodes namely, E-

6013 as per the AWS classification SFA 5.1 is
acceptable for all other welding.
ESAB, ADVANI OERLIKON & D&H SECHERON make

electrodes will only be permitted to be used in the works.
Based on above, fabricator shall furnish samples of welding
electrodes to Engineer-in-Charge for approval.
4.1 All individual tank data sheets shall have

dimensional/design as well as material specification. Final
drawing with revisions, if any, shall be issued after award of
contract/purchase order.
4.2 Contractor shall prepare all design calculations in
Page 6 of 32
accordance to API 650 with product density 0.86 for shell,
Bottom & FR and fabrication drawings based on the
drawings/ written instructions issued on award of
contract/purchase order and shall include the following:
1. Drawing index and Schedule of Submission.
2. Design calculation for Bottom, Shell ands floating roof

for HPCL review.
3. GA drawing covering all details shown in HPCL data

sheets like list of appurtenances, lists of standards and
specifications, materials of construction, Tank design
data, General Notes including details of test to be
conducted on tank, specification and brand-name of
welding electrodes to be used etc.
4. Plate layout, details of welding as per approved WPS for

each weld joint and bill of material for bottom sketch and
annular plates.
5. Development details of welding as per approved WPS

for each weld joint and Bill of Materials for shell
including shell extensions showing location of nozzles
and stairway on developed shell.
6. Plate layout, details of welding as per approved WPS for

each weld joint and Bill of Material for Floating Roof.
8. Details of spiral stairway and extension stairway to still

well platform/ LT platform, landings and handrails with
bill of materials.
9. Details of wind girders with Bill of Material.
Page 7 of 32
10. Details of rolling ladder and track and Earthing
connections with Bill of Material for floating roof tanks.
11. Details of Roof Supporting Structure and Buoys with Bill

of Material for Floating roof tanks.
12. Details of shell nozzles and Inlet/ Outlet Troughs and

shell earthing cleats with Bill of Material.
13. Details of Primary Foam seal and Secondary Seal and

details of earthing shunts for F.R. Tanks.
14. Details of Floating Roof appurtenances, roof stopper

and leg supports for Floating Roof including Bill of
Materials for FR Tanks.
15. Orientation of floating roof appurtenances, leg supports,

plate joints, rolling ladder track etc. for FR Tanks.
16. Details of primary roof drain and Drain sump for F.R.
tanks including Bill of Material.
17. Details of still-wells, Gauge hatch and Bill of Material.
18. Details of mounting of Rim vents.
19. Details of Emergency Roof Drains.
20. Details of Foam Cooling System along with Foam

makers and orifice plates.
21. Details of Fixed water spray cooling System along with

deflector plates along with structural supports mounted
atop secondary and tertiary wind girders and spray
nozzles and orifice plates.
Page 8 of 32
22. Details of Roof opening for Automation level/
temperature gauge.
22. Plate cutting diagrams for all free issue material.
23. Plate reconciliation statement for free issue material.
In case the contractor intends to make some

modification for accommodating his fabrication facilities
or available materials, the same shall be submitted to
HPCL for approval with supplementary design
calculations. The approved modifications shall be
incorporated in fabrication drawing and submitted to
HPCL for approval.
4.4 Requisite number (as per the Time schedule of this

Work/Tender document) of prints of detailed fabrication
drawings prepared by contractor shall be sent to HPCL
for approval and one copy shall be returned to the
contractor after comments/approval. No fabrication /
erection shall be carried out without approved drawings.
5.1 Plates
a] Plates edges shall preferably be sheared or machine

cut as per code. All machined parts shall be suitably
protected before assembly.
b] Pug/Gas cut plates shall be grounded to the

satisfaction of the Engineer- in-Charge.
c] All formed plates shall be match marked with paint on
Page 9 of 32
the concave side with numbers as shown on erection
drawings.
5.2 Structural steel and Roof
a] Structural steel fabrication shall be carried out to the

required shapes for making the structure.
b] A pre-assembly of a sufficient part of roof structure may

be called for by the Engineer-in-Charge to assess the
correct workmanship.
5.3 Bottom
a) Prior to bottom plate laying, foundation (

Murrum/Sand pad) shall be checked for
unevenness/elevation difference which shall not be
more than +/-3mm in any 3 meter of circumference
and +/- 13mm in total circumference.
b) The clear extension of annular plate shall be 80mm
from the outer surface of the first shell.
c) The annular plate will be 10mm thick and the

bottom/sketch plate shall be 8 mm
d)Bottom slope shall be 1in 100 for Cone up or cone

down tanks or as shown in the respective tank
drawings.
e] Overlaps shall be properly cleaned with steel wire

brush before welding.
f] Single pass welds are not permitted.
g] Arrange the laps to shade the water towards the Bottom
Page 10 of 32
drain Nozzle/ shell.
h] Annular plates shall be assembled by butt welding with
backing strips and the sketch plates shall be lap welded
to the Annular plates.
i] Three plates lap joints shall be suitably joggled to a
length of 150 mm minimum to facilitate welding.
Joggling shall be to the satisfaction of Engineer-in-
Charge.
j] Contractor shall provide a Welding sequence which

shall be adopted so as to give minimum shrinkage and
distortion and it shall be indicated on fabrication
drawings. The contractor shall submit the methodology
which shall describe the welding sequence along with
stiffeners or any other special methodology to keep
distortion to minimum.This shall be approved by
Engineer-in-Charge.
k] Bearing plate under each leg support for floating roof

tanks shall be centered and welded to the bottom plate
by a continuous fillet weld of size equivalent to bottom
plate thickness. Plates shall be 600 mm round or square
and 10 mm thick (minimum).
l) The backing strip provided underneath of annular plate
shall be 10mm thick 150mm wide throughout the length
of the butt joint.
m) The annular butt joint will be subjected to 50%
Radiography as per API 650.
n) The bottom/sketch/annular plates shall be painted
underneath & top along with Copper slag blasting as per
the painting specification provided in the tender
document.
o) All the fillet/butt welds shall be performed by the approved
welder having approved WPQR only duly vetted by TPI
and EIC.
Page 11 of 32
5.4 Shell
a) Shell erection shall be carried out by Jack – up method

only. Calculations for deployment of number of jacks
and their placement/ location shall be submitted by the
Contractor for HPCL’s approval. The deployed jacks
along with accessories like hydraulic tubes, power pack,
end connections, traverse corrugations on the stem
shall have necessary certification /vetting by TPI for
safety reasons. The operating /maintenance procedure
for the jacks shall be submitted for HPCL for approval
along with TPI vetting. The proposed Lube oil usage
shall be strictly as per manufacturers recommendation
and the same shall be vetted by the TPI for no. of
changes, storing and usage etc.
b) All vertical and horizontal shell joints shall be full

penetration and full fusion welds using any one of the
edge preparations permitted by the Code API
650/ASME Section IX. Single side butt welds are not
permitted. The Single “V” edge preparation(60+/- 1
degree) shall be made for all the vertical butt welds of
shell plates thickness 8mm.The Double “V” edge
preparation (60 +/- 1 degree)shall be made for all the
vertical butt welds of shell plates thickness more than
10mm. the Horizontal welds up to 10mm thick shall
have single “v” edge preparation(45+/- 1 degree) and
Double “v” edge preparation(45+/- 1 degree) shall be
made for all the thickness of shell plates more than
12mm.
c] Top curb angle shall be lap or butt welded to the top

course with flange turned outside. Whenever Curb angle
is provided as a lap on the shell it shall a clear over
Page 12 of 32
hang of 25mm from the top of the shell. The thickness of
curb angle shall in no case shall be less than 8mm.
d) The height of any shell shall not be less than 1000mm

and it is to be ensured while jacking up that approved
drawing is followed in toto.
e) The height of Extension plate shall be at least 1000mm

and shall have a clear fillet weld on the Curb angle of
minimum size 8mm.
f) The stiffening ring provide as walkway shall not have a

clear width less than 710mm and shall be located
1100mm below the Curb angle.
g] Drain holes of 20 mm diameter suitably staggered shall

be provided on the horizontal plates of the stiffening ring
(wind girder).
h] Hand railing shall be provided all around when stiffening

ring is used as walkway for floating roof rank.
i] Curb angle and stiffening ring butt joints shall stagger by

300mm minimum with the vertical shell plate welds.
j] Vertical joints should preferably be offset by at least

1000mm.
k] First shell course plates shall be so arranged that the

vertical joints clear the annular ring welds or sketch
plates welds by at least 300 mm. Vertical joints of the
shell courses shall also clear the nozzle attachment
welds or reinforcement pad welds as per code and
applicable appendices.
Page 13 of 32
l) The shell to bottom joints are performed as fillet welds
for the annular plate thickness less than 12mm. The
bottom edge preparation for the first shell plate more than
12mm thick annular plate shall be a Double”V” as per
clause no: 5.1.5.7/fig: 5-3.c of API 650 11th edition
m] Holes shall not be made in shell plates for erection

purpose.
n] Shell plate alignment shall be within the limits specified

in code API 650.
HPCL has achieved the vertical alignment/plumb per 15
meter height in the range of 15mm, thus the expected
plumbness is in the range of 15mm+/- 20%
o] For floating roof tanks, internal diameter shall be

maintained in all shell courses.
p) The erection cleats for jacks or any other purpose shall

be removed properly and the same need to be refilled
with electrode of 7018 and grinded to make good the
surface irregularities’ to the satisfaction of EIC
p] After completion, the inside surface of floating roof tanks

walls shall be ground to remove any roughness liable to
impair the seal.
5.5 Floating Roof
5.5.1 Overview
a] Floating Roof of tanks less than or equal to 12Min dia

and more than 60M in dia shall be of double deck type
construction. Tanks having dia greater than 12M but
less than or equal to 60 shall be of Single deck annular
Page 14 of 32
pontoon type construction with or with out buoys.
b] When floating roof is in the highest position, tank shall

be capable of holding its design capacity.
c] Floating roof shall be designed by Contractor

considering design data given on each drawing / tender.
Roof shall be designed to eliminate the presence of any
air vapor mixture under the deck.
d] The floating roof shall be provided with at least one

manhole of 750 NB. This manhole shall be provided
with a ladder for stepping down to bottom when the roof
is in the lowest position. For tanks greater than 8 m dia.
Additional manhole of 600 NB shall be provided. These
manholes shall have suitable clearance from tanks
internals.
e] On the bottom side of deck, where flexure can be

anticipated adjacent to girders supports or other
relatively rigid members, full fillet welds not less than
150mm long on 250mm centers shall be used on any
plate laps that occur within 300 mm of any such
members. Additionally, the remaining lengths of all lap
seams shall be stitch welded for 50 mm lengths @
400mm c/c.
f] Contractor shall design the parameters of the floating

roof such that when floating in product (of specific
gravity 0.70) the maximum submergence shall be within
95% of the rim height under conditions as listed below:
(i) For single deck annular pontoon type external

floating roofs for the following conditions:
Page 15 of 32
- The submergence of outer rim when 254
mm rain water is accumulated on the roof with
primary Roof Drain inoperative.
- The submergence of inner and outer rim

near the punctured compartments when deck and
two adjacent pontoon compartments are
punctured.
(ii) For Double Deck Floating Roof Tanks
The submergence of outer rim near the punctured
compartments when any two adjacent
compartment are punctured.
g] Contractors shall carry out buoyancy (including

tilting) calculations for the floating roof for all the
conditions of (f) mentioned above, when it is floating on
test water, Calculated value shall be compared with
actual submergence measured during floatation test.
The provisions of Clause C.3.4.2 of API 650 shall also
be satisfied.
h) Top decks of double deck & of Pontoon section shall

have minimum slope of 1 in 64.
5.5.2 Contractor shall submit design calculations for external

floating roofs for sufficient buoyancy to keep the roof afloat
and with primary roof drains inoperative for the following
conditions
(a) For single deck annular pontoon type external

floating roofs considering
- The submergence of outer rim when 254
mm rain water is accumulated on the roof with
primary Roof Drains inoperative.
Page 16 of 32
- The submergence of inner and outer rim
near the punctured compartments when deck
and two adjacent pontoon compartments are
punctured with No water or live load.
b) Design of leg supports, bleeder vent, emergency

drain and primary drains.
b) Design of pontoons and Deflection of deck and

structural integrity of floating roof for annular pontoon
type floating roofs when centre deck is loaded by its
design rain water or when the centre deck and two
adjacent pontoons are punctured. The provisions of
Clause C.3.4.2 of API 650 shall also be satisfied.
5.5.3 a) Deck shall have level surface with permanent

slope towards the drain sump to avoid stagnation
of rain water.
b) Each compartment of the floating roof shall be

provided with a 500 NB manhole with cover.
c) Each buoy, if provided, shall have 150 NB

inspection opening with cover and bolting.
c) Central deck and pontoon shall be suitably stiffened,

if required, and calculation for the structural integrity
of the floating roof shall be submitted to HPCL for
approval.
5.5.4 Seal
Details of Liquid Mounted Mechanical Shoe seal and

Secondary seal in G.I construction shall be as per the
specification annexure attached in this tender.
Page 17 of 32
5.5.5 Floating Roof Supports
a) Support shall be adjustable to two position
1) The lower position (minimum 1200 mm)

shall permit the roof to go as low as possible
without interference with any internal
accessories and roof seal mechanism.
2) The upper position (for cleaning) shall
provide a clearance of 1800mm between the
pontoon / deck edges and bottom.
b) The number of leg supports shall be determined
& designed to ensure that while resting they do
not deform the tank bottom and roof; the effective
length of the pipe support should be taken as 1.5
times of actual length of the pipe support in clean-
out position.
c) Pipe sleeves shall project sufficiently above the

roof to take care of flooded condition of roof and
extend sufficiently below the roof to prevent
escape of vapour (minimum 200 mm).The pipe
sleeves shall be brazed for a length of 50mm at
the top and bottom of the sleeve and the cotter
pin shall be of stainless steel as shown in the
drawings.
d) Pipe support length shall be readjusted after

hydraulic testing of tank so as to take care of the
initial settlement of the tank bottom.
e) The maximum spacing between the leg support
shall be 5 ( Five) metre.
Page 18 of 32
5.5.6 Rolling ladder and track shall be provided as per HPCL
Standard Drawings enclosed in this Document.
5.5.7 Roof Drains

a) Roof Drains of Repeatable lay pattern shall be
provided by the Contractor as per Manufacturer
recommendations with internal supports and
shoes/ Guards, Connecting piping duly supported
from Roof drain sump to inlet of system and
Connecting piping from outlet side of system to
Roof Drain Nozzle on shell, if any; Swing check
Non return valve with CI body and brass/bronze
valve and seat shall be provided for the primary
drain for single deck floating roofs. Detailed
specifications are provided in annexure-
Specification for flexible pipe for Tank Roof
Drain system for floating Roof tanks.
b) The slope of deck leading to primary roof drain

sump shall be planned for complete water
drainage equivalent to maximum recorded rainfall
per hour for given site without allowing any
accumulation of water, the deck being at the
lowest operating level.
c) Emergency drain shall be provided to take care of

primary roof drain failure. This drain shall be
equipped with water seal sump inside the roof to
prevent back flow of the stored product. It should
start functioning after accumulation of around
200mm of rain fall on deck.
d) The minimum thickness of drain pipe shall be
Page 19 of 32
Sch. 40.
5.5.8 Vents
a) Roof shall be provided with automatic bleeder

vents designed to open before the roof reaches
its lowest positions and to close when the roof
rises above this point. Also same operation
should follow in the clean-out position.
5.5.9 Gauge Well/Anti-rotational Device
Gauge hatch size shall be as indicated in the drawing

and it shall have a quick opening cover. Gauge hatch
shall be spark proof type. Gauge well pipe and Pipe for
Level Transmitter/ TE shall be located on either side of
Rolling Ladder. This shall also act as anti-rotational
device. No additional anti-rotational device is suggested.
5.5.10 Earthing of Floating Roof
a) Copper cables shall be provided between ladder

and track and also between ladder and shell. Two
such independent connections should exist in
parallel.
b) Adequate number of earthing shunts shall be

provided for the seal.
Page 20 of 32
6.0 APPURTENANCES
6.1 Nozzles & Accessories
a) All appurtenances and accessories as shown in

the respective tank drawings shall be supplied by
the Contractor.
b) Manhole and nozzles with blind flanges shall be

provided with gaskets and boltings.
c) Nozzle and manholes may be shop assembled.
d) Flange faces shall be varnished and protected by

wooden discs using at least three bolts.
e) All nozzles and accessories shall be prefabricated

and attached to the shell plate. The prefabricated
assembly shall be stress relieved prior to
installation, wherever required as per code and
6.2 Stairways, Roof Access and Handrailing.

Each tank shall be provided with stairway and roof access.
Handrailing if not indicated otherwise on tank drawings shall
be provided all around.
6.3 Settling Marker :

Marker shall be provided on the shell, 500mm from the
bottom to check tank settlement. Size shall be 50x50x5mm
angle and 100mm long. The distance between setting
market is approximately 5 meter.(minimum 4 numbers).
Page 21 of 32
Shell settlement measurement shall be made after tank
erection, prior to hydro testing and during water filling.
While taking measurement on settling markers, rim space

(distance between shell and outer rim) shall also be
measured at location corresponding to settling markers for
floating roof tanks.
Bottom internal measurements shall be made after hydro

testing; such measurement shall be made at all pipe
support location. Additional measurements shall be made in
annular plate region at 5 meter intervals around the tank
shell.
Inspection shall be co-ordinated by Engineer-in-Charge at

all stages.
7.1 Inspection
a) All tanks shall be offered for inspection at all

stages as desired by Engineer-in-Charge.
b) HPCL’S representatives shall have free access to

the entire contractor’s as well as to worksite.
c) The contractor shall provided all facilities, such as

access ladder, lighting, tools and tackles,
instruments etc. and personnel to inspectors, for
proper execution of their inspection.
Page 22 of 32
d) All the inspection shall be carried out in
accordance with the relevant codes and
requirements of drawings and specifications.
d) Approval of the HPCL’S Engineer-in-Charge shall

in no way relieve the contractor of his
responsibilities for proper execution of work.
7.1.2 Welding Procedure

a) No weld joint will be performed by welder without
having approved WPQR and WPS for the
particular joint.
b) Welding procedure specification(WPS)- QW-482
ASME Section-IX: WPS for all the joints will be
written by the party incorporating all the
requirements like joints/groove design, pre/post
weld treatments, filler metal details like
6013/7018,No.of weld layers including no.of
beads per layer with electrode class&
dia/current/volt/traverse speed/other remarks etc.
All the WPS will be vetted by HPCL approve TPI
agency prior to approval of EIC.
c) The performance qualification record (PQR) QW-
483 ASME Section-IX: PQR will be carried out for
establishing the mechanical properties and all
other requisite variables. It shall be done for 6013
& 7018 separately for Horizontal & Vertical on
test coupon thickness recommended by ASME
Section IX for work to be undertaken. Required
destructive test will be undertaken as per ASME
section IX. The entire PQR process will be done
Page 23 of 32
under the supervision of third party.
d) The Welder performance qualification record
(WPQR) QW-484 ASME Section-IX: WPQR will
be performed under the supervision of HPCL
approved third party and approval vetting will be
granted by TPI for successful welders I
prescribed format recommended by ASME
Section-IX. During this process TPI will also vet
the various accessories like Welding rectifier,
regulator, holder; cable etc and the record will be
maintained for the same. The records shall be
used as benchmarking for QC.
c) No welding shall be undertaken without approval
of the welding procedure and welder qualification
test by the Engineer-in-charge.
Note: as a sample WPS/WPQR/PQR used at other HPCL
sites are attached.
7.1.3 Radiography and Inspection of Welds
a) All welds shall be inspected and tested as per

Section 6.1 of API 650, eleventh/latest edition and
this specification.
b) All long seams of fabricated nozzles shall be fully

radiographed.
c) Weld areas/shots to be radiographed shall be

designated by the Engineer-in-charge. No. of
shots will be as per API 650 as per clause 8.1.2
of eleventh edition.
Page 24 of 32
d) Radiographs shall be taken as soon as welding of
the Joint is completed. If repairs are required,
these shall be carried out before starting other
welds. New radiography examination of such
repairs shall also be carried out by the Contractor
at his own cost. The no. and location of
radiograph along with welder identification shall
be properly maintained by the contractor as per
figure 8.1 of API 650 of Clause 8.1 ,11th edition.
d) Radiograph film length shall be 250 mm min.
except if the weld is less than 250 mm long. In
such cases, film length shall be full length of weld.
f) Radiographic film shall be of approved quality
KODAK/approved make by HPCL/TPI.
g) Welds examined by radiography shall be judged
acceptable or unacceptable by standards of
paragraph UW-51(b) in section VIII of the ASME
code (attached)
h) The radiography films and reports shall be
reviewed and approved by a HPCL approved
Third Party Agency. The quoted rates are
deemed to include same. The evaluator (TPI
person) shall have a Level-II/III of certification of
ASNT-SNT-TC-IA. The film shall have a proper
identification marks vide point no:d above along
with TPI certification.
7.1.4 Liquid penetrant examination:
Wherever specified in drawing/code, liquid penetrant
examination shall be carried out as per specifications and
codes. Additionally, all Horizontal and vertical Shell joints
including extensions above the Maximum Design Liquid
Page 25 of 32
Level shall be Dye Penetrant Tested after Root Run and
necessary repairs carried out.
It is to be noted that the entire weld joints which are non
accessible to any type of regular tests like vacuum box,
Hydro test, Pneumatic test shall undergo DP test for root
run mandatorily.
The bottom to shell joint root run shall undergo Kerosene-
chalk test prior to DP test from both inside to outside and
vice versa mandatorily.
7.2 Testing
All equipment required for testing shall be supplied by the
contractor.
Opening other than those used for hydrostatic test or any
other test shall be closed by plugs and blind flanges
supplied by the contractors.
7.2.1 Bottom test

a) A detailed description of the proposed test
method shall be first submitted for approval to the
Engineer-in-Charge.
b) Vacuum box testing shall be carried out for

detection of leaks in the bottom s per clause no:
8.6 API 650 11th edition. All the fillet joints of
bottom/Annular/Sketch shall undergo vacuum box
test at 35 Kpa(3.5 PSI) for 10 minutes prior to
shell erection/fixing leg bearing plate for support
for various appurtenances like leg, Gaugewell
etc..,
Page 26 of 32
c) The weld joints under the shell periphery shall be
Vacuum box tested (i.e. annular butt joint) as
above(7.2.b) before erection and welding of first
shell course.
e) Contractor shall test the tank bottom for the entire

weld length in the presence of the Engineer-in-
Charge and test reports shall be issued
accordingly.
f) The root run of all joints of central sum shall
undergo DP test in presence of EIC.The central
Sump in Cone down type of Tanks shall be hydro
tested at a pressure of 10.5 Kg/cm2 for 4 hour
duration.
7.2.2 Shell Test

a) Bottom to shell joints shall be tested as follows:
i) Inner fillet weld shall be inspected and tested

prior to welding the outside fillet weld. Leak test
shall be performed with penetrating oil after
removal of slag. Oil shall be removed before,
welding the outer fillet.
ii) Examination for inner fillet to detect cracks shall

be performed using either the liquid penetrant
method or DP test.
b) All welded lugs and brackets used for erection
Page 27 of 32
purpose shall be carefully removed from inside
and outside surface of the tank to the satisfaction
c) The shell joints above the Design Liquid level and

not subjected to Hydro test shall be radiographed
in accordance with API and all such joints shall be
Dye penetrant tested for entire length after Root
run.
d) Contractor shall perform the hydrostatic test in the

presence of Engineer-in-Charge on each tank
after complete erection. Any defects observed
during the test shall be repaired by the contractor.
No Hot work shall be permitted after Hydrotest.
e) Filling of the tank may be restricted by HPCL

Engineer-in-Charge for preloading of foundation
and hydrostatic test may be extended over a
period of 4 weeks or more to ensure proper
settlement of the tanks.
f) The filling height, for floating roof tanks shall be

restricted to maximum height so that weather
shield does not go beyond curb angle while
carrying out the hydrostatic testing /filling up
water. The steps shall be as follows:
1) On completion of tank and after cleaning, the

tank shall be filled with water as follows, unless
otherwise specified in the tender documents.
Page 28 of 32
Filling shall be in 4 stages- 25%, 50%, 75%
and 100%. After each stage a load stabilization
period shall be observed:
- 24 hrs between each stage for tanks with a
capacity equal or more than 10,000 cu.m.
capacity under 10,000 cu.m.
Filling rate shall not exceed 5 metres per day.
g) When the tank is full all the weld joints shall be
hammered by the Contractor in the presence of
Engineer-in-Charge. In case of any defect it shall
be repaired and retested by the Contractor as per
instructions of Engineer-in-charge.
h) Tank shall be emptied at a maximum water level
variation rate of 5 metres per day or as per
instructions of Engineer-in-Charge.
i) All weld repairs shall be done with water level
minimum 300 mm below the joint being repaired.
7.2.3 Floating roof testing
Floating roof test shall be as recommended in API Standard

650 Appendix C or Appendix H and also as given below :
a) During floatation test of roof, contractor shall carry

out the proof test as follows on each size of the
tank selected by Engineer-in-Charge.
i) For annular pontoon type external floating roofs,
with primary drains closed, water equivalent to
10” of rainfall over the tank area shall be poured
Page 29 of 32
on the deck and in the stabilized state
submergence of outer rim shall not exceed 65%
of its height at any point.
ii) For annular pontoon type external as well as
internal floating roofs the condition of deck and
two adjacent pontoon compartments punctured
shall be simulated and the submergence of inner
rim and outer rim at the punctured pontoon shall
be compared with the calculated value.
iii) Failing to meet the above requirements contractor
shall rectify the floating roof and test at his cost till
the above requirements are satisfied.
b) All compartment including buoys shall be tested

for liquid tightness.
c) Sealing devices shall be installed after floatation

test.
7.2.5 Nozzle Reinforcing Plates

Nozzle reinforcing plates shall be pneumatically tested at
1.05 kg/cm2g with soap solution. This test shall be carried
out before filling the tank for hydrostatic testing.
7.2.6 Primary Drains

Drain pipes in floating roof tank shall be pressure tested
with water at 4 kg/cm2g. During the floatation test, the roof
drain valve shall be kept open and observed for leakage of
the tank contents into pipe drain.
Page 30 of 32
8.0 CALIBRATION
Strapping and Calibration of all tanks shall be done in

accordance with IS:2007 & 2008 (Latest editions) and
certified/stamped and signed by Inspector of weights and
measures department.
9.0 PAINTING
For details of primer and painting, Painting specification

shall be referred to.
10.0 TOLERANCE
10.1 Shell
For tanks to have acceptable appearance and to permit
proper functioning of floating roof, they shall have
tolerances strictly as specified in applicable codes/tender
document whichever is stringent.
10.2 Floating Roof Tolerance
Tolerance allowed on the annular clearance between shell
and floating Roof shall be compatible with the requirement
specified by seal manufacturer. This shall be maximum 50
mm radially.
11.0 IDENTIFICATION, PACKING AND TRANSPORTATION

11.1 Identification
Each plate and structural member shall be clearly marked
with the specification number, drawing number and
assembly number.
Page 31 of 32
11.2 Packing and Transportation
a. All plates shall be transported in tractor or trailer and shall
not be dragged.
b. All rolled shell plates shall be packed properly to retain the
shape and shall be handled carefully to avoid damage
during transit.
c. Contractor shall be responsible for transportation of material
fabricated in his workshop or worksite.
12.0 GUARANTEE
Guarantee, if not covered by the General Conditions of
contract, shall be as following:
12.1 The entire Work shall be guaranteed in accordance with
conditions given in the “General terms and Conditions of
Contract” and “Special Conditions of Contract”.
12.2 Any part of tank found detective within 12 months from the
date of Completion of work as per Completion Certificate
and not having been subjected to faulty operations or
incorrect service conditions shall be promptly
replaced/repaired and reassembled by the contractor at his
own cost, failing which owner has the right to get the same
replaced/repaired by others and charge the cost incurred
to the contractor.
13.0 INTERNAL FLOATING ROOF

Internal floating roofs shall be designed, fabricated,
erected ,welded ,inspected, tested commissioned complete in
all respects per API 650,Appendix –H (latest edition)and
HPCL,s EIC’s approved drawings and procedures.
Page 32 of 32
TECHNICAL SPECIFICATIONS
FOR
SELF SUPPORTED
FIXED CONE ROOF TANK

(UN INSULATED/INSULATED)
Page 1 of 22
CONTENTS
1.0 SCOPE
2.0 REFERENCE
6.0 APPURTENANCES
8.0 CALIBRATION
9.0 PAINTING
10.0 TOLERANCES
11. IDENTIFICATION, PACKING AND TRANSPORTATION
12.0 GUARANTEE
Page 2 of 22
STANDARD SPECIFICATIONS FOR FABRICATION,
ERECTION AND TESTING OF ABOVE GROUND STORAGE
SELF SUPPORTING CONE ROOF TANKS WITH CONE
DOWN BOTTOM & SUMP
1.0 SCOPE
1.1 This specification covers the minimum requirements for

design, selection of materials, fabrication, erection,
inspection, testing, fitting of other attachments and
appurtenances, cleaning, calibration and painting of A/G
SELF SUPPORTING FIXED CONE ROOF TANKS
storage and is intended to supplement the minimum
requirements of the applicable codes.
1.2 Engineering drawings shall take precedence over

specifications/standards.
1.3 The Review/ approval of design by HPCL shall not

absolve Contractor from the responsibility of successful
performance of Self Supporting Cone Roof. It shall be the
sole responsibility of the Contractor to ensure successful
performance of Roof design.
1.4 The tanks shall be designed as per API 650 strictly. The
design calculation in the scope of contract includes
Bottom Plate(Annular/Sketch), Shell, Wind girders if any,
Top Kerb Angle, Roof Plates, Self Supporting
Trusses(Main Beam) and Rafters ,Check for overturning of
tank under wind load, seismic design etc for HPCL’s
approval prior to drawing preparation .
Page 3 of 22
2.0 REFERENCE
2.1 Design Codes
The following codes in their latest edition shall form the

basis for design, fabrication, inspection, testing and
acceptance of storage tanks :
API Standard 650 : Welded steel tanks for oil

(Latest edition) storage
IS : 875 (Part 3) : Code of practice for design loads

Wind loads (other than
earthquake) for building and
structures.
IS : 1893 : Criteria for earthquake resistant

design of Structures.
API : 2000 : Venting atmospheric and low

pressure storage tanks.
IS : 2007 : Method for calibration of Vertical

Oil Storage tanks.
IS : 2008 : Method for computation of

capacity tables for Vertical Oil
storage tanks
API : RP 2003 : Protection against ignitions arising

out of static, lightning and stray
currents.
OISD-129 : Inspection of storage tanks.
OISD-11 : Fire Protection facilities for Petroleum

Depots and Terminals
Page 4 of 22
OISD-118 : Layouts for Oil & Gas installations.
OISD-105 : Work permit system.
2.2 Materials Codes
Material to be used shall conform to:

Steel plates confirming to IS 2062.
Indian Standard Specifications or ASTM standards as
Applicable
2.3 Regulations
Central laws and regulations together with local bye-laws

for the location wherever the tanks are to be erected must
be compiled with.
3.1 All materials shall be as per applicable Codes.
3.2 Manhole necks, nozzle necks 250 mm NB and above may

be fabricated from same plate material as used for shell.
3.3 Plate material used for ring flanges shall have a minimum
UTS of 4200 Kg./cm2 . For Flange thickness over 38 mm,
plate material shall be boiler quality, fine-grained, killed,
normalised and impact tested as per the requirements of
API Standard 650.
3.4 All clips and attachments shall be fabricated from carbon

steel plates of weldable quality.
3.5 Gaskets for manholes fitted with blind flanges shall

conform to IS: 2712.Thickness of gasket shall be 3.0 mm.
Champion OIL Service gaskets may be used.
Page 5 of 22
3.6 Bolts and nuts for all nozzles fitted with blind flanges shall
conform to IS: 1367, ASTM A-307 Gr. B, A-193 Gr. B-7, or
A-194 Gr. 2H. Bolts and nuts for all structurals shall
conform to IS: 1363.
3.7 Following classifications of electrodes are recommended

for welding. However, minimum requirements of applicable
codes and appendices should be adhered to:
a] Low hydrogen electrodes namely, E-7018 shall

be used for all manual metal-arc welds of shall
courses having a thickness of 12mm or more
and for attachment of shell courses to bottom or
annular plates.
b] High cellulose/rutile type electrodes namely, E-

6013 as per the AWS classification SFA 5.1 is
acceptable for all other welding.
ESAB and ADVANI OERLIKON make electrodes will only

be permitted to be used in the works. Based on above,
fabricator shall furnish samples of welding electrodes to
Engineer-in-Charge for approval.
4.1 All individual tank data sheets shall have

dimensional/design as well as material specification. Final
drawing with revisions, if any, shall be issued after award
of contract/purchase order.
Contractor shall submit the detailed design calculation for

self supporting Cone roof (C.R.) to HPCL for vetting and
review of design and approval by HPCL.
Page 6 of 22
4.2 Contractor shall prepare all design calculations and
fabrication drawings based on the drawings issued on
award of contract/purchase order and shall include the
following:
1. Drawing index and Schedule of Submission.
2. Design calculation for Self supporting Cone roof for

HPCL review & approval.
3. GA drawing covering all details shown in HPCL data

sheets like list of appurtenances, lists of standards and
specifications, materials of construction, Tank design
data, General Notes including details of test to be
conducted on tank, specification and brand-name of
welding electrodes to be used etc.
4. Plate layout, details of welding and bill of material for

bottom sketch & annular plates, Central sump and
arrangement of supports for the pipes dipping in to the
sump. The Bottom shall be Cone down type with a
Sump of approx. capacity 200 litres at the centre.
5. Development details of welding and Bill of Materials

for shell including shell extensions showing location of
all the Shell appurtenances including Manholes,
nozzles, inlet trough and stairway on developed shell
through a Nozzle orientation drawing.
6. 2 No. Water draw off Nozzle & 1 No. Fast Flush

Nozzle are provided with pipes that extend up to the
Sump and dip in to the sump. This arrangement is to
be shown on drawing.
7. Plate layout, details of welding and Bill of Material for

Cone Roof Layout.
Page 7 of 22
8. Details of spiral stairway and extension stairway to
Top platform, landings and handrails with bill of
materials.
9. Details of wind girders with Bill of Material.
10. Details of Earthing connections for Shell with Bill of

Material.
11. Details of Roof Supporting Structure with Bill of

Material.
12. Details of shell nozzles and Inlet Troughs with Bill of

Material.
13. Details of Roof appurtenances including Roof

manholes, vents, Temperature transmitter Nozzles,
Temperature hatch, Gauge well & Dip Pipe, Gauge
Hatch along with respective Bill of Materials.
14. Nozzle Orientation of roof appurtenances, plate joints,

Stairway, etc.
15. Details of mounting of Roof vents.
16. Details of Foam Cooling System, supports for the

Foam intake pipes, Foam intake pipes along with
Foam makers and orifice plates.
17. Details of Pressure relief lines & pressure transmitter

nozzles.
18. Plate cutting diagrams for all free issue material.
19. Plate reconciliation statement for free issue material.
Page 8 of 22
20. Details of all datum plates.
In case the contractor intends to make some

modification for accommodating his fabrication
facilities or available materials, the same shall be
submitted to HPCL for approval with supplementary
design calculations. The approved modifications shall
be incorporated in fabrication drawing and submitted
to HPCL for approval.
4.3 Requisite number (as per the Time schedule of this

Work/Tender document) of prints of detailed
fabrication drawings prepared by contractor shall be
sent to HPCL for approval and one copy shall be
returned to the contractor after comments/approval.
No fabrication / erection shall be carried out without
approved drawings.
5.1 Plates
a] Plates edges shall preferably be sheared or machine

cut as per code. All machined parts shall be suitably
protected before assembly.
b] Gas cut plates shall be grounded to the satisfaction

c] All formed plates shall be match marked with paint on

the concave side with numbers as shown on erection
drawings.
5.2 Structural steel and Roof
a] Structural steel fabrication shall be carried out to the

required shapes for making the structure.
Page 9 of 22
b] A pre-assembly of a sufficient part of roof structure
may be called for by the Engineer-in-Charge to assess
the correct workmanship.
5.3 Bottom
a] Bottom slope shall be as indicated in the respective
tank drawings. The Bottom shall be Cone Down type with
a central sump of approx. 200 litres capacity.
b] Overlaps shall be properly cleaned with steel wire

brush before welding.
c] Single pass welds are not permitted.
d] Arrange the laps to shade the water towards the

Central Sump. Pipes from Water draw off nozzle and
Fast Flush Nozzle on shell shall dip into the sump.
Suitable supports from the bottom shall be provided
for these pipes.
e] Annular plates shall be assembled by butt welding with

backing strips and the sketch plates shall be lap
welded to the Annular & Sketch plates.
f] Three plates lap joints shall be suitably joggled to a

length of 150 mm minimum to facilitate welding.
Joggling shall be to the satisfaction of Engineer-in-
Charge.
g] Contractor shall provide a Welding sequence which

shall be adopted so as to give minimum shrinkage and
distortion and it shall be indicated on fabrication
drawings. This shall be approved by Engineer-in-
Charge.
Page 10 of 22
h] Bearing plates & Datum plates shall be fabricated as
per standard drawings and positioned as per AFC
Drawings.
5.4 Shell
a) Shell erection shall be carried out by Jack – up

method only. Calculations for deployment of number of
jacks and their placement/ location shall be submitted
by the Contractor for HPCL’s approval.
b) All vertical and horizontal shell joints shall be full

penetration and full fusion welds using any one of the
edge preparations permitted by the Code. Single side
butt welds are not permitted.
c] Top curb angle shall be lap or butt welded to the top

course with flange turned outside.
d] Drain holes of 20 mm diameter suitably staggered

shall be provided on the horizontal plates of the
stiffening ring (wind girder).
e] Hand railing shall be provided all around when

stiffening ring is used as walkway for floating roof rank.
f] Curb angle and stiffening ring joints shall not coincide

with the vertical shell plate welds.
g] Vertical joints should preferably be offset by at least

1000mm.
h] First shell course plates shall be so arranged that the

vertical joints clear the annular ring welds or sketch
plates welds by at least 300 mm. Vertical joints of the
shell courses shall also clear the nozzle attachment
Page 11 of 22
welds or reinforcement pad welds as per code and
i] Holes shall not be made in shell plates for erection

purpose.
j] Shell plate alignment shall be within the limits

specified in code and as approved by HPCL.
k] For floating roof tanks, internal diameter shall be

maintained in all shell courses.
l] During erection, strapping must be carried out at three

different levels for each strake as a crosscheck for
plumb.
5.5 Fixed Roof
a) The Roof plates shall be supported by structures as

indicated in the drawings.
b) The slope of the Cone Roof shall be in accordance with

API 650.
c) All supporting structures shall be designed to carry the

minimum loads as specified in codes. While designing,
contractor shall also consider lateral loads caused by
one bay loaded and the other bay not loaded.
d) Roof shall be joined to the shell by means of continuous

fillet (5mm max) weld on the curb angle. Roof to shell
joint shall be frangible type.
e) Roof plates shall not be welded to the supporting

structure. The roof plates shall rest on the structure.
Page 12 of 22
5.6 Vents
Roof shall be provided with 300mm diameter goose

neck type vent.
5.7 Gauge Wells
Gauge hatch size shall be as indicated in the drawing

and it shall have a quick opening cover. Gauge hatch
shall be spark proof type. Gauge well pipe and
Telescopic Pipes for Radar Gauge/Temperature
transmitter shall be located accessible to Top landing
platform. Gauge well pipes shall be provided with slot
holes.
6.0 APPURTENANCES
6.1 Nozzles & Accessories
a) All appurtenances and accessories as shown in

the respective tank drawings shall be supplied
by the Contractor.
b) Manhole and nozzles with blind flanges shall be

provided with gaskets and boltings.
c) Nozzle and manholes may be shop assembled.
d) Flange faces shall be varnished and protected

by wooden discs using at least three bolts.
e) All nozzles and accessories shall be

prefabricated and attached to the shell plate.
The prefabricated assembly shall be stress
Page 13 of 22
relieved prior to installation, wherever required
as per code and applicable appendices.
6.2 Stairways, Roof Access and Handrailing.
Each tank shall be provided with stairway and roof

access. Hand railing shall be provided all around.
6.3 Settling Marker :
Marker shall be provided on the shell, 500mm from the

bottom to check tank settlement. Size shall be
50x50x5mm angle and 100mm long. The distance
between settling marker is approximately 5
meter.(minimum 4 numbers).
Shell settlement measurement shall be made after tank

erection, prior to hydro testing and during water filling.
Bottom internal measurements shall be made after

hydro testing; such measurement shall be made at all pipe
support locations. Additional measurements shall be made
in annular plate region at 5 meter intervals around the tank
shell.
Inspection shall be carried out by HPCL Engineer-in-

Charge at all stages.
7.1 Inspection
a) All tanks shall be offered for inspection at all

stages as desired by Engineer-in-Charge.
Page 14 of 22
b) HPCL’S representatives shall have free access
to the entire contractor’s shops as well as to
worksite.
c) The contractor shall provided all facilities, such

as access ladder, lighting, tools and tackles,
instruments etc. and personnel to inspectors, for
proper execution of their inspection.
d) All the inspection shall be carried out in

accordance with the relevant codes and
requirements of drawings and specifications.
e) Approval of the HPCL’S Engineer-in-Charge

shall in no way relieve the contractor of his
responsibilities for proper execution of work.
7.1.2Welding Procedure
a) Welding procedure qualification shall be carried
out as per Exhibits enclosed in tender and as
per details in Scope of Work.
b) No welding shall be undertaken without

approval of the welding procedure and welder
qualification test by the Engineer-in-charge.
7.1.3Radiography and Inspection of Welds
a) All welds shall be inspected and tested as per

Section 6.1 of API 650 and this specification.
Page 15 of 22
b) All long seams of fabricated nozzles shall be
fully radiographed.
c) Weld areas to be radiographed shall be

designated by the Engineer-in-charge.
d) Radiographs shall be taken as soon as welding

of the Joint is completed. If repairs are required,
these shall be carried out before starting other
welds. New radiography examination of such
repairs shall also be carried out by the
Contractor at his own cost.
e) Radiograph film length shall be 250 mm min.

except if the weld is less than 250 mm long. In
such cases, film length shall be full length of
weld.
f) Radiographic film shall be of approved quality.

g) The radiography films and reports shall be
reviewed and approved by a HPCL approved
Third Party Agency. The quoted rates are
deemed to include same.
7.1.4 Liquid penetrant examination:

Wherever specified in drawing/code, liquid penetrant
examination shall be carried out as per specifications and
codes.
7.2 Testing
All equipment required for testing shall be supplied by the
contractor.
Page 16 of 22
Openings other than those used for hydrostatic test or any
other test shall be closed by plugs and blind flanges
supplied by the contractors.
7.2.1 Bottom test

a) A detailed description of the proposed test
method shall be first submitted for approval to
the Engineer-in-Charge.
b) Vacuum box testing shall be carried out for

detection of leaks in the bottom.
c) The weld joints under the shell periphery shall

be tested before erection and welding of first
shell course.
d) Contractor shall test the tank bottom for the

entire weld length in the presence of the
Engineer-in-Charge and test reports shall be
issued accordingly.
7.2.2Shell Test
a) Bottom to shell joints shall be tested as follows:
i) Inner filter weld shall be inspected and tested

prior to welding the outside fillet weld. Leak test
shall be performed with penetrating oil after
removal of slag. Oil shall be removed before,
welding the outer fillet.
Page 17 of 22
ii) Examination for inner fillet to detect cracks shall
be performed using either the liquid penetrant
method or Magnetic particle method.
b) All welded lugs and brackets used for erection

purpose shall be carefully removed from inside
and outside surface of the tank to the
satisfaction of the Engineer-in-Charge.
c) The shell joints upto kerb angle shall be

subjected to hydrotest.
d) Contractor shall perform the hydrostatic test in

the presence of Engineer-in-Charge on each
tank after complete erection. Any defects
observed during the test shall be repaired by the
contractor. No Hot work shall be permitted after
Hydrotest.
e) Filling of the tank may be restricted by HPCL

Engineer-in-Charge for preloading of foundation
and hydrostatic test may be extended over a
period of 4 weeks or more to ensure proper
settlement of the tanks.
f) The filling height shall be restricted to a

maximum height while carrying out the
hydrostatic testing /filling up water. The steps
shall be as follows:
g) On completion of tank and after cleaning,

the tank shall be filled with water as follows,
unless otherwise specified in the tender
documents.
Page 18 of 22
Filling shall be in 4 stages- 25%, 50%, 75%
and 100%. After each stage a load stabilization
period shall be observed:
capacity equal or more than 10,000 cu.m.
capacity under 10,000 cu.m.
Filling rate shall not exceed 5 metres per
day.
d) When the tank is full all the weld joints shall be
hammered by the Contractor in the presence of
Engineer-in-Charge. In case of any defect it shall
be repaired and retested by the Contractor as per
instructions of Engineer-in-charge.
e) Tank shall be emptied at a maximum water level
variation rate of 5 metres per day or as per
instructions of Engineer-in-Charge.
f) All weld repairs shall be done with water level
minimum 300 mm below the joint being repaired.
7.2.3 Fixed roof testing

a) After filling the tank upto curb angle or max.
liquid level,all openings in the roof shall be
closed and internal air pressure shall be
applied equivalent to the weight of roof plates
b) Pressure testing of roof for leak detection
shall be carried out as per code.
c) For vacuum test the tank shall be emptied
up to 1m level from the bottom. The openings
shall be closed and draining continued with
care until the vacuum of 25mm water gauge
or the design vacuum whichever is higher is
obtained and checked by vacuum gauge.
However for tanks having diameter 20m and
Page 19 of 22
above, design check for vacuum shall be
made before proceeding with the test.
7.2.4Nozzle Reinforcing Plates
a) Nozzle reinforcing plates shall be pneumatically tested
at 1.05 kg/cm2g with soap solution. This test shall be
carried out before filling the tank for hydrostatic testing. All
the weld joints in roof shall be checked with soap suds for
detection of leaks.
b) Observations will be made for leakages during
Hydrostatic testing.
7.2.5 Pipes for water draw off & fast flush

Pipes for above shall be pressure tested with water at 6
kg/cm2g.
8.0 CALIBRATION
Strapping and Calibration of all tanks shall be done in
accordance with IS:2007 & 2008 (Latest editions).
9.0 PAINTING
For details of primer and painting, Painting specification
shall be referred to.
10.0 TOLERANCE
10.1 Shell
For tanks to have acceptable appearance and to permit
proper functioning, they shall have tolerances strictly as
specified in applicable codes.
Page 20 of 22
11.0 IDENTIFICATION, PACKING AND TRANSPORTATION
11.1 Identification
Each plate and structural member shall be clearly marked
with the specification number, drawing number and
assembly number.
11.2 Packing and Transportation

a. All plates shall be transported in tractor or trailer and shall
not be dragged.
b. All rolled shell plates shall be packed properly to retain the
shape and shall be handled carefully to avoid damage
during transit.
c. Contractor shall be responsible for transportation of
material fabricated in his workshop or worksite.
12.0 GUARANTEE
Guarantee, if not covered by the General Conditions of
contract, shall be as following:
12.1 The entire Work shall be guaranteed in accordance with
conditions given in the “ General terms and Conditions
of Contract” and “Special Conditions of Contract”.
12.2 Any part of tank found detective within 12 months from the
date of Completion of work as per Completion Certificate
and not having been subjected to faulty operations or
incorrect service conditions shall be promptly
replaced/repaired and reassembled by the contractor at
his own cost, failing which owner has the right to get the
same replaced/repaired by others and charge the cost
incurred to the contractor.
Page 21 of 22
13. STRUCTURAL STEEL
Structural Steel sections manufactured by SAIL, RINL,

VIZAG, TISCO or JINDAL only shall be permitted to
satisfactory sample testing.
14.0 INSULATED TANKS
Insulated tanks i.e. Tanks operating at elevated

temperatures shall be designed, fabricated, erected ,welded
,inspected, tested commissioned complete in all respects per
API 650,Appendix –M (latest edition)and HPCL,s EIC’s
approved drawings and procedures.
Page 22 of 22
STANDARD
SPECIFICATION
FOR SHOP
AND
FIELD PAINTING
Page 1 of 10
STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING
1.0 GENERAL
1.1 These technical specifications shall be applicable for the work covered by the
Contract. It is understood that Contractor shall complete the work in all respects
with best quality materials and workmanship, best engineering practice,
Manufacturer recommendations, ITP and instructions of HPCL.
1.2 All the items covered in this specification are required to be supplied by the
Contractor only.
2.0 SCOPE
Scope of work covered in this specification shall include but not limited to the
following:
1. Surface preparation for all components of A/G product storage tanks covered in
this Contract.
2. Selection, procurement and application of primers, paints and other materials on

various metallic surfaces including providing all requisite scaffolding, spray
equipment, compressors, applicators, brushes, etc.
3. Lettering, marking as per HPCL requirements.
3.0 CODES AND STANDARDS
3.1 REFERENCE STANDARDS

IS : 5
IS : 101
ASTM STANDARDS
3.2 SURFACE PREPARATION STANDARDS
SWEDISH STANDARD : SIS-05-5900-1967/ISO-8501-1-1988

THIS STANDARD CONTAINS PHOTOGRAPHS OF THE VARIOUS
STANDARDS ON FOUR DIFFERENT DEGREES OF RUSTED STEEL.
MANUFACTURER’S BROCHURES AND INSTRUCTIONS WITH RESPECT TO

STORAGE, SURFACE PREPARATION, MIXING AND THINNING, APPLICATION
AND CURING INTERVALS.
Page 2 of 10
4.0 EQUIPMENT
All tools, brushes, rollers, spray guns, abrasive materials, sand, hand/ power tools
for cleaning, scaffolding materials, air compressors, instrument for measuring
humidity, profilemeter etc required for the works shall be supplied by the
Contractor.
5.0 SURFACE PREPARATION, COATING APPLICATION AND DOCUMENTATION
5.1 GENERAL
5.1.1 In order to achieve the maximum durability, copper slag cleaning shall be
followed.
5.1.2 Mill scale, rust, rust scale, etc. shall be fully removed by copper slag blast cleaning
to SA 2 ½ or equivalent as per
SWEDISH STANDARD: IS-05-5900-1967/ISO-8501-1-1988.
5.1.3 Copper slag Blast cleaning shall not be performed where dust can contaminate
surfaces undergoing such cleaning or in conditions where the humidity exceeds
85%.
5.1.4 The first coat of primer must be applied on dry surface immediately and in any
case within 4 hrs of cleaning of surface.
5.1.5 Blasting and painting shall in general be avoided during unfavorable weather
conditions.
5.2 PROCEDURE FOR SURFACE PREPARATION

5.2.1 COPPER SLAG BLAST CLEANING
SPECIFICATIONS FOR COPPER SLAG BLASTING :
1. The surface shall be cleaned of all dust and heavier layers of rust by copper slag
blasting the entire internal surface to photographic standard SIS: 055900-1967.
2. The consumption rate of copper slag is 1.6 Kg/Sqm of the blasted area. This has
to be ensured strictly.
3. All tools, equipments, base material, hand and power tools for cleaning, including
scaffolding material, copper slag blasting equipment, air compressor etc. shall be
arranged by the contractor at site in sufficient quantity.
4. The compressor used shall be of size enough to produce displacement of 5.6 to

7.0 Cum/Min of air at a pressure of 7 Kg/sqcm. Standard blasting equipment,
hoppers, hoses nozzles and attachments shall be used to obtain best test results and
to maintain safety standards. The rate of cleaning shall be about 15 sq.mt. per hour
Page 3 of 10
at a pressure of 7 kg/sq.cm.
5. The abrasive used shall be of the physical properties as mentioned below and
shall be free from oil, loan and mud etc.
6. The blast cleaned surface shall be blasted with dry compressed air before
applying primer. This should be done even if the surface appears very clean and
white in colour. The white colour may be due to deposition of silicon and reflection of
light on the surface.
7. Proper earthing and bonding arrangements shall be made to prevent any damage
by sparks produced by static electricity. Bonding shall be done between tank and
blast nozzles and hopper and air compressor also. The bonding conductor should
not be less than 16 SWG single strand copper cable.
8. The time gap between blast cleaning and application of primer shall not be more
than THREE hours. Blast cleaning work shall, commence from top to bottom.
9. The blast cleaning operation shall be carried out keeping the nozzle at an angle of
30 degree to the vertical in order to prevent rebounding abrasive from showing down
the abrasives emerging from nozzle and from under cutting the material to be
removed.
A blast cleaning, the percentage of bare metal obtained shall be between 95% to 100%
of each of sq.cm. of the blasted area corresponding to photographic visual standards
of SA 2 ½ of the Swedish standard referred above.
10. Arrangements for inspection of various stages of the job shall be made available
by the Contractor so that the entire copper slag blasted area is available for
inspection. Any defective work noticed shall be immediately rectified and even
reblasting shall be done if necessary.
Physical Properties of Copper Slag :
Colour : Black.
Grain shape : Granulated, Angular multifaceted.
Hardness : 5 to 7 Moh’s scale.
Sp. Gravity : 3.2 to 3.7
Bulk Density : 1.87 Kg/ltr.
Moisture Content : less than 1 %
Sieve Analysis of copper slag :
Sieve Size ( mm ) Range (%)

-4.0 to +3.0 2 to 4
-3 to +2.36 3 to 12
Page 4 of 10
-2.36 to + 1 40 to 55
-1 to + 0.5 15 to 30
-0.5 to + 0.212 6 to 12
-0.212 below 0.2 to 1.0
5.3 COATING PROCEDURE AND APPLICATION
5.3.1 Copper Slag blasted surface upon inspection and clearance by HPCL shall be
coated with one complete application of primer as soon as practicable and in no
case later than 4 hrs on the same day. Applied paint shall have the required Dry
Film Thickness (DFT) after drying which shall be measured and recorded by the
contractor and should be submitted to HPCL.
5.3.2 Each coat shall be in a proper state of cure or dryness before the application of
succeeding coat. Manufacturer’s instructions shall be followed for intercoat
interval.
5.3.3 The type of application may be Airspray or Airless spray or Brush application as
per manufacturer recommendation and HPCL instructions for getting satisfactory
results.
5.3.4 For each coat, the painter should know the WFT corresponding to the specified
DFT and standardize the paint application technique accordingly. This has to be
ensured in a qualification trial by Contractor.
5.4 SCAFFOLDING
Double pipe scaffolding shall be used and all the painters shall be provided with
Safety belts for ensuring accident free working.
5.5 DOCUMENTATION
1. A written quality Plan with procedure for qualification trials and for actual work.
2. Daily progress Report with details of humidity, surface preparation, surface profile,
Dry film thickness particulars of applications, number of coats applied, type of
materials used, methodology-Air or Airless or Brush, progress of work vs
programme.
3. Code and Batch numbers of primers and paint materials used.
Page 5 of 10
4. Type of testing equipments and their calibration.
5. Elcometer and Profilemeter readings for the various components jointly recorded
with HPCL.
6. Paint consumption statement along with the Theoretical consumption

requirements.
6.0 RECOMMENDED MANUFACTURERS

• ASIAN PAINTS
• BERGER PAINTS
• GOODLASS NEROLAC
• JENSON AND NICHOLSON
• SHALIMAR PAINTS
• BOMBAY PAINTS
7.0 HPCL LOGO AND LETTERING

HPCL will provide their LOGO with sizing, Flow, coloring and same is to be
provided to the Tanks.
HPCL will also convey to the Contractor in writing details of the lettering for
product and tank details along with the desired color-coding and same has to be
arranged by the Contractor.
8.1 All painting materials including primers and thinners brought to site by the
Contractor for application shall be directly procured from Approved manufacturers
as per specifications and shall be accompanied by Manufacturer Test Certificates.
8.2 HPCL may call for tests for the primers and paints including verification of
batchwise tests for physical and chemical analysis. The Contractor shall carry out
the same at his own cost and provide the results to HPCL.
8.3 The painting work shall be subjected to inspection by HPCL at all times. Stages of
inspection are as follows:
1) Surface preparation
2) Primer application
3) Each coat of paint
All records of inspection shall be maintained in Registers and jointly signed by
HPCL and Contractor.
Page 6 of 10
Any defect noticed during the various stages of inspection shall be rectified by the
Contractor to the satisfaction of HPCL before proceeding further. Irrespective of
the inspection, repair and approval at intermediate stages of work, Contractor
shall be fully responsible for making good any defects found during Final
inspection or during the Defect Liability period. DFT shall be checked and
wherever shot same shall be made up with additional coats.
8.4 The shades of successive coats should be slightly different in colour in order to
ensure application of individual coats in consultation with manufacturer.
8.5 Calibrated Digital Elcometers, surface profile gauges (calibrated Profilemeter) and
any other inspection instrument required by HPCL shall be provided by the
contractor at site.
8.6 The contractor shall arrange expert technical support at site by paint Manufacturer
who will cross verify independently regarding surface preparation and DFT and
quality and provide a report to HPCL.
9.0 PRIMERS AND FINISH COATS DESIGNATIONS
PRIMERS
P-6 : EPOXY ZINC PHOSPHATE PRIMER
FINSIH COATS/ PAINTS
F-2 : ACRYLIC POLYURETHANE FINISH

F-6 : HIGH BUILD EPOXY FINISH COATING
F-7 : HIGH BUILD COAL TAR EPOXY COATING
F-9 : INORGANIC ZINC SILICATE COATING
PAINTING FOR PIPING

SL.NO. TYPE OF SURFACE PAINT SYSTEM TOTAL
PIPING PREPARATION DFT IN
FIELD FINISH MICRONS
PRIMER PAINT
Page 7 of 10
1 FIRE SA 2 1/2 1 COAT OF F-9 @ 65- 1 COAT OF F- P-6 AS
WATER 75 MICRONS DFT/ 6 @ 100 STRIPE
COAT + MICRONS COAT
1 COAT OF P-6 @ 40 DFT/COAT+ 1 (RED
MICRONS DFT/ COAT OF F-2 SHADE);
COAT @ 40 F-6
(65+40=105) MICRONS (GREY)
DFT/COAT AND F-2
(100+40 (FIRE
=140) RED;
IS:536)
2 FOAM SA 2 1/2 1 COAT OF F-9 @ 65- 1 COAT OF F- P-6 AS
75 MICRONS DFT/ 6 @ 100 STRIPE
COAT + MICRONS COAT
1 COAT OF P-6 @ 40 DFT/COAT+ 1 (RED
MICRONS DFT/ COAT OF F-2 SHADE);
COAT @ 40 F-6
(65+40=105) MICRONS (GREY)
DFT/COAT AND F-2
(100+40 (GOLDEN
=140) YELLOW;
IS:356)
ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF
EPOXY ZINC PHOSPHATE PRIMER PRIOR TO TAKING UP F-6
PAINTING FOR FLOATING ROOF TANKS: INTERNAL
SL.NO. COMPONENT SURFACE PAINT SYSTEM TOTAL

PREPARATION DFT IN
FIELD FINISH MICRONS
PRIMER PAINT
1 Underside of Floating SA 2 1/2 1 COAT OF F-9 @ 3 COAT OF F-6
roof deck and pontoon 65-75 MICRONS F-6(AMINE (GREY)
bottom, product side of DFT/ COAT CURED) @ Total=365
annular and sketch 100 microns
bottom plate, inside MICRONS
surface of shell upto 1m DFT/COAT
ht from bottom, outer (300)
surface of still well from
bottom to max. Liquid
level, structural steel
roof ladders, ladder on
still well, roof supports
upto long leg ht, datum
plate, inside face of all
shell nozzles and
trough.
2 Inside pontoon SA 2 1/2 1 COAT OF F-9 @ 2 COAT OF F-6
65-75 MICRONS F-6(amine (GREY)
Page 8 of 10
DFT/ COAT cured) @ 80 Total=225
MICRONS microns
DFT/COAT
(80x2=160)
ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF
EPOXY ZINC PHOSPHATE PRIMER PRIOR TO TAKING UP F-6.
PAINTING FOR FLOATING ROOF TANKS: EXTERNAL

SL.NO. COMPONENT SURFACE PAINT SYSTEM TOTAL DFT IN
PREPARATION MICRONS
FIELD FINISH PAINT
PRIMER
1 Soil side of SA 2 1/2 1 COAT OF F-9 3 COATs OF F-7 @ Total=365 microns
bottom plates @ 65-75 100 MICRONS 1 coat-black shade; 2 nd
MICRONS DFT/ DFT/COAT (300) coat: tanned brown and
COAT 3 rd coat: black)
2 External shell, SA 2 1/2 1 COAT OF F-9 1 COAT OF F-6(AMIDE F-6(Grey)

wind girders, WG @ 65-75 CURED)@ 100 Total=285microns)
supports, Floating MICRONS DFT/ MICRONS DFT/COAT
COAT + 1 COAT + 2 COATS OF F-2 @
roof topside with
OF P-6(RED) @ 40MICRONS
associated 40 MICRONS DFT/COAT
structurals, roof DFT/COAT (100+2 X40=180)
supports above (65+40=105)
roof, rolling
ladder, spiral
stairway incldg.
Gratings,
chequered plates,
kerb angle, foam
dam, hatches,
covers, pontoon
top, sides and
deck top
3 Inside surface of SA 2 1/2 1 COAT OF F-9 1 COAT OF F-6(AMIDE F-6(Grey)
shell from top @ 65-75 CURED)@ 100 Total=285microns)
edge to Max. MICRONS DFT/ MICRONS DFT/COAT
design liquid
level(that is, 40 MICRONS DFT/COAT
1.50m above DFT/COAT (100+2 X40=180)
Max. liquid level) (65+40=105)
4 All still well pipes SA 2 1/2 1 COAT OF F-9 1 COAT OF F-6(AMIDE F-6(Grey)
above max. liquid @ 65-75 CURED)@ 100
MICRONS DFT/ MICRONS DFT/COAT
Total=285microns)
level
40 MICRONS DFT/COAT
DFT/COAT (100+2 X40=180)
(65+40=105)
ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF EPOXY ZINC
PHOSPHATE PRIMER PRIOR TO TAKING UP F-6.
Page 9 of 10
PAINTING FOR FIXED CONE ROOF OF INTERNAL FLOATING ROOF TANKS:
EXTERNAL
SL.NO. COMPONENT SURFACE PAINT SYSTEM TOTAL DFT IN

PREPARATION MICRONS
FIELD FINISH PAINT
PRIMER
1 EXTERNAL SA 2 1/2 1 COAT OF F-9 1 COAT OF F-6(AMIDE F-6(Grey)
SURFACE OF @ 65-75 CURED)@ 100 Total=285microns)
FIXED CONE MICRONS DFT/ MICRONS DFT/COAT
ROOF OF
INTERNAL 40 MICRONS DFT/COAT
FLOATING ROOF DFT/COAT (100+2 X40=180)
(65+40=105)
ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF EPOXY ZINC
PHOSPHATE PRIMER PRIOR TO TAKING UP F-6.
Page 10 of 10
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Page 15 of 15
STANDARD
INSPECTION
TEST PLAN
FOR
PIPELINE JOBS
Page 1 of 4
1.0 GENERAL
The enclosed ITPs shall be followed for the works to be performed by the Contractor
under this Tender. The provisions indicated for stagewise inspection by HPCL are a
minimum and the contractor shall develop a detailed ITP and obtain approval for the
same prior to commencement of work. Contractor to carry out 100% examination of all
activities.
2.0 LEGEND
HP: Hold point;

A point which requires inspection/ verification and acceptance by HPCL before
any further processing is permitted. The Contractor shall not process the
activity/ item beyond a Hold point without written approval by HPCL.
W: Witness Point;
An activity which requires witnessing by HPCL when the activity is performed.
Rw: Review of Contractor’s documentation.
S: Surveillance Inspection by HPCL;

Monitoring or making observations to verify whether or not materials/ items or
services conform to specified requirements. Surveillance activities may include
audit, inspections, witness of testing, review of quality documentation & records,
etc.
WC: 100% examination by Contractor.
Responsibility for execution of the inspection/testing is with the Contractor.
______________________________________________________________________
Page 2 of 4
S.NO. ACTIVITY CONTRACTOR HPCL
________________________________________________________________________
A. PRIOR TO FABRICATION
1. Acceptance of the survey work prior to pipeline laying WC HP
2. Acceptance of the Pipe support sleepers WC HP
3. Incoming Material
- Owner’s Supply WC Rw
- Contractor’s supply, including check testing WC HP
4. Welding Filler Material Approval/Qualification

a) Manufacturing Test Certificate/Documents WC Rw
b) Testing, if any WC W
5. WPS/PQR ( For Product Piping only )

a) Procedure WC HP
b) Testing
i) Carbon Steel WC HP
c) Approval of Final WPS/PQR WC HP
Note : Party to establish WPS/PQR within 15 days from the date of LOI
6. a) Welder performance Qualification Test WC W

b) Certification & Approval of welder WC HP
(For Product Piping Only)
7. Review & approval of P&ID, GAD & Isometric drawings WC HP
8. Fabrication, erection, testing procedure for job WC HP
B. FABRICATION, ERECTION, WELDING & TESTING OF PIPES
1. Blast cleaning (For Product piping only) and painting of pipes WC W
2. Pipe edge preparation, aligning over sleepers WC W
3. Erection & fitup of pipes including fittings, flanges etc., WC W
4. Sequence of welding WC S
5. Baking of electrodes WC S
6. Inter-pass cleaning WC S
7. Visual check of welding WC W
Page 3 of 4
8. DPT/RADIOGRAPHY of the joints WC HP
9. Erection of valves WC W
10. Pipe supports welding WC W
11. Hydrotesting WC HP
Page 4 of 4
TECHNICAL
SPECIFICATIONS
FOR
CONCRETE AND
REINFORCEMENT
WORKS
Page 1 of 15
1. CONCRETE AND STEEL REINFORCEMENT
1.1 GENERAL:
This section describes and specifies work required for plain and reinforced cement
concrete including reinforcement and form work. Unless otherwise specified or agreed
in writing by the EIC, all materials and methods used in the production, testing and
handling of concrete shall comply with the latest editions or amendments of the relevant
Indian Standards.
1.2 MATERIALS:
All materials shall be obtained from sources approved by the EIC. The agreed source or
quality of any material shall not be changed during the course of the contract except
with the approval of the EIC.
Whenever requested by the EIC, the Contractor shall provide a certificate from the
manufacturer, for each and every delivery of material, showing the source, quantity
delivered and confirming that the material has been tested and conforms to the required
Indian Standard.
1.3 TESTING OF CONCRETE MATERIALS :

Prior to the commencement of concrete work, the contractor shall get all cement
aggregates and water tested in the laboratories approved by the EIC and shall keep the
approved samples in the site office for inspection at any time of the concreting
operation. The test certificates shall be submitted to EIC for review & approval before
concreting. During construction also, the materials shall be sampled and tested as often
as deemed necessary and also as per the “Periodicity of Testing” by the EIC. Samples
shall be taken and tested in accordance with the latest revision of relevant Indian
Standard Specifications and the cost thereto shall be borne by the Contractor.
1.4 CEMENT :
The cement used throughout the work shall be to the approval of the EIC. A certificate
shall be obtained from the manufacturers and produced to EIC for each delivery of
cement and it shall comply with the requirements of as mentioned in the “Technical
Specification – Materials” . The Contractor shall store the cement in storage sheds to be
provided by him for this purpose at site. The cement shall be delivered to the site in
bags sealed with the manufacturer's seal and different types of cement shall be stored
separately. The storage sheds with watertight walls and roof, shall be maintained in a
perfectly dry and wall ventilated condition, 12" above ground level and the cement shall
be stored a per instructions issued by EIC. It shall be turned over from the bottom as
and when required by the EIC. Any cement which has been deteriorated caked or which
has been damaged due to any reason whatsoever shall not be used. No cement shall
be used for the works that has been stored at site for more than three months. Test
samples of cement may be drawn from each consignment as delivered and tested by
the EIC. Should the results of such test show that any samples does not comply with
the specified requirement, the whole consignment from which the sample was taken,
shall be rejected and forthwith removed entirely from the site and replaced with cement
of satisfactory quality.
Page 2 of 15
1.5 SAND :
Sand to be used for concrete shall be well graded mixture from coarse to fine grains,
complying with the requirements of IS 383 Latest edition. It shall be clean, hard and free
from salt, earth, clay and other impurities. Fine sand confirming to Zone – iv shall not be
used. It will comply with sieve analysis in accordance with IS 2386 Part I & II.
Unless initially clean, all sand shall be thoroughly and carefully cleaned by screening
and washing in fresh and clean water. The screened and washed sand shall not contain
more than 8% by volume of clay, dust and silt immediately after allowing it to settle for 3
hours in water.
Field tests shall be carried out regularly to ensure the suitability of sand.
Sample loads shall be available at site for inspection of the EIC and if approved by him
all sand in the work shall be of quality at least equal thereto.
In case of sand containing moisture the proportions of concrete materials shall be
adjusted to give the correct mixture.
1.6 COARSE AGGREGATE :

The coarse aggregate for the reinforced concrete work shall consist of crushed gravel,
black trap, granite or other stone to the approval of the EIC and shall be free from dust
confirming to IS – 383 latest edition. If considered necessary by the EIC, the aggregate
shall be washed specially until an approved cleanliness is obtained. The use of
laminated stone, flat or flaky material will not be permitted. The combined coarse
aggregate shall in all respects be so graded as to allow 95% to 100% by weight to pass
a 20mm I.S. sieve 25% to 55% by weight to pass a 5mm I.S. sieve and 0% by weight to
pass a 5mm I.S. sieve. The aggregates of different sizes shall be stored in separate
stacks in clean state and free from all dirt.
The coarse aggregate where absorption of water after 24 hours immersion is more than
5% by weight shall not be used.
When required by the EIC the tests indicated in I.S. 383 or IS-2386 ( all parts ) shall be
got carried out by the Contractor at his cost to show the acceptability of the materials.
Stowage piles of aggregate shall have good drainage, preclude inclusion of foreign
matter and preserve the gradation.
1.7 WATER :
Water used for all purpose in this contract shall be free from oil, acid, vegetable matter,
salts or dirt of any kind which will have adverse effect on cement or steel in the case of
reinforced concrete. Whenever called for, the Contractor shall produce test results for
water being used on work. The water quality shall confirm to IS-456-2000.
1.8 ADMIXTURES:
Page 3 of 15
Admixtures or Cement containing additives (such as accelerators, retarders, water
proofing agents etc.) shall not be used unless specified or otherwise directed or
approved by the EICs). The Admixtures shall confirm to IS-9103 latest edition.
1.9 FORM WORK :
The form work shall be designed and constructed in such a manner that all concrete
work shall be true to line, level and size, and free from honeycombing, pinholes, surface
irregularities and every other defect whatsoever.
All form work shall be adequately propped, braced and framed to prevent deformation
under weight and pressure of wet concrete, constructional loads, wind, vibrations and
other forces. All joints in shuttering shall be close fitting to prevent the loss of cement
paste or mortar from the concrete.
All form work shall be carefully cleaned and coated with an approved proprietary mould
oil before use, care being taken to keep all reinforcement away from contact with such
oil. All moulds shall be free from sawdust, shavings, dirt, mud or other debris by hosing
with water or oil free compressed air.
The shuttering for beams and slabs shall be erected so that the shuttering on the sides
of the beams and of the soffits of the slabs can be removed without disturbing the beam
bottoms. For beams having spans greater than 6 meters and for cantilevers, the form
work shall be given adequate upward camber as directed by the EIC.
Details of all temporary work (timbering, staging etc.) are to be submitted for the
approval of the EIC and the form work shall be inspected and approved by the EIC
before concrete is placed within it. Notwithstanding such approval, any damage or
consequences arising there from shall be the Contractor's entire responsibility.
1.10 PROPORTIONS FOR CONCRETE:
The contractor shall design concrete mixes (by Ready Mix Concrete Plants ) to produce
concrete of the required strengths. The contractor must submit full designs done from
RMC plants of the mixes for approval of EIC and trial mixes will be prepared by the
contractor in the presence of the EIC, having workability, strength, minimum cement
content and surface finish as criteria. Notwithstanding the acceptance by the EIC of any
mix design and series of trial mixes, variations may be made to the proportions when
considered necessary by the EIC. Such variations may be made also to normal mixes if
used, but variations of this nature will not be allowed to affect the unit price of concrete.
For both Nominal as well as Design mix concrete, the quantity of cement shall be
determined by weight. Where standard bags of cement are used, their weight shall be
checked at frequent intervals and any loss in weight due to leakage etc. shall be made
good.
In the case of Nominal Mix concrete, aggregates shall be measured by volume, cement
by weight and mixing water in graduated cans. In the case of controlled concrete all
Page 4 of 15
aggregates and cement shall be measured by weight in approved weigh batching
equipment. Mixing water shall be measured in graduated cans.
While calculating the amount of mixing water, the moisture content of the aggregates
shall be taken into account.
The grades of concrete shall be in accordance with Table below the cement content of
the mixes specified shall not exceed the minimum content specified in Table by more
than 20%.
READY MIX CONCRETE :
The provision in this section shall apply to all concrete grades and is to be considered
as a supplementary to general provisions for Plain Cement Concrete & Reinforced
Cement Concrete works.
• Ready mix concrete (RMC) may be manufactured in a central automatic weigh batching
plant and transported to the job by agitating Transit mixers. The RMC is to be sourced
from reputed & approved batching plants as mentioned in the approved list of
manufacturers or suppliers only. The design mix has to be submitted to HPCL before
concreting and the same has to be approved by HPCL before concreting is done.
• The design mix is to be carried out as per IS-10262.
• Note : No puzzolonic material such as Fly ash, Metakaoline & rice husk ash etc shall be
used for the work.
• The standard deviation for concrete mix design will be considered as per Table 8 of IS-
456-2000.
• The proportion of fine aggregates to coarse aggregates should be adjusted so as to

keep them within the specified limits as mentioned in IS-383.
• The Bidders have to submit the Quality Assurance Plan of theirs as well as the RMC
plant for approval and shall strictly adhere to the same.
• The admixtures used shall confirm to IS-9103.
APPLICABLE CODES AND SPECIFICATIONS;
The following specifications, standards and codes are made a part of this specification. All
standards, tentative specifications, codes of practice referred to herein shall be the latest
editions including all applicable official amendments and revisions.
In case of discrepancy between this specification and those referred to herein, this
specification shall govern.
APPLICABLE IS SPECIFICATIONS AND CODES OF PRACTICE:

Page 5 of 15
IS 269:- Specification for ordinary, rapid hardening and low heat portland cement.
IS-10262: Recommended guidelines for concrete mix design.
IS 8112:- Specification for high strength ordinary, portland cement.
IS 1489 - Specification for portland - pozzolona cement.
IS 383:- Specification for coarse and find aggregates from natural source for concrete.
IS 455: - Specification for Portland Slag Cement
IS 2386:- Methods of test for aggregates for concrete. (Part I to VIII)
IS 516:- Method of test for strength of concrete.
IS 1199:- Method of sampling and analysis of concrete.
IS 3025:- Methods of sampling and test (Physical and chemical) water used in industry.
IS 432:- Specification for mild steel and medium tensile steel (parts I & II) bars and hard drawn
steel wire for concrete reinforcement.
IS 1139:- Specification for hot rolled mild steel and medium tensile steel deformed bars for
concrete reinforcement.
IS 4926: Ready Mix Concrete – Code Of Practice
IS 1566:- Specification for plain hard drawn steel wire fabric (Part I) for concrete
reinforcement.
IS 1786:- Specification for cold twisted steel bars for concrete reinforcement.
IS 2645:- Specification for integral cement waterproofing compound.
IS 456:- Code of practice for plain and reinforced concrete.
IS 3370:- Code of practice for concrete structures for storage of liquids (Part I to IV)
IS 2502:- Code of practice for bending and fixing of bars for concrete reinforcement.
IS 2571:- Code of practice for laying in situ cement concrete flooring.
IS 3596:- Safety code for scaffolds and ladders. (Part I & II)
IS 1200:- Method of measurement of building works.
Page 6 of 15
In the event that state, city or other Government bodies have requirements, more stringent
than those set forth in this specification, such requirements shall be considered part of this
specification and shall supersede this specification where applicable.The quality of materials ,
method and control of manufacture and transportation of all concrete works irrespective of the
mix , whether reinforced or otherwise, shall conform to the applicable portion of this
specification.Engineer shall have the right to inspect the source/s of material/s , the layout of
operations of procurement and storage of materials, the concrete batching and mixing
equipment and quality control system. Such an inspection shall be arranged and approval of
Engineer-In-Charge shall be obtained prior to starting of concrete work. Concrete shall be
mixed by mechanical mixer only and no hand mixing shall be allowed for RCC works.
GENERAL:
The quality of materials and method and control of manufacture and transportation of all
concrete work irrespective of mix, whether reinforced or otherwise, shall conform to the
applicable portions of this specification.Engineer shall have the right to inspect the source/s of
material/s, the layout and operation of procurement and storage of materials, the concrete
batching and mixing equipment, and the quality control system. Such an inspection shall be
arranged and Engineer’s approval obtained, prior to starting of concrete work.
MATERIALS FOR STANDARD CONCRETE:
The ingredients to be used in the manufacture of standard concrete shall consist solely of a
standard type portland cement, clean sand, natural coarse aggregate, clean water and
admixtures, if specially called for on drawings or specifications.
CONSISTENCY:
The consistency of the concrete shall be such that it flows sluggish during pumping of concrete
into the forms and around the reinforcement without any segregation coarse aggregate from
mortar. The slump tests are mandatory and shall be carried out at regular intervals so that the
consistency concrete can be monitored.
PLACING OF CONCRETE:
Concreting shall commence only after inspection and written approval by EIC.
Shuttering shall be clean and free from deposits of foreign materials and proper deshuttering
agent shall be applied to the surface.
Proper arrangements shall be provided for conveying the concrete the place of deposition
without disturbing the reinforcement.
COMPACTION:
Concrete shall be compacted immediately after placing by means of mechanical vibrators.

All RCC works shall be cured for a minimum period of 14 days or more as advised by EIC.
INSPECTION AND RECTIFICATION OF DEFECTS:
Page 7 of 15
Immediately on removal of forms, the RCC works shall be examined by the Engg. -in-Charge /
Architects before any defects are made good.
The work that has sagged or contains honey combing to an extent detrimental to the structural
safety or architectural concept shall be rejected.
Surface defects on a minor nature may be accepted and the same shall be rectified as follows
:
a) Bulges due to movement of forms, ridges at forms, ridges at form joints shall be carefully
chipped and then rubbed with a grinding stone.
b) Honeycombed and other defective areas must be chipped out, the edges being out as
straight as possible and perpendicular to the surface. Shallow patches are first treated with
a coat of thin grout (1 cement : 1 sand) and then filled with mortar similar to that used in
concrete. Large and deep patches shall be filled up with concrete held in place by forms
and shall be reinforced.
c) Holes left by bolts shall be filled carefully with mortar. Holes extending right through the
concrete shall be filled with mortar with a pressure gun.
d) The same amount of care to cure the material in patches should be taken as with the whole
structure.
POST TREATMENT OF SURFACE :
The surface which has to receive plaster or where it has to be joined with brick masonry walls
shall be properly roughened immediately after the shuttering is removed.
ACCEPTANCE CRITERIA OF CONCRETE WORK : will be as per IS-456-2000(CL.16).
MEASUREMENT
All measurements shall be as per IS 1200
1.11 MIXING OF CONCRETE:
Mixing of concrete shall continue until there is a uniform distribution of material and the
concrete is uniform in colour and consistency and for at least two minutes.
Page 8 of 15
Mixes and weigh batches shall be maintained in first class condition throughout the
contract and any mixer or plant which is faulty shall not be used. The drums on all
mixers shall revolve at the speed recommended by the maker. A mixer of any type
which has been out of use for more than 20 minutes shall be thoroughly cleaned out
before any fresh concrete is mixed. All equipment shall be maintained in a clean
serviceable condition and their accuracy periodically checked.
1.12 SLUMP TEST :
The Contractor shall keep at the site of the works for the EIC’s use or his representative
a standard slump test mould and shall provide facilities throughout the construction for
tests to be made as and when the EIC may require.
1.13 COMPRESSIVE STRENGTH : Concrete shall confirm to IS-456-2000.(Clause.16)
The Contractor shall keep on site minimum 12 no.s standard 15 cm test cube moulds
and ancillary equipment for preparing test cubes. Before the Contractor commences
any concrete construction he shall make six cubes of mix concrete with the cement
sand, aggregate and water which he proposes using on the contract and shall have
them tested at a Laboratory approved by the EIC/EIC. Three cubes shall be tested at 7
days and three cubes at 28 days after casting and curing. In all cases the cubes shall
give the minimum compressive strength. No concrete construction shall be commenced
until Preliminary Tests on the six cubes referred above have been completed and
results show the concrete to have the minimum compressive strength. As construction
proceeds samples from fresh concrete shall be taken as per IS 1199 - 1959 and cubes
shall be made, cured and tested in accordance with IS 516 1959.
Three test specimens shall be made from each sample for testing at 28 days. Additional
cubes may be required for various purposes as to determine the strength of concrete at
7 days or at the time of striking form work, or to determine the duration of curing, or to
check the testing error.
The test strength of the sample shall be the average of the strength of three specimens.
The individual variation should not be more than 15 percent of the average.
Any part of the work from which the cubes fail to give the required minimum
compressive strength shall be dealt with by the Contractor as directed by the EIC and at
the expenses of the Contractor.
The concrete is also liable to be rejected or repaired as per the instructions of the
EIC/EIC if it is porous or honeycombed, its placing has been interrupted without
providing a construction joint or the reinforcement has been disproportionately
displaced. The rejected concrete has to be demolished and redone to the satisfaction of
the EIC free of cost.
Page 9 of 15
The Contractor shall keep a daily record (Concrete Pour Card ) showing the date when
each portion of concrete is poured in slab, beam, column etc., curing, removal of form
work and test cube results at 7 days and 28 days period. They shall be sent
immediately to the EIC/EIC.
1.14 TRANSPORTING, PLACING AND COMPACTING OF CONCRETE :
The concrete shall be transported maintaining required workability in a manner such as

to avoid the segregation of the constituent materials, and loss of any of the ingredients.
It shall be deposited as nearly as practicable in its final position to avoid re handling. It
shall be placed and compacted before setting commences and should not be
subsequently disturbed. Methods of pouring should be such as to preclude segregation,
and to avoid displacement of reinforcement and movement of form work. Concrete
Pumping needs to be arranged for conveying the concrete from transit mixers to work
spot.
The concrete should be thoroughly compacted and fully worked around the
reinforcement, around embedded fixtures and into the corner of the form work without
formation of honeycombing, pinholes or surface irregularities and any other defects
whatsoever.
The use of mechanical vibrators having capacity of producing vibrations at a rate not
less than 5000 cycles per minute is recommended. Over vibration or vibration of very
wet concrete is harmful. In addition to mechanical vibration, sufficient hand tools must
be used to assure full consolidation around reinforcement and at edges and corners.
The deposition of concrete shall be carried out as continuously as possible to reduce to

minimum joints between new concrete and concrete which has set. Where construction
joints are necessary they shall be formed at right angles to the axis of the member
concerned by the insertion of rigid stopping off forms, against which concrete can be
properly rammed or as per the advise of Structural EIC..
No unset concrete shall be brought into contact with unset concrete containing cement
of different type. Special permission and instructions shall be obtained when concrete
has to be deposited under water.
Accumulation of set concrete on the reinforcement shall be avoided. Before fresh

concrete is deposited upon or against any concrete which has already hardened, the
surface of hardened concrete shall be well roughened if necessary by chipping and
laitance remove. The surface shall then be swept clean with wire brushes, thoroughly
wetted and covered with a thin layer of cement mortar.
1.15 PROTECTION OF CONCRETE :
Newly placed concrete shall be protected by approved means from rain, sun and drying
winds. Concrete placed below the ground shall be protected from falling earth during
and after placing. Approved means shall be taken to protect immature concrete from
damage by debris, excessive loading, vibration, abrasion, deleterious ground-water,
Page 10 of 15
mixing with earth or other materials that may impair the strength and durability of
concrete.
1.16 CONSTRUCTION JOINTS :
Before construction commences the Contractor shall submit to the EIC, for his
approval, sketches showing proposed positions of construction joints.
Each section of concrete shall be poured continuously between construction joints.

Shuttering to all construction joints should be so made that it produces on the face of
joints a suitable grooved or indented surface to act as a sheer key or bond for the
subsequent concrete. Inclined joints shall not be permitted.
If the concrete has been allowed to harden excessively, the surface shall be chipped
over its whole surface to a depth of at least 3/8"and thereafter thoroughly washed. If the
concrete has not fully hardened, all laitance shall be removed by scrubbing the wet
surface with wire brushes to avoid dislodgement of particles of aggregate. Before fresh
concrete is added to the other site of a construction joint the surface of the old concrete
will be thoroughly wetted and then covered with a thin layer of cement mortar of the
same quality as that in the concrete.
No distortion or displacement of reinforcement from the positions shown on the

drawings shall be permitted at construction joints.
Water stoppers shall be provided to the construction joints of terrace slabs, kitchen and
bathroom slabs, and water retaining structures where water leakage poses serious
problems.
1.17 STRUCTURAL JOINTS :
Expansion joints or other permanent structural joints shall be provided in the positions
and of the form described in the drawings or elsewhere. In no case shall the
reinforcement, corner protecting angles or other fixed metal items, embedded or
bonded into concrete run continuously through as expansion joint. The placing of
concrete on either side of the expansion joint shall be done separately after an interval
of atleast 7 days.
1.18 CUTTING INTO CONCRETE :
No concrete shall be cut into, nor shall it be interfered with in any way, without the prior
approval in writing of the EIC. Necessary holes shall be provided as required for
plumbing work and for electrical pipes etc. at the time of execution.
1.19 CURING OF CONCRETE :
Exposed surfaces of concrete shall be kept continuously in a damp or wet condition for
at least seven days from the date of placing of concrete.
Page 11 of 15
Approved curing compounds may be used in lieu of moist curing with the permission of
the EIC. Such compounds shall be applied to all exposed surfaces of the concrete as
soon as possible after the concrete has set.
1.20 SUPERVISION:
Constant and strict supervision of all the items of the construction is necessary during
the progress of the work, including the proportioning and mixing of the concrete.
Supervision is also of extreme importance to check the reinforcement and its placing
before being covered.
Before any important operation, such as concreting or striking off the form work is
started, adequate notice shall be given to the EIC.
1.21 CONTRACTOR'S RATES TO INCLUDE :
The rates of contractor for providing and laying cement concrete in various grades or
proportions in the Schedule of Quantities shall, apart from any other factors specified
elsewhere in the tender documents, include for the following:
(a) For all factors and method of work described in these specifications.
(b) For all materials, labour, tools and plants, scaffolding, etc. mixing, conveying and
placing concrete in position, ramming, vibrating, trawling, curing, providing necessary
scaffolding and removing the same after the work is complete.
(c) Unless otherwise specified in the Schedule of Quantities the cost for concrete items
shall include for providing and fixing form work as described inclusive of erecting,
propping to required heights, bracing, providing stays, struts, bolts, nuts and everything
necessary to keep the forms rigid, smoothening the surface to receive concrete as per
detailed drawing, striking and stripping form work after the concrete is cured, hacking
the concrete surface required to receive plaster etc.
(d) The reinforcement in case of Reinforced Concrete work will be paid for separately
unless otherwise stated in the particular items, but rate shall include for pouring
concrete and packing around reinforcement.
(e) The measurement of concrete will be as per detailed drawings, shapes and size based
on net structural sizes as per drawings i.e. exclusive of plaster.
(f) Rates for concrete items shall cover for any shape of structural members like columns,
beams, facias, fins, louvers etc. and for cantilevered beams slabs etc.
(g) Formation and treatment of contraction and expansion joints (where water bars like
copper strips or joint fillers like 'Shalitex' are specified, such materials shall be paid for
separately.
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(h) Design of mixes where so required by specification in an approved Laboratory and on
tests of materials and work required in the opinion of the EIC and described in these
specifications.
(i) Fixing all inserts like pipes, plugs, forming holes etc. as described.
(j) Weigh-batching using a Mechanical weigh-batcher or a batching plant or where so

specified for volumetric batching.
(k) For taking out dowel bars, fan hooks etc. through shuttering.
(l) In case where at the junctions of beams, columns, slabs, the composition of concrete
mix or specified strength be different for columns, beams and slabs, then in such cases
only the richer concrete among those specified for in all these members shall be used at
the junctions and rate quoted for columns, beams and slabs or any member entering
such junctions shall allow for the same. Rate shall also cover for spill over of richer
concrete in beams to natural angle of repose of wet concrete required from practical
considerations, while concreting the junctions.
(m) For forming drip moulds in Chajjas, sills, etc. and where shown in the drawings or as
directed.
(n) For work at all levels.
2 STEEL REINFORCEMENT :
2.1 HIGH STRENGTH DEFORMED BARS :

Wherever deformed high strength reinforcement bars are specified, the contractor shall
use one of the following, accompanied by a certificate from the Manufacturer like
TATA/SAIL/VIZAG only confirming to IS-1786 latest edition.
2.2 CLEANING OF REINFORCEMENT :

Before steel reinforcement is placed in position, the surface of the reinforcement shall
be cleaned of rust, dust, grease and other objectionable substances.
2.3 CUTTING OF REINFORCEMENT :

Before the reinforcement bars are cut, the contractor shall study the lengths of bars
required as per drawings and shall carry out cutting only to suit the sizes required as per
drawings.
2.4 PLACING AND SECURING :

Reinforcement bars shall be accurately placed and secured in position and firmly
supported or wedged by precast concrete blocks of suitable thickness, at sufficiently
close intervals, so that they will not sag between the supports or get displaced during
the placing of concrete or any other operation of the work. It is most important to
maintain reinforcement in its correct position without displacement and to maintain the
Page 13 of 15
correct specified cover. Contractor shall be responsible for all costs for rectification
required in case the bars are displaced out of their correct position.
2.5 BINDING WIRE :

The reinforcement shall be securely bound wherever bars cross or wherever required
with 18 gauge soft annealed steel wire.
2.6 WELDING :
Welding of bars shall not be carried out unless specially authorised in writing by
Structural EIC.
2.7 BENDS ETC :

Bends, cranks etc. on steel reinforcement shall be carefully formed, care being taken to
keep bends out of winding. Otherwise, all rods shall be truly straight. If any bend shows
signs of brittleness or cracking, the rod shall be removed immediately from the site.
Minimum radius of 9 times diameter of the bar shall be used unless otherwise specified
in the drawings. However, in respect of standard hooks the radius of bend shall be 2
times of diameter of bar. Heating of reinforcement of bar to facilitate bending will not be
permitted. The bars shall always be bent cold.
In case of mild steel reinforcement bars of larger sizes, where cold bending is not
possible, they may be bent by heating with written permission of the Project Engineer.
Bars when bent hot shall not be heated beyond cherry red colour and after bending,
shall be allowed to cool slowly without quenching. The bars damaged or weakened in
any way in bending shall not be used on the work. High strength deformed bars shall in
no case be heated to facilitate bending or cranking.
2.8 INSPECTION OF REINFORCEMENT :

No concreting shall be commenced until the Structural EIC has inspected the
reinforcement in position and until his approval has been obtained.
A notice of at least 24 hours shall be given to the Project Engineer by the Contractor for
inspection of reinforcement.
If in the opinion of the Project Engineer any material is not in accordance with the
specification or the reinforcement is incorrectly spaced, bent or otherwise defective, the
contractor shall immediately remove such materials from the site and replace the same
and rectify any other defects in accordance with the instruction of the Project Engineer
to his entire satisfaction.
2.9 NET MEASUREMENTS :

Reinforcement shall be placed as shown on the structural drawings and payment will be
made on the net measurements from drawings. No laps, dowels, chairs and pins in
reinforcement shall be paid for. The Contractor shall allow in his quoted rate for all
wastage which will not be paid for.
Page 14 of 15
2.10 RATES QUOTED FOR REINFORCEMENT SHALL IN ADDITION TO ANY FACTORS
MENTIONED ELSEWHERE SHALL ALSO INCLUDE FOR :
(a) All cutting to lengths, labour in bending and cranking, forming hooked ends, handling,
hoisting and everything necessary to fix reinforcement in work as per drawings.
(b) Cost of binding wire required as described.
(c) Cost of PVC blocks to maintain cover and holding reinforcement in position.
(d) For fabricating and fixing reinforcement in any structural member irrespective of its
location, dimensions and level.
(e) Removal of rust and every other undesirable substances, using wire brush etc. as
described.
(f) Stock piling of reinforcement as described.
(g) Work at all levels.
Page 15 of 15
SPECIFICATION OF MECHANICAL SHOE SEAL (LIQUID MOUNTED
MECHANICAL SEAL)
Mechanical Shoe Seals comprise a metallic sealing ring, which is held in

permanent contact with the tank shell and extends into the product by a system
of independent hanger and pusher mechanisms, and with a continuous sealing
apron curtain closing the gap between the rim and the top of the “Shoe”. The
product vapors are contained between the “shoe”, apron curtain and the floating
roof.
The design of the Mechanical Shoe Seal should be “Channel Hanger” Type with
independent hanger and pusher devices. The design of the Mechanical Shoe
Seal should be such that in service installation is enabled with no hot work
allowed i.e. no welding or flame cutting. The Mechanical Shoe Seal should
conform tightly to shell plate contours
adaptable to existing rim and shell configuration, including wide variations in rim
gap.
The seal is characterized by a shoe-to-shoe slip joint connection, which allows

for any variation in the rim space irregularities between the rim and tank shell,
while containing the product vapors.
It should be custom designed to suit the tank.
The Channel hanger type assembly should successfully maintain a constant seal
elevation even with a wide rim space.
Stainless steel shoes shall have a minimum nominal thickness of 1.2 mm (18
gauges). Stainless steel shall conform to the requirements of ASTM A 240/A
240M (austenitic type only).
Pusher mechanism should be SS conforming to the requirement of Stainless

Steel as given above.
Static Shunt to be SS conforming to the requirement of Stainless Steel as given

above.
All fasteners shall be Stainless Steel only.

Hanger Channels assembly should be minimum 14 gauge.
Seal Curtain/ Dip Curtain should be compatible with stored product,
recommended 0.5mm thk PTFE.
A protective mechanism should be provided to protect the vapour curtain.
VENDOR / MANUFACTURER ELIGIBILTY

Vendor shall have proven experience in supplying & installing the mechanical
Shoe Seal in India with necessary documentary proof for having executed such
jobs in the last 2 Years for a minimum dia of 30 Mtr.
Page 1 of 5
INSPECTION CRITERIA :
Maximum seal gap area will be 200 cm2/m of tank diameter.
Vendor should inspect the seals once in six months during guarantee / warrantee
period & Vapour loss calculations meeting CPCB standards to the relevant
clause using Tank 4.0 (latest version) software, incorporating local weather
conditions shall be provided along with the inspection report.
Scope of Third Party Inspection
Seal Curtain: Testing of properties to be witnessed and verified.

Other tests to be carried out at a reputed laboratory and the results shall be
furnished for review / approval.
GUARANTEE: 24 months from the date of installation & 30 months from the date of
supply which ever is earlier.
Page 2 of 5
Specifications of Secondary Seal
Secondary seal shall be of compression plate rim mounted horizontal or vertical

(preferably horizontal), made from series of metallic sheet joined together to form
a ring with a non-metallic tip that slide on the inside surface of the tank shell. The
joints to be bolted or sliding and to incorporate gasket at the point of overlap of
the compression plate.
Compression plate of the secondary sealing system should be sized to match
the existing annular space between the tank shell & the floating roof. The
compression plate should be clamped on the Rim flat/angle with channels duly
galvanized. The compression plate to have the compression channel gasketing.
It should provide “Leak tight” joint between the plates. Each seal plate should be
sealed with the adjacent plate in a fashion to eliminate vapor loss.
Stainless steel compression plates shall have a minimum nominal thickness of

1.2 mm (18 gauge). Stainless steel shall conform to the requirements of ASTM A
240/A 240M (austenitic type only).
Static Shunt to be SS conforming to the requirement of Stainless Steel as given

above.
All fasteners to be galvanized for seals of galvanized construction & SS for SS

construction.
A protective mechanism should be provided to facilitate smooth re-entry of the
secondary Seal onto the Tank Shell in the event of Tank overfilling.
Secondary seal system shall be tight fitted, rim mounted, with a wiper Tip made
of a polymer compatible to the stored product.
The Sealing Gasket to be made of a polymer compatible to the stored product.
Seal shall have very low coefficient of friction, shall not damage or score the tank
shell. Metallic seal components shall have adequate corrosion protection for long
life. All material used in the seal manufacturing shall be tested and certified for
extended use in hydrocarbon products.
It should be custom designed to suit the tank.

Additionally, the secondary seal should have the following design features,
A. Safely ground lightening strike.

B. Minimize seal gap and shed water to the extent possible.
C. Capable in operating effectively over irregular rim gaps.
D. To install from above the deck without any hot works.
Page 3 of 5
E. Seal material must be compatible with product stored.
F. Non-metallic parts must resist cracking and tearing.
G. Metallic components must resist corrosion.
H. To be able to dismantle the secondary seal, without affecting
evaporative loss control characteristics of primary seal.
I. Secondary seal shall extend from the roof to the tank shell and shall
not be attached to the primary seal.

Vendor shall have proven experience in supplying & installing the mechanical
Shoe Seal in India with necessary documentary proof for having executed such
jobs in the last 2 Years for a minimum dia of 30 Mtr.
INSPECTION CRITERIA :
Maximum seal gap area will be 20 cm2/m of tank diameter.
Vendor should inspect the seals once in six months during guarantee / warrantee
period & Vapor loss calculations meeting CPCB standards to the relevant clause
using Tank 4.0 (latest version) software, incorporating local weather conditions
shall be provided along with the inspection report.
Scope of Third Party Inspection.
Wiper Tip Material : Testing of properties to be witnessed and verified.

Tests of other components to be carried out at a reputed laboratory and the
results shall be furnished for review / approval.
GUARANTEE : 24 months from the date of installation & 30 months from the date of
supply which ever is earlier.
Page 4 of 5
Page 5 of 5
Specification for Gauge Pole Sleeve / Landing Leg Sleeve
The Gauge Pole Sleeve shall consist of a flexible enclosure to be installed over existing
slotted gauge pole along the height of the pole and can adjust its height depending
upon the height of the deck in an external floating roof tank. The Landing Leg Sleeve is
a flexible enclosure to be installed over existing telescopic landing legs along the height
of the pipe. This flexible enclosing device should completely enclose the slotted gauge
pole and the landing leg while eliminating VOC emission pathway from inside the tank
through the gauge pole slots and the landing legs. It should also seal any opening
between well cover and any other openings in the gauge pole well & landing leg area.
Gauge pole sleeve / Landing leg sleeve shall be self adjusting type and can be easily
retrofitted on existing gauge poles & landing legs. The Gauge Pole Sleeve / Landing leg
sleeve shall be provided to minimize emissions through the gauge pole slots and
landing leg area.
The detailed specifications of the gauge pole sleeve shall be as follows,

1. It should be custom designed to suit the pole & leg of the floating roof tank.
2. Gauge pole sleeve / Landing Leg Sleeve material shall be a minimum of 0.4 mm
thickness.
3. The Sleeve material shall be non corrosive while handling petroleum hydrocarbons.
4. The Sleeve material shall withstand Rain water.
5. The Sleeve material shall be 100% compatible & corrosion free for any type of
Hydrocarbons.
6. The finished sleeve material shall be free of all oils, solvents and release agents. The
material should be of uniform thickness and be free from cosmetic defects.
7. The sleeve Material fabric shall not wick or become brittle during its service life. The
Gauge pole sleeve material will be resistant to the effects of wind, rain, sand, UV rays &
be suitable for service up to +800 C.
8. The gauge pole sleeve / landing leg sleeve should be able to be installed while the
tank is in service.

Vendor shall have proven experience in supplying & installing the gauge pole sleeve /
landing leg sleeve in India with necessary documentary proof for having executed such
jobs in the last 2 Years.
INSPECTION CRITERIA:
Vendor should inspect the Sleeve once in six months during guarantee / warrantee
period & Vapor loss calculations using Tank 4.0 (latest version) software, incorporating
local weather conditions shall be provided along with the inspection report.
Scope of third party inspection

Gauge Pole / Landing Leg Sleeve Material: Testing of Properties to be witnessed &
Verified.
Page 1 of 2
Tests of other components to be carried out at a reputed laboratory and the results
shall be furnished for review / approval.
GUARANTEE : 36 months from the date of installation & 42 months from the date of supply
which ever is earlier.
Page 2 of 2
SPECIFICATION FOR
UNBONDED FLEXIBLE PIPE
FOR
TANK ROOF DRAIN SYSTEM
OF
FLOATING ROOF TANKS
Page 1 of 3
1.0 SCOPE
1.1 This specification covers design, manufacturer, supply, testing

supervision of installation and guarantee of unbonded flexible hose pipe
including connecting flanges for floating roof tank as per API-650 latest
edition.
1.2 The manufacturing plant shall be API – 17J certified. Approved
Manufacturer ( A) Coflexip (Flexi France) ( B) Well stream Holding Plc
U.K (C) NKT Flexible Denmark
2.0 TECHNICAL SPECIFICATION
2.1 Flexible pipe shall consist of two layers, each layer unbonded to each other as
follows:
Inner layer shall be SS type 304 Carcass.
Outer layer shall be polyamide/thermoplastic made of Nylon 11,

Rilsan brand.
Each layer shall be un bonded as per Cl.3.46 of API17J(3rd edition, July

2008).Interchangeability of layers is not allowed.
The inner carcass should be of interlocked metallic construction as per

cl.3.12 of API17J(3rd edition, July 2008).
Flexible pipe must be 100% resistant to aromatics and petroleum

products stored in the subject tanks and should confirm to Cl.5.2.1 of API
17J. The design life of pie should be 20 years.
Flexible pipe must provide Repetitive Lay Pattern (RLP) without any
external support or accessories like tethered assemblies, ballasting etc.,
during its full operational life.
Poly amide extrusions should confirm to Cl.8.3.1.2 of API17J(3rd edition,

July 2008).
Assembled hose will not be acceptable. The bidder shall manufacturer

both layers independently as per 17J.
Flexible pipe shall have Built-in end fittings with ASME B 165, 150# CS
RF swivel flange.
Page 2 of 3
Full length of pipe shall be in single continuous length without any
intermediate joints in between the two end flanges. Vulcanization is not
acceptable.
The unbounded flexible hose should be designed in such way that the
inner SS type 304 carcass is held in tension to keep the hose in same
position as it was when installed. No kinking of flexible pipe shall take
place during movement (upward/downward) of the roof.
No chemical attack, Gas penetration or ballasting and mechanical wear

shall take place with the flexible pipe.
Flexible pipe shall not induce lateral forces on the floating roof.
2.2 Vendor shall guarantee the product for minimum 3 years after installation.
2.3 Vendor /Manufacturer of the flexible pipe must have a minimum of 3 years of
field proven reference in India for similar application in floating roof tanks.
Relevant document from the customers shall be furnished along with bid.
2.4 Flexible pipe shall be inspected by Lloyds/DNV/EIL/ABS/Bureau Veritas or any

other Third Party Inspection Agency approved by HPCL and relevant certificates
shall be furnished.
2.5 The manufacturer shall provide hydro test certificates for the flexible pipe duly
certified by Third Party Independent Inspection agency.
2.6 Bidder shall specify the make offered in their unpriced bid along with all
necessary literature, catalogues, etc. for above.
Page 3 of 3
1. The vendor’s scope covers design, manufacture, supply, testing, installation, hydro test,
supervision of commissioning & guarantee of stainless steel armored hose as per API-650
(latest edition) including connecting flange for floating roof tank.
2. Stainless steel armored hose as per API 650 in contact with liquid stored in the tank must
be 100 % resistant to aromatics.
3. Stainless steel armored hose as per API 650 must provide REPETITIVE LAY PATTERN
(RLP) without any external support or accessories like tethered assemblies, ballasting,
chain etc, during its full operational life.
4. Assembled hose shall not be acceptable.
5. Flexible tube shall have built in end-fittings with ASME B 16.5 #150, A105 Flange.
6. The designed working pressure rating for the flexible drain tube should be 30 PSI and the
test pressure should be 60 PSI.
7. Full length of tube shall be in single continuous length without any intermediate joints
in between the two end flanges
8. The stainless steel armored hose should be designed in a way that the hose shall be kept
in the same position as it was when installed. No kinking of stainless steel armored hose
as per API 650 shall take place during movement (upward/downward) of the roof.
9. No chemical attack, gas penetration or ballasting and mechanical wear shall take place
with flexible tube
10. Stainless steel armored hose shall not induce lateral force on the floating roof.
11. Stainless steel armored hose shall be inspected by third party inspection agency
LLOYDS/DNV/CEIL/BV or any other third party inspection agency approved by HPCL.
12. Relevant certificate / documents (along with each flexible line) shall be furnished along
with supply
13. Third party inspection includes pressurizing the flexible hose to the test pressure (60 psi),
allow it to stabilize and maintain pressure for 4 hours & carry out a visual inspection for
leaks
14. The manufacturer shall provide hydro test certificate for the flexible hose duly certified
by third party inspection agency.
15.Vendor shall confirm the adequacy of the design of stainless steel armored hose as per
API 650(its size & length) for 100% evacuation when the roof is in its lowest position
during maximum rainfall intensity period
TECHNICAL
SPECIFICATIONS
FOR
PIPES
Page 1 of 4
TECHNICAL NOTES FOR PIPES
1.0] GENERAL
1] All pipe and their dimensions, tolerance, chemical composition and physical properties. Heat
treatment hydro test and other testing and marking shall conform to the codes and standards
specified herein. In case of any deviations the same should to be highlighted.
2] Test report shall be supplied for al mandatory test as per the applicable material specifications
Test report shall also be furnished for any supplementary test specified herein.
3] Material test certificates (physical properties chemical composition and Heat treatment report)
shall also be furnished for the pipes supplied.
4] Steel made by acid Bessemer process shall not be acceptable.
5] All longitudinally welded pipes other than IS: 3589 should employ automatic welding only.
Vendor shall specify the type of welding technique which will be employed.
6] Pipe shall be supplied in single random length OF 4 – 7 Mtrs.
7] Seamless and LSAW pipes shall not have any circumferential seam joint in a random length.
8] Pipes with Bevel ends shall be in accordance with ANSI B-16.25 weld contours shall be as
follows.
Material Wall Thickness Weld Contour

Carbon Steel [Except low Upto and incl. 22mm Fig. 2 type A
Temp. CS.]
9] Specified heat treatment for CS shall be carried out after weld repairs, number of weld repairs at
same spot shall be restricted to max two by approved repair procedure.
2.0] HYDRO TEST

As per relevant IS code ie. IS1978 / 3589 or 1239
3.0] MARKING AND DESPATCH
1] All pipe shall be marked in accordance with the applicable codes, standards and specifications.
In addition the PO No and item digit code will also be marked.
2] Point or ink marking shall not carry any harmful metal or metallic salts such as lead. Zinc or
copper which causes corrosive attack on heating.
3] Pipe shall be dry, clean and free from moisture, dirt and loss foreign material of any kind.
4] Pipe shall be protected from rust, corrosion and mechanical damage during transportation,
shipment and storage.
5] Rust preventive used on machined surfaces to be welded shall be easily removable with a
petroleum solvent or shall not be harmful to welding.
6] Both ends of the pipe shall be protected with the following material:
PE Plastic Cap
BE Wood, Metal or Plastic cover.
End protectors to be used on BE shall be securely and tightly attached with belt or wire.
Page 2 of 4
4.0] Quality and data/ documentation requirements
1] QA plan
Vendor during bidding stage shall confirm compliance to his Quality Assurance plan consisting
of relevant procedures covering various activities like design and engineering material
procurement, manufacture, inspection and testing documentation dispatch to site erection and
commissioning wherever applicable and maintenance of quality records in the post order stage.
The vendor shall confirm the validity of their QA plans and submit only deviation/revisions if
any to these plans to Sr. Manager –E&P HPCL 1 floor Hindustan Bhavan for approval within
two weeks from the date of receipt of FOI/PO whichever is earlier.
2] ITP
Vendor shall submit inspection and test plan for approval within 2 weeks of FOI/PO and before
commencement of manufacture to Sr. Manager –E&P and should cover bought out items from
sub vendors.
3] Drawing Schedule
Vendor shall submit a total index of drawings and documents required for review/records along
with the scheduled date of submission of each drawing/document within 2 weeks from date of
issue of FOI PO whichever is earlier where ever required.
4] Progress report and Schedule

Vendor shall submit Monthly Progress Report and update procurement engineering and
manufacturing schedule every month starting from 2 weeks from date of issue of FOI/PO
whichever is earlier.
5] Waiver and deviation

Vendor shall strictly comply with the PO stipulations and no deviations shall be permitted.
6] Procurement of Bought out Materials

All critical materials such as casting, forging, fitting, pressure holding parts electrical and
instrument accessories etc. shall be purchased by the vendor from HPCL approved suppliers
only. It would be preferable for the vendor to enlist the services of vendor having EIL approval.
Vendor shall submit a list of bought out materials for HPCL approval within 2 weeks from the
date of issue of FOI/PO whichever is earlier.
7] Calibration Records
Vendor shall use only calibrated measuring and test instruments and maintain calibration
records. Vendor shall furnish records of calibration of measuring and test instruments including
recalibration records to Third party inspection Agency on demand.
8] Inspection test status

Inspection and test status of products shall be identified by using markings. Authorized stamps,
tags, route cards, inspection cards etc. during the course of manufacture to clearly indicate
acceptance rejection of tests stages of inspection performed during its manufacturing cycle.
Page 3 of 4
9] Quality records
Vendor shall maintain quality records as per his procedures inspection reports & test records
copies shall be furnished to HPCL/Third Party Inspection Agency.
10] Identification and Traceability

Vendor shall establish and maintain a standard written procedure for identifying the products
from applicable drawing specifications or other documents during all stages of production
delivery and installation. A copy of this standard procedure shall be made available to
HPCL/Third Party Inspection Agency. The Vendor shall ensure that each product which is going
in the process of fabrication / manufacture / construction / erection has proper identification
throughout the process including the final output.
11] Vendor document for Review and Records
General
1] All documents shall be in English language and MKS system of units.

2] Review of the Vendor drawing by Third Party Inspection Agency / HPCL would be only
to review the compatibility with basic design and concepts and in no way absolve the
vendor of his responsibility to comply with PO requirements applicable codes,
specifications and statutory rules/regulations.
3] Submission of documents for review/records shall commence within 2 weeks from the
date of issue of FOI/PO
4] Unless otherwise agreed the vendor shall submit all drawings and document sin number
of copies as stipulated in the vendor data requirement from along with documents index.
The documents shall be submitted in soft copies wherever specified.
11.1] Vendor shall ensure that each drawing shall contain the following information:
PO No name of equipment, tag no., name of project, Client, Drawing/Document title,
Drawing No., Revision and date.
The drawing document shall be checked approved and duly signed stamped by the vendor
Revisions and date.
11.2] Documents under review Category.

Following review codes shall be used for review of vendor documents / drawings.
Code 1 Approved
Code 2 Proceed with manufacture / fabrication as per commented
Document revised document required.
Code 3 re submit for review as marked.
12] Final Documents

Final drawings/documents consisting of Technical Data Manual is a compilation of As-Built
Certified. Drawing and data manufacturing and test records.
Installation operating and maintenance instructions and each set shall include six copies.
Page 4 of 4
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bracings etc_ for approval of purchaser.
e) Cold straightening of section and plates, whenever they are bent and
kinked.
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g) Making arrangements for and conducting tests, such as chemical analysis,
physical and mechanical tests on raw materials 'here specified/as directed
by the purchaser,
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l. Loading, transportation from fabrication workshop to site of erection and

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3.3.5.6 Instrumental checking of correctness of initial setting out of structures and

adjustment of alignment shall be carried out in sequence and at different
stages as required. The final leveling and alignment shall be carried out
immediately after completion of each section of a building.
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5.1.3 INSPECTION AND APPROVAL OF SURFACE
• All painting materials including primers and thinners brought to site by the Contractor
for application shall be directly procured from Approved manufacturers as per
specifications and shall be accompanied by Manufacturer Test Certificates.
• HPCL may call for tests for the primers and paints including verification of batch wise
tests for physical and chemical analysis. The Contractor shall carry out the same at his
own cost and provide the results to HPCL.
• The painting work shall be subjected to inspection by HPCL at all times. Stages of
inspection are as follows:
• Surface Preparation
• Primer application
• Each coat of paint
• All records of inspection shall be maintained in Registers and jointly signed by HPCL
and Contractor.
• Any defect noticed during the various stages of inspection shall be rectified by the
Contractor to the satisfaction of HPCL before proceeding further. Irrespective of the
inspection, repair and approval at intermediate stages of work, Contractor shall be fully
responsible for making good any defects found during Final inspection or during the
Defect Liability period. DFT shall be checked and wherever shot same shall be made up
with additional coats.
• The shades of successive coats should be slightly different in colour in order to ensure
application of individual coats in consultation with manufacturer.
• Calibrated Digital Elcometers, surface profile gauges and any other inspection
instrument required by HPCL shall be provided by the contractor at site.
• The contractor shall arrange expert technical support at site by paint Manufacturer who
will cross verify independently regarding surface preparation and DFT and quality and
provide a report to HPCL.
5.1.4 DOCUMENTATION:
1.A written quality Plan with procedure for qualification trials and for actual work.
2.Daily progress Report with details of humidity, surface preparation, surface profile,
Dry film thickness particulars of applications, number of coats applied, type of
materials used, methodology-Air or Airless or Brush, progress of work vs programme.
3.Code and Batch numbers of primers and paint materials used.
4.Type of testing equipments and their calibration.
5.Elcometer readings for the various components jointly recorded with HPCL.
6.Paint consumption statement along with the Theoretical consumption requirements.
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ANNEXURE-V
PAINTING SYSTEM FOR STRUCTURAL STEEL/ MS GRATING/ SWING

PLATFORMS
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LIST OF APPROVED MAKE
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5 Paints M/s Berger Paints
M/s Asian Paints
M/s Goodlass Nerolac
M/s Jenson & Nicholson
M/s Shalimar Paints
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%
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*-07,-70 13 0< .15?
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& #
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, 7+1 0* 045 5 < * 040)2 E F ,1 6 +*
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- 0 / * .2 2 ,-)/ 0 *- 0- -( 3 12). *( 114 , 0 7115 / )2 2
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,( 0
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( / 3 12 0 ). 0, 6 .-0 00 2 - -( 7-*)2 -( +)+ 8. -6 0 -( . 6 6 0+)+ * . --(),< 0
-( . 66
Contractor
Date: P.O. No:

Tank No: Party:
Activity:- Job:
Heat No: Plate use Location:
Surface preparation
BOTTOM PLATE FINAL PAINT
DFT Reading - High Build Coal Tar

Signature
Sl No Plate No Epoxy Coating @ 365 micron in finall Remarks
1 2 3 4 5 Contractor HPCL
QC Engineer Site Incharge

Contractor. H.P.C.L.
Contractor
Date: P.O. No:

Tank No: Party:
Activity:- Job:
Surface preparation
ANNULAR PLATE PAINTING REPORT

Surface
Preparation DFT Reading - Inorganic Zinc Silicate Signature
Sl No Plate No on as per Coating @ 65-70 micron Remarks
standerd S/A
2½

Contractor. H.P.C.L.
API NAME PLATE
TANK NO.
JOB NO. 1
HP LOGO CONTRACT NO.
NAME OF THE CONTRACTOR
DESIGNED BY
MANUFACTURED FOR Hindustan Petroleum Corporation Limited
ITEM NO. Floating Roof/ Cone Roof Tank
MANUFACTURER SERIAL NO.
INSPECTED BY HPCL YEAR OF FABRICATION
CODE/ APPENDIX API 650 - Appendix C
NOMINAL DIAMETER DESIGN TEMP. 65.0 Degree C
NOMINAL HEIGHT DESIGN PRESSURE Atmospheric
NOMINAL CAPACITY TEST PRESSURE Full of water
DESIGN LIQUID LEVEL PARTIAL STRESS RELIEF NIL
DESIGN SPECIFIC GRAVITY DATE OF CALIBRATION

Contractor
GRIT BLASTING SURFACE PREPARATION SA 2½
Date: P.O. No:

Tank No: Party:
Activity:- Cu slag Blasting and Primer Job:
Surface preparation
SHELL PLATE FINAL PAINTING REPORT

Surface
Preparation on as DFT Reading - Inorganic Zinc Silicate Signature
Sl No Plate No per standerd S/A Coating @ 65-70 micron Remarks
2½ (profile meter
reading) 1 2 3 4 5 Contractor HPCL

Contractor H.P.C.L.
Contractor
GRIT BLASTING SURFACE PREPARATION SA 2½
Date: P.O. No:

Tank No: Party:
Activity:- Job:
Surface preparation
BOTTOM PLATE SOIL SIDE BLASTING & PAINTING REPORT

Surface
Preparation DFT Reading - Inorganic Zinc Silicate Signature
Sl No Plate No on as per Coating @ 65-70 micron Remarks
standerd S/A
2½ 1 2 3 4 5 Contractor HPCL

Contractor H.P.C.L.
Hindustan Petroleum Corporation Limited.
Calibration Chart
Owners Name : Hindustan Petroleum Corporaion Limited.
Location
Tank No. :9
Type : Vertical Cylindrical Singal Deck Floating Roof Tank.
Avg. Internal Dia. : 21.993 Mtrs.
Actual Height : 14.55 Mtrs.
Reference Height : 16.63 Mtrs.
Capacity - Safe Filling : 4858 KL
Nominal capacity : 5000 KL
Tilt TO The Tank : 2.0 Cms.
Height of datum plate : 19.0 Cms.
Wt. of Roof : 51000 KGS.
Legs Positions L.Legs : 137.2 Cms.
H.Legs : 197.2 Cms.
Product : MS
Calibrated On : 02.02.2007.
Valid Upto : 01.02.2012.
Safe Filling Height : 12.80 Mtrs.
Notes :
The level of Datum plate of the tank immediately below the Gaugewell pipe should be
taken as zero depth in the calibration chart.
This calibration chart is valid upto 01.02.2012 or even earlier to the date of making
any addition or alteration in the tank or change its position.
Calibration chart table is set out to show litres at the intervals of 5.0 cms .Use fraction
part table for immediate dips to get accurate results.
Certified that calibration upto cone top for Bottom plate was physically done by filling water
through water meter.
Page 1/12
Calibration Chart Tank No.
Ownres Name : Hindustan Petroleum Corporation Limited.
Dip In Volume In Dip In Volume In Dip In Volume In Fractions
Cms. Litres Cms. Litres Cms. Litres Cms. Litres
0 6233 250 945026 500 1894985 0.1 380
5 16033 255 964027 505 1913983 0.2 760
10 33610 260 983027 510 1932981 0.3 1140
15 52190 265 1002027 515 1951979 0.4 1520
20 71191 270 1021028 520 1970977 0.5 1900
25 90191 275 1040028 525 1989975 0.6 2280
30 109187 280 1059029 530 2008973 0.7 2660
35 128190 285 1078029 535 2027972 0.8 3040
40 147198 290 1097029 540 2046971 0.9 3420
45 166208 295 1116030 545 2065970 1.0 3800
50 185224 300 1135030 550 2084969 1.1 4180

55 204242 305 1154031 555 2103968 1.2 4560
60 223256 310 1173031 560 2122966 1.3 4940
65 242266 315 1192031 565 2141965 1.4 5320
70 261275 320 1211032 570 2160964 1.5 5700
75 280281 325 1230032 575 2179963 1.6 6080
80 299287 330 1249032 580 2198962 1.7 6460
85 318291 335 1268033 585 2217960 1.8 6840
90 337280 340 1287033 590 2236959 1.9 7220
95 356257 345 1306034 595 2255958 2.0 7601
100 375231 350 1325034 600 2274957 2.1 7981

105 394204 355 1344034 605 2293956 2.2 8361
110 413171 360 1363035 610 2312955 2.3 8741
115 432141 365 1382035 615 2331953 2.4 9121
120 451111 370 1401036 620 2350952 2.5 9501
125 470082 375 1420036 625 2369951 2.6 9881
130 489052 380 1439034 630 2388950 2.7 10261
135 508022 385 1458032 635 2407949 2.8 10641
140 527010 390 1477030 640 2426947 2.9 11021
145 546011 395 1496028 645 2445946 3.0 11401
150 565013 400 1515026 650 2464945 3.1 11781

155 584014 405 1534024 655 2483944 3.2 12161
160 603016 410 1553022 660 2502943 3.3 12541
165 622017 415 1572020 665 2521941 3.4 12921
170 641019 420 1591018 670 2540940 3.5 13301
175 660020 425 1610016 675 2559939 3.6 13681
180 679021 430 1629014 680 2578942 3.7 14061
185 698021 435 1648012 685 2597946 3.8 14441
190 717022 440 1667010 690 2616949 3.9 14821
195 736022 445 1686008 695 2635953 4.0 15201
200 755022 450 1705005 700 2654956 4.1 15581

205 774023 455 1724003 705 2673960 4.2 15961
210 793023 460 1743001 710 2692963 4.3 16341
215 812024 465 1761999 715 2711967 4.4 16721
220 831024 470 1780997 720 2730970 4.5 17101
225 850024 475 1799995 725 2749974 4.6 17481
230 869025 480 1818993 730 2768977 4.7 17861
235 888025 485 1837991 735 2787981 4.8 18241
240 907025 490 1856989 740 2806985 4.9 18621
245 926026 495 1875987 745 2825988
Pg 2/12
Calibration Chart Tank No.
Ownres Name : Hindustan Petroleum Corporation Limited.
Dip In Volume In Dip In Volume In Dip In Volume In Fractions
Cms. Litres Cms. Litres Cms. Litres Cms. Litres
750 2844992 1000 3794992 1250 4744867 0.1 380
755 2863995 1005 3813989 1255 4763865 0.2 760
760 2882999 1010 3832986 1260 4782863 0.3 1140
765 2902002 1015 3851983 1265 4801861 0.4 1520
770 2921006 1020 3870981 1270 4820858 0.5 1900
775 2940009 1025 3889978 1275 4839856 0.6 2280
780 2959013 1030 3908975 1280 4858854 0.7 2660
785 2978016 1035 3927972 ----- ----- 0.8 3040
790 2997020 1040 3946970 0.9 3420
795 3016023 1045 3965967 1.0 3800
800 3035027 1050 3984964 1.1 4180

805 3054030 1055 4003961 1.2 4560
810 3073034 1060 4022958 1.3 4940
815 3092037 1065 4041956 1.4 5320
820 3111041 1070 4060953 1.5 5700
825 3130045 1075 4079950 1.6 6080
830 3149046 1080 4098947 1.7 6460
835 3168044 1085 4117945 1.8 6840
840 3187043 1090 4136942 1.9 7220
845 3206041 1095 4155939 2.0 7601
850 3225040 1100 4174936 2.1 7981

855 3244038 1105 4193934 2.2 8361
860 3263037 1110 4212931 2.3 8741
865 3282036 1115 4231928 2.4 9121
870 3301034 1120 4250925 2.5 9501
875 3320033 1125 4269923 2.6 9881
880 3339031 1130 4288920 2.7 10261
885 3358030 1135 4307918 2.8 10641
890 3377029 1140 4326916 2.9 11021
895 3396027 1145 4345913 3.0 11401
900 3415026 1150 4364911 3.1 11781

905 3434024 1155 4383909 3.2 12161
910 3453023 1160 4402907 3.3 12541
915 3472021 1165 4421905 3.4 12921
920 3491020 1170 4440902 3.5 13301
925 3510019 1175 4459900 3.6 13681
930 3529017 1180 4478898 3.7 14061
935 3548016 1185 4497896 3.8 14441
940 3567014 1190 4516894 3.9 14821
945 3586013 1195 4535891 4.0 15201
950 3605011 1200 4554889 4.1 15581

955 3624010 1205 4573887 4.2 15961
960 3643009 1210 4592885 4.3 16341
965 3662007 1215 4611883 4.4 16721
970 3681006 1220 4630880 4.5 17101
975 3700004 1225 4649878 4.6 17481
980 3719003 1230 4668876 4.7 17861
985 3738000 1235 4687874 4.8 18241
990 3756997 1240 4706872 4.9 18621
995 3775994 1245 4725869
Pg 3/12
Hindustan Petroleum Corporation Limited Tank NO.
Shell Capacity Calculation.
1 2 3 4 5 6 7 8 9
Avg.Ext.Circum. 3.1428 69.2200 69.2180 69.2010 69.1900 69.1860 69.1770 69.1620 69.1630 69.1580
Thickness 14.0 14.0 12.0 10.0 8.0 8.0 6.0 6.0 6.0
Thick 2 py t 0.087998 0.087998 0.075427 0.062856 0.050285 0.050285 0.037714 0.037714 0.000000
V.Jts. 0.012 0.012 0.012 0.012 0.012 0.012 0.012 0.012 0.012
Total Dedudction 0.099998 0.099998 0.087427 0.074856 0.062285 0.062285 0.049714 0.049714 0.012000
Avg.Int.Circum. 69.1200 69.1180 69.1136 69.1151 69.1237 69.1147 69.1123 69.1133 69.1460
Radius 6.2856 10.99656 10.99625 10.99554 10.99579 10.99715 10.99572 10.99534 10.9955 11.0007
Lit./5 Cms. 21.993 19002.06 19000.96 18998.53 18999.39 19004.10 18999.16 18997.82 18998.37 19016.36
CDW 0.576 19001.49 19000.39 18997.95 18998.82 19003.53 18998.58 18997.24 18997.79 19015.78
Lit / Cms. Avg. 3800.257 3800.297 3800.077 3799.590 3799.763 3800.706 3799.716 3799.449 3799.559 3803.157
Shell Height 201 200 150 150 152 151 150 151 150
C. Height 25.5 175.500 175.5 375.5 525.5 675.5 827.5 978.5 1128.5 1279.5 1429.5
Cap.Of shell 666952 760015 569939 569964 577707 573757 569917 573733 570474
CDW Common dead wood.

C. Height Commulative Height
Page 4/12
Addition , Deduction Tank No.
0 0-5 5.-10 10.-15 15.-20 20.-25 25-30 30-35 35-40 40-45 45-50
6233 9800 17577 16680 19001.487 19001.487 19001.487 19001.487 19001.487 19001.487 19001.487
1900 -0.236 -0.788 -0.788 4.700 1.270 3.820
-1.329 1.630 3.270 -0.788 5.220 4.240
1.650 3.300 3.270 -0.788 5.220
0.388 3.880 3.300 3.270 -0.788
-4.429 -4.429 3.880 3.300 3.270
-3.250 -3.610 -4.429 3.880 3.300
-3.610 -4.429 3.880
-3.610 -4.429
-3.610
6233 9800 17577 18580 19001.487 18999.922 18996.688 19003.110 19007.810 19009.600 19016.390
50-55 55-60 60-65 65-70 70-75 75-80 80-85 85-90 90-95 95-100 100-105
19001.487 19001.487 19001.487 19001.487 19001.487 19001.487 19001.487 19001.487 19001.487 19001.487 19001.487
4.240 4.240 4.240 4.240 4.240 4.240 4.240 4.240 4.240 4.240 4.240
4.240 4.240 4.240 4.240 4.240 4.240 4.240 4.240 4.240 4.240 2.970
5.220 5.220 5.220 5.220 5.220 5.220 3.133 -11.400 -20.360 -20.360 -20.360
-0.788 -0.788 -0.788 -0.788 -0.788 -0.788 -0.236 -0.970 -0.970 -0.970 -0.970
3.270 2.940 3.880 1.940 -4.429 -0.490 -0.970 -4.429 -4.429 -4.429 -4.429
3.300 0.990 -4.429 -4.429 -3.610 -4.429 -4.429 -3.610 -3.580 -6.400 -6.400
3.880 3.880 -3.610 -3.610 -3.610 -3.610 -3.610 -3.610 -3.610
-4.429 -4.429
-3.610 -3.610
19016.810 19014.170 19010.240 19008.300 19006.360 19005.870 19003.855 18989.558 18977.018 18974.198 18972.928
105-110 110-115 115-120 120-125 125-130 130-135 135-140 140-175 19001.4870 680-825 19003.5286
19001.487 19001.487 19001.487 19001.487 19001.487 19001.487 19001.487 175-180 19000.4950 825-830 19001.0550
0.424 -20.360 -20.360 -20.360 -20.360 -20.360 -8.960 180-375 19000.3870 830-975 18998.5800
-20.360 -0.490 -4.429 -4.429 -4.429 -4.429 -1.950 375-380 18998.1935 975-980 18998.1795
-0.970 -4.429 -6.400 -6.400 -6.400 -6.400 -2.820 380-525 18997.9521 980-1125 18997.2449
-4.429 -6.400 525-530 18998.7285 1125-1130 18997.4100
-6.400 530-675 18998.8160 1130-1275 18997.7947
-2.890 675-680 19003.0585
18966.862 18969.808 18970.298 18970.298 18970.298 18970.298 18987.757
Page 5/12
Hindustan Petroleum Corporation Limited. Tank No.
Dead Wood Calculation
Discription
Dip Pipe 29.21 cms dia 0.27 Litres / 5 cms Comman dead wood
0.54 for 2 nos.
Temp. Sensor Pipe 2" 0.036 Litres / 5 cms comman dead wood
Manhole 60.0 x 18 0.848 4.24 Ltr / 5 cm + 45.5 to 105.5 cms.
Manhole 60.0 x 18 0.848 4.24 Ltr / 5 cm + 43.5 to 103.5 cms.
Central Roof drain pipe 0.7229 3.61 Ltr / 5 cm - 25.5 to 109 cms.
36.66 legth
Central R.D.Drum 4.07 20.36 Ltr / 5 cm - 87.2 to 137.2 cms.
Pipe inlet nozzle 47.5x28 1.04458 5.22 Ltr / 5 cm + 35.5 to 83.0 cms.
Pipe inlet nozzle 29*29 0.6605 3.3 Ltr / 5 cm + 27.5 to 56.5 cms.
Trough 0.0788 0.788 Ltr / 5 cm - 23.5 to 81.5 cms.
Trough 0.0788 0.788 Ltr / 5 cm - 23.5 to 81.5 cms.
Emergency drain 2 nos 0.194 0.97 Ltr / 5 cm - 77.5 to 112.5 cms.
Leg support
43 nos 4" sleeve 0.03 6.4 Ltr / 5 cm - 23.5 to 137.2 cms.
43 nos 3" legs 0.02 4.429 Ltr / 5 cm - 92.2 to 137.2 cms.
Pg 6/12
Hindustan Petroleum Corporation Limited Tank No.
Mathematical Computation
"0" 6233 Litres
from 0 to 5 cms 9800 Litres
from 5 to 10 cms 17577 Litres
from 10 to 14.5cms. 18580 Litres
when bottom covered with water, reading at datum plate is 14.5 cm
we will deduct 2 nos. gauge well pipe and 1 no temp sencor pipe throuout shell ht by 0.576 lit / 5 cms.
From 15 to 20 cms. 19001.487 Lit / 5 cm
From 20 to 25 cms. 19001.487 Lit / 5 cm

Trough 2nos. -0.236 Lit / 1.5 cm
Deduction for legs support pipe -1.329 Lit / 1.5 cm
18999.922 Lit / 5 cm
From 25 to 30 cms. 19001.487 Lit / 5 cm

Trough 2nos. -0.788 Lit / 5 cm
Pipe 12" 1.63 Lit / 2.5 cm
Pipe 12" 1.65 Lit /2. 5 cm
Pipe 0.388 Lit / 0.5 cm
Deduction for legs support pipe -4.429 Lit / 5 cm
Deduction for roof drain pipe -3.25 Lit / 4.5 cm
18996.688 Lit / 5 cm
From 30 to 35 cms. 19001.487 Lit / 5 cm

Pipe 12" 3.270 Lit / 5 cm
Pipe 12" 3.300 Lit / 5 cm
Pipe 3.880 Lit / 5 cm
Deduction for roof drain pipe -3.610 Lit / 5 cm
19003.110 Lit / 5 cm
From 35 to 40 cms. 19001.487 Lit / 5 cm

Pipe inlet 18" 4.700 Lit / 4.5 cm
Pipe 12" 3.270 Lit / 5 cm
Pipe 12" 3.300 Lit / 5 cm
19007.810 Lit / 5 cm
Pg 7/12
From 40 to 45 cms 19001.487 Lit / 5 cm
Addition for manholes 1.270 Lit / 1.5 cm
Pipe inlet 18" 5.220 Lit / 5 cm
Pipe 12" 3.270 Lit / 5 cm
Pipe 12" 3.300 Lit / 5 cm
19009.600 Lit / 5 cm
From 45 to 50 cm 19001.487 Lit / 5 cm

Addition for manholes 4.240 Lit / 5 cm
Pipe 12" 3.270 Lit / 5 cm
Pipe 12" 3.300 Lit / 5 cm
19016.390 Lit / 5 cm
From 50 to 55 cm 19001.487 Lit / 5 cm

Pipe 12" 3.270 Lit / 5 cm
Pipe 12" 3.300 Lit / 5 cm
pipe inlet 3.880 Lit / 5 cm
19016.810 Lit / 5 cm
From 55 to 60 cm 19001.487 Lit / 5 cm

Trough 2nos. -0.788 Lit / 0.3 cm
Pipe 12" 2.940 Lit / 4.5 cm
Pipe 12" 0.990 Lit / 1.5cm
19014.170 Lit / 5 cm
From 60 to 65 cm 19001.487 Lit / 5 cm

19010.240 Lit / 5 cm
Pg 8/12
From 65 to 70 cm 19001.487 Lit / 5 cm

Pipe 1.940 Lit / 2.5 cm
19008.300 Lit / 5 cm
From 70 to 75 cm 19001.487 Lit / 5 cm

19006.360 Lit / 5 cm
From 75 to 80 cm 19001.487 Lit / 5 cm

Emergancy Drain -0.490 Lit / 2.5 cm
19005.870 Lit / 5 cm
From 80 to 85 cm 19001.487 Lit / 5 cm

Pipe inlet 18" 3.133 Lit / 3.0 cm
Trough 2nos. -0.236 Lit / 1.5cm
Emergancy Drain -0.970 Lit / 5 cm
19003.855 Lit / 5 cm
From 85 to 90 cm 19001.487 Lit / 5 cm

Deduction R Drum -11.400 Lit / 2.8 cm
18989.558 Lit / 5 cm
Pg 9/12
From 90 to 95 cm 19001.487 Lit / 5 cm

Deduction R Drum -20.360 Lit / 5 cm
Deduction for sleeves -3.580 Lit / 2.8 cm
18977.018 Lit / 5 cm
From 95 to 100 cm 19001.487 Lit / 5 cm

18974.198 Lit / 5 cm
From 100 to105 cm 19001.487 Lit / 5 cm

Deduction for sleeves -6.400 Lit / 5 cm
18972.928 Lit / 5 cm
From 105 to 110 cm 19001.487 Lit / 5 cm

18966.862 Lit / 5 cm
From 110 to 115 cm 19001.487 Lit / 5 cm

Emergancy Drain -0.490 Lit / 2.5cm
18969.808 Lit / 5 cm
Pg 10/12
From 115 to 135 cm 19001.487 Lit / 5 cm

18970.298 Lit / 5 cm
From 135 to 140 cm 19001.487 Lit / 5 cm

Deduction R Drum -8.960 Lit / 2.2cm
18987.757 Lit / 5 cm
Pg 11/12
Hindustan Petroleum Corporation Limited.
Instruction of use of calibration chart for tank no.

1 For dip reading not given in the table, take the capacity shown against the nearest lower depth and add to it at every or
proportionate fraction table.
2 No deduction for roof weight is to be made when the liquid is not touching the floating roof.
(a) when the roof is on LOW LEGS , the off float position is 137.2 cms. depth.
(b) when the roof is on HIGH LEGS, the off float position is 197.2 cms. depth.
3 (a) The fully floating position of the roof depends upon the gravity of the tank contents.
The following is the method for finding the fully floating positions of the roof.
Fully flaoting position of the roof = off float position in cms+Roof weight displacement in cms.
Roof weight in Kilograms 1
Roof weight displacement in cms. = --------------------------------------------- X----------------------------------------
Density of stock at tank temp. in Kgs./ Ltrs. Liters / cms. for the tank.
Eg. Tank contents = MS , Tank Temperature

= 32 C.
Density of Stock = 0.73 kgs / ltrs. at 32 C
51000
Displacements due to roof weight = -------------------------------
= 18.38 cms.
3800.257 X 0.73
Fully floating positions of the roof = 137.2+18.38=155.58 When roof on Low LEGS
= 197.2+18.38=215.58 When roof on High LEGS
(b) When roof is fully floating, the tank volume must be corrected for roof weight displacement.
DATA :- Gauge readings = 253.7 cms Tank Temperature = 32 C.

Density of stock = 0.73 Kgs / ltrs.
51000
Volume of oil displacement due to roof weight = ---------------------------------- = 69863 Litres
0.73
Calculations : -
Capacity for 250.0 cms .= 945026 Ltrs.
Capacity for 3.0 cms.= 11401 Ltrs.
Net capacity for 253.7 cms = 959087 -69863 =889224 Ltrs.
4 The roof is to be considered as partly submerged where the level is in between off float position and full float position
proportionate capacity due to roof weight is to be deducted when the roof is partly submerged.
A typical calculations would be as follows :-
DATA Gauge readings = 145.0 cms.Tank Temperature = 32 C Density of stock = 0.73 Kgs/ Ltrs.
69863
Now Approximate disp. = X (145-137.2) =
-------------------- 29648 Litres
18.38
Calculations : - Capacity for 145 cms.at tank temperature 546011 Ltrs.

Total displacement due to roof weight 69863 Ltrs.
Approx .displacement 29648 Ltrs.
Net volume for 145 cms at tank temperature = 546011-29648 516363 541015
Ltrs Ltrs.
5 Volume obtained when roof is partly submerged as in (4) above are not accurate . The roof should, therefore, be always kept
either fully floating or completely - Off float by pushing water at the bottom.
6 The roof should always be maintained on Low legs while the tank is in service.
Pg 12/12
Contractor
FABRICATION REPORT
Date: P.O. No:

Tank No: Party:
Job:
SL. DIMENTION
DRG NO ITEM NO DESCRIPTION SIZE QTY Contractor HPCL REMARKS
NO. CHECKED
QC ENGINEER SITE INCHARGE

Contractor HPCL
TANK NO: QCR NO:
DATE:
DESCRIPTION/ TYPE OF SIGNATURE
SL NO JOINT NO SIZE THICKNESS FITUP DATE REMARKS
LINE NO JOINT
' ( (
(
! $
& # )& #
$ *
! " # $ ! " # $
" # %& " # %&
Page 1 of 2
TANK NO: P.O. NO:
DATE:
UNDULATION SIGNATURE
SL TYPE OF
JOINT NO THICKNESS OF ANNULAR DATE REMARKS
NO JOINT Contractor HPCL
JOINT
INTERNAL MATERIAL INSPECTION REPORT (IMIR)
JOB :
PO NO. :
PARTY:
MATERIAL DATE OF REQUIREMENT AS PER Contractor's

SL NO DESCRIPTION INSPECTION PO ACTUAL sign HPCL sign REMARKS
Hindustan Petroleum Corporation Limited
Paint Consumption Report
JOB : Paint:
PO No: Colour:
Contractor: Consumption / Sqm:
Qty Area of
Date of Qty Recd Cumu Qty Date of Cumul Contractor HPCL
RGP No Batch No. Mfg Dt. Consumed Painting Location Painting in Balance
Receipt in Ltrs Recd Consmptn Consmptn Sign Sign
in Ltr Sqm
Contractor
POST WELDING INSPECTION READINGS FOR SHELL
Date: P.O. No:

Tank No: Party:
Job: Shell No:
PLUMB READING
Plumb Area 0 / 360º 45º 90º 135º 180º 225º 270º 315º
Top
Middle
Bottom
RADIUS READING in mm
Radial Area 0 / 360º 45º 90º 135º 180º 225º 270º 315º
Top
Middle
Bottom
DIA READING in mm
DIA AT FOLLOWING 0-180 45-225 90-270 135-315
Top
Middle
Bottom
CIRCUMFERENCE READING in mm
Circumference of Shell (Averege reading) TOP MIDDLE BOTTOM

Contractor HPCL
Contractor
PRE WELDING INSPECTION READINGS FOR SHELL
Date: P.O. No:

Tank No: Party:
Job: Shell No:
PLUMB READING
Plumb Area 0 / 360º 45º 90º 135º 180º 225º 270º 315º
Top
Middle
Bottom
RADIUS READING in mm
Radial Area 0 / 360º 45º 90º 135º 180º 225º 270º 315º
Top
Middle
Bottom
DIA READING in mm
DIA AT FOLLOWING 0-180 45-225 90-270 135-315
Top
Middle
Bottom
CIRCUMFERENCE READING in mm
Circumference of Shell (Averege reading) TOP MIDDLE BOTTOM
ROOT GAP READING in mm
Joint No 1 2 3 4 5 6 7 8
Top
Middle
Bottom

Contractor HPCL
TANK NO: PO NO:
DATE:
SIGNATURE
SL JOINT TYPE OF WELD WELDER
THICKNESS DATE REMARKS
NO NO JOINT VISUAL NO Contractor HPCL
Documentation for fabrication
Date: P.O:
Tank No: Party:
Activity: - Job:
Sr.No Plate No Length Thickness Remarks

MM (Randomly)
MM
Contractor
Date: P.O:
Tank No: Party:
Activity: - Job:

MM (Randomly)
MM
QC Engineer Site in Charge

Contractor H.P.C.L
Contractor
Date: P.O:
Tank No: Party:
Activity: - Job:

MM (Randomly)
MM

Contractor H.P.C.L
Contractor
Date: P.O:
Tank No: Party:
Activity: - Job:
Sr.No Plate No Length Breadth Thickness Diagonal check both Remarks

MM MM (Randomly) side. MM
MM
Q.C Enginee Site Incharge

Contractor HPCL
Contractor
Date: P.O:
Tank No: Party:
Activity: - Job:

MM (Randomly)
MM

Contractor H.P.C.L
Contractor
GRIT BLASTING SURFACE PREPARATION SA 2 ½
Date: P.O:
Tank No: Party:
Activity: - Cu slag Blasting and primer Job:
Plate Use Location:
Surface Preparation:
Sr. No. Plate Heat L*B*T Surface DFT Reading – primer Signature Remark
No. No. preparation name @ micron
on as per
standard
S/A 2 1/2

Contractor H.P.C.L
CONTRACTOR
FINISH PAINT DFT READING
Date: P.O:
Tank No: Party:
Activity: - Finish Paint Job:
Plate Use Location:
Sr. Plate L*B*T DFT Reading – High Build Epoxy Signature Remark
No. No. MM Finish Coating @ 100 micron

Contractor H.P.C.L
Contractor
GRIT BLASTING SURFACE PREPARATION SA 2 ½
Date: P.O:
Tank No: Party:
Activity: - Job:
Plate Use Location:
Sr. Plate Heat L*B*T Surface DFT Reading – Inorganic Zinc Signature Remark
No. No. No. MM preparatio Silicate Coating @ 65-70
n on as micron
per
standard
S/A 2 1/2
Contra HPCL
1 2 3 4 5
ctor

Contractor H.P.C.L
DOC.NO.
DATE:
PAGE :
TITLE
QUALITY ASSURANCE PLAN
RECORDS REQD.TO
ACTION /EXTENT OF CHECK BY BE SUBMITTED /
SL.NO. ACTIVITY/ DESCRIPTION CHARACTERISTICS TO BE CHECKED TYPE / METHOD OF CHECK TYPE AND EXTEND OF CHECK BY JACOBS TYPE OF RECORD/BASIS
CONTRACTOR MAINTAINED BY
CONTRACTOR
A CIVIL WORK
1 Accuracy Measurement Detail Check 100 % Review records Yes Lab Reports/ Site Test
Calibration of Test / Measuring Instruments
2.a Construction Materials
Sand Physical properties Physical Tests Detail Check 100 % Review records Yes Lab Test/ Site Test
Soil Usability Visual Detail Check 100 % Review records Yes Site Report
Ready Mix Concrete Physical properties Physical Tests Detail Check 100 % Review records Yes Lab Test/ Site Test
Physical & Chemical Properties
Cement Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate
Aggregrates Physical properties Physical Tests Detail Check 100 % Review records Yes Lab Test/ Site Test
Bitumen Physical Properties Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate
Reinforcement Physical & Chemical Properties Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate
Physical & Chemical Properties Mfrs Test Certificate/

Foundation Bolt Review Records Detail Check 100 % Review records Yes
Lab. Test Report
Coating Thickness Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate
b Construction Equipments
Excavator Workability Visual Detail Check 100 % Review records Yes Site Report
RTO Permission(If reqd.) Review Records Detail Check 100 % Review records Yes RTO Permits
Concrete Mixer Workability Visual Detail Check 100 % Review records Yes Site Report
Vibrators Workability Visual Detail Check 100 % Review records Yes Site Report
Trucks / Dumper Workability Visual Detail Check 100 % Review records Yes Site Report
c Consumables
Water Chemical Properties Chemical Tests Detail Check 100 % Review records Yes Lab Test
DOC.NO.
DATE:
PAGE :
TITLE

RECORDS REQD.TO
CONTRACTOR
3 Survey and Layout Dimensions Measurement Detail Check 100 % Check/witness Yes Joint Record
4.a Tank Pad Foundation

Excavation Dimension Measurement Detail Check 100 % Check/witness Yes Field Books,Record of
profile and final Level,
Field Test Records
Hard Strata Visual Detail Check 100 % Check/witness at random Yes Site Report & Records
Check/witness at random
Sand filling Dimension Measurement Detail Check 100 % Yes Site Report & Records
Consolidation Phy.test Detail Check 100 % Yes Site Report
Check/witness
Ring Beam Dimension Detail Check 100 % Yes Site Report
Measurement & Visual
Review records
Pre-concreting Check Check list Detail Check 100 % Yes Site Report
Check/witness
Cube CR Strength Physical Tests Detail Check 100 % Yes Lab Test / Site Test
Check/witness
Bitumen carpet Dimension,Profile Measurement Detail Check 100 % Yes Site Report
Check/witness
Consolidation Visual Detail Check 100 % Yes Site Report
Apron work Dimension,Profile Detail Check 100 % Yes Site Report
b Road work Dimension,Profile Detail Check 100 % Yes Site Report/Joint Records
Consolidation Visual Detail Check 100 % Check/witness at random Yes Site Report/Joint Records
5 Safety Awarness / Implement & apply as per Review Detail Check 100 % Close Vigliance on Day to day basis Yes
records of periodic checks
norms of tools & tackles,Lifting
Machinery ,Electrical
equipments etc
6 As Built Drawing Dimensions with co-ordinates Review Submit Review records Marks up on Drawings
Drawings
DOC.NO.
DATE:
PAGE :
TITLE

RECORDS REQD.TO
CONTRACTOR
B TANK CONSTRUCTION
1 Calibration of Tests/Measuring Instruments Accuarcy Measurement Detail Check 100 % Review records Yes Lab reports/Site Tests
2a Materials
Plates and Structurals Physical,Chemical Properties Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate
Lab Test Certificate

Dimensions and surface quality Detail Check 100 % Review records Yes Site Report
Measurements and Visual
Physical,chemical properties
Pipes for nozzles Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate
Dimensions and surface quality
Detail Check 100 % Review records Yes Site Report
Measurements and Visual
Physical,chemical properties,
Flanges for nozzles Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate
heat treatment
Dimensions and surface quality

Lamination free Visual,UT(If reqd.) Detail Check 100 % Review records Yes Mfrs Test Certificate
Site Report
Pipe fittings Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate
heat treatment Lab Test Certificate

Dimensions and surface quality Measurement & Visual
Bolts, nuts for nozzle flanges & Structurals

Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate
heat treatment

Dimensions and surface quality Measurement & Visual
DOC.NO.
DATE:
PAGE :
TITLE
RECORDS REQD.TO
CONTRACTOR
b Equipments
DG Set Workability Visual Detail Check 100 % Review records Yes Site Report,Callibration
Report /Fit Certificates
Hydra Workability Visual Detail Check 100 % Review records Yes Site Report,Load test
certificates
Welding Rectifiers Workability Visual Detail Check 100 % Review records Yes Site Report,Calibration
Report
Grinding Machines Workability Visual Detail Check 100 % Review records Yes Site Report
Cutting Sets Workability Visual Detail Check 100 % Review records Yes Site Report
Erection Jacks Workability Lab Test/Visual Detail Check 100 % Review records Yes Site Report,Load test
certificates

Chain Pully Blocks Workability Lab Test/Visual Detail Check 100 % Review records Yes Site Report
Load Test Certificate
c Consumables
Electrodes Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate
Physical, chemical Properties
Grinding Wheel Workability Visual Detail Check 100 % Review records Yes Site Report / MTC
Gases Workability Visual Detail Check 100 % Review records Yes Site Report
3 Fabrication Drawing Technical Requirements Review of Drawing Detail Check 100 % Review and Approve Yes Approved Drawings ED
318
4 Detail Check 100 % Check/witness Yes Joint Report

Pre Erection Take over of foundation Dimension, Profile Consolidation Measurement / Visual
CSF-52-301
5 Fabrication and Erection
a Bottom plates
Fabrication Dimension, checking diagonal & Detail Check 100 % Review records Yes Site Report /ED316
Measurement / Visual
squaring
Annular Plate Alignment,Fitup,Root gap Cleanliness Detail Check 100 % Check/witness at random Yes Site Report /ED316
of joint
Dimension & Shape Detail Check 100 % Check/witness at random Yes Site Report /ED316
Smoothness and reinforcement of Visual Detail Check 100 % Check/witness at random Yes Site Report /ED316
final weld
Internal flow Radiography Detail Check 100 % Review records Yes Site Report /ED328
DOC.NO.
DATE:
PAGE :
TITLE

RECORDS REQD.TO
CONTRACTOR
Fitment, dimension, Slope

Bottom sketch plates Detail Check 100 % Check/witness Yes Site Report /ED316
Weld soundness Detail Check 100 % Check/witness Yes Site Report /ED316
Visual/Vacuum Box Testing
Fitment, dimension Detail Check 100 % Check/witness at random Yes Site Report /ED316
Annular plate to Bottom sketch plate Measurement / Visual
Visual/Vacuum Box Testing
Annular plate to shell plate Fitment,dimension Detail Check 100 % Check/witness at random Yes Site Report /ED316
Visual/Oil-chalk Testing
Leak tightness LPT Detail Check 100 % Check/witness Yes Site Report /ED327
b Shell plates
Fabrication Dimension,Checking diagonal & Detail Check 100 % Review records Yes Site Report /ED316
squaring
Fitment of weld Joints Detail Check 100 % Check/witness at random Yes Site Report /ED316
Alignment,Fitup,Root gap Measurement / Visual
Plumbness
Cleanliness of joint Visual Detail Check 100 % Check/witness at random Yes Site Report /ED316
Dimension & Shape Detail Check 100 % Check/witness at random Yes Site Report /ED316
Root run after back gauging of Butt weld Free of flow Visual Detail Check 100 % Check/witness at random Yes Site Report /ED316
Joints
Smoathness and reinforcement of
Finished Butt Weld Joints Visual Detail Check 100 % Check/witness at random Yes Site Report /ED316
final weld
Internal Radiography Detail Check 100 % Review records Yes Site Report /ED328
(10% & all Tee joint)
Peaking,Banding, Detail Check 100 % Check/witness Yes Site Report /ED320
Measurement / Plumbness
Verticality,Circularity
DOC.NO.
DATE:
PAGE :
TITLE

RECORDS REQD.TO
CONTRACTOR
c Roof Structure,Curb angle,Wind Girder

Etc.
Fabrication Layout Detail Check 100 % Check/witness at random Yes Site Report /ED390
Fitment, Dimension Detail Check 100 % Check/witness at random Yes Site Report
Weld soundness Visual Detail Check 100 % Check/witness at random Yes Site Report /ED324
Erection Layout Detail Check 100 % Check/witness at random Yes Site Report /ED390
Fitment,dimension,slope Detail Check 100 % Check/witness at random Yes Site Report /ED390
Weld soundness Visual / Pneumatic Test Detail Check 100 % Check/witness Yes Site Report /ED390
d Roof Plates
Fabrication Dimension, checking diagonal & Detail Check 100 % Review records Yes Site Report /ED316
squaring
Erection Fitment, dimension,Slope Detail Check 100 % Check/witness at random Yes Site Report /ED316
Weld soundness Visual / Air Test Detail Check 100 % Check/witness Yes Site Report /ED316
e Shell appurtenances
Fabrication Dimension Detail Check 100 % Check/witness at random Yes Site Report
Alignment,Fitup,Root Gap Detail Check 100 % Check/witness at random Yes Site Report
Cleanliness of joint
Orientation Dimension Measurement Detail Check 100 % Witness Yes Site Report
Fitment of weld Joints Alignment,Fitup,Root Gap Detail Check 100 % Witness Yes Site Report
(Nozzle to Shell)
Dimension & Shape Detail Check 100 % Check/witness at random Yes Site Report
Finished Weld joints Smoathness and reinforcement of Visual Detail Check 100 % Check/witness at random Yes Site Report
final weld
RF Pad/ Nozzle to shell Leak tightness DP Test / Air Test Detail Check 100 % Check/witness Yes Site Report
DOC.NO.
DATE:
PAGE :
TITLE QUALITY ASSURANCE PLAN

RECORDS REQD.TO
CONTRACTOR
f Roof appurtenances
Fabrication Dimension Detail Check 100 % Check/witness at random Yes Site Report
Alignment,Fitup,Root Gap Detail Check 100 % Check/witness at random Yes Site Report
Orientation Dimension Measurement Detail Check 100 % Witness Yes Site Report
Fitment of weld Joints Alignment,Fitup,Root Gap Detail Check 100 % Witness Yes Site Report
(Nozzle to Roof)
Dimension & Shape Detail Check 100 % Check/witness at random Yes Site Report
Finished Weld Joints Smoothness and reinforcement of Visual Detail Check 100 % Check/witness at random Yes Site Report
final weld
Completeness,Cleanliness,Overall Measurements / Visual
g Detail Check 100 % Witness/ Review of Film Yes Site Report
Inspection prior to release for Hydrotest dimension, Plumbness,Orientation, Verification of Documents
Radiography etc
h Inspection during hydrotest Leak tightness Visual Detail Check 100 % Witness Yes Site Report
vertically Detail Check 100 % Witness Yes Site Report
Measurement / Plumbness
Settlement Measurement Detail Check 100 % Witness Yes Site Report

i Calibration Capacity with filling height Measurement Detail Check 100 % Check/witness at random Yes Calibration Chart
5 safety Awarness, implement and apply as Review Detail Check 100 % Yes records of periodic checks
per norms Close Vigliance on Day to day basis of tools & tackles,Lifting
Machinery ,Electrical
Equipments etc
6 As Built Drawing Dimensions with co-ordinates Review Submit Review records Mark up on Drawings
Drawing
DOC.NO.
DATE:
PAGE :
TITLE

RECORDS REQD.TO
CONTRACTOR
C WELDING AND TESTING

1 Accuracy Measurement Detail Check 100 % Review records Yes Lab Reports/Site Test
Calibration of Test/ Measuring Instruments
2a Base Material Correctness Review Detail Check 100 % Review records Yes Lab Reports/Site Test
b Welding Equipment
Welding Rectifiers Workability Visual Detail Check 100 % Review records Yes Site Report,calibration
Certificates
Grinding Machines Workability Visual Detail Check 100 % Review records Yes Site Report
c Consumables
Electrodes Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate
Physical,Chemical Properties
3 Welding Procedure Specification Submit Review records Yes Welding Procedure Spec.
ASME Sec IX /ED-323
4 Welding Procedure Qualification
a Welding of Test Piece Establishing Correctness of welding Conduct Witness Witness Yes Site Report
variables
b NDT Internal Radiography(100%) Detail Check 100 % Review records Yes Site Report
Destructive Test Physical Test Physical Properties Witness Witness Yes Lab Test Certificate
5 Welder Performance Qualification
Welder Test Ability of Welder to Perform Conduct Witness Witness Yes Site Report
NDT Internal Flow Radiography(100%) Detail Check 100 % Review records Yes Site Report
6 Procedure
a Radiography Correctness Scrutiny Preparation & Submit Review records / Procedures Approval Yes Approved Procedure
ASME Sec V
b Dye Penetrant Correctness Scrutiny Preparation & Submit Review records / Procedures Approval Yes Approved Procedure
ASME Sec V
c Ultrasonic Correctness Scrutiny Preparation & Submit Review records / Procedures Approval Yes Approved Procedure
ASME Sec V
d Diesel Chalk Test Correctness Scrutiny Preparation & Submit Review records / Procedures Approval Yes Approved Procedure
ASME Sec V
e Vacuum Box Correctness Scrutiny Preparation & Submit Review records / Procedures Approval Yes Approved Procedure
API 650 & Sec V
f Air Test Correctness Scrutiny Preparation & Submit Review records / Procedures Approval Yes Approved Procedure
API 650 & Sec V
g Hydro Test Correctness Scrutiny Preparation & Submit Review records / Procedures Approval Yes Approved Procedure
API 650 & Sec V
DOC.NO.
DATE:
PAGE :
TITLE
RECORDS REQD.TO
CONTRACTOR
D PAINTING
Lab Reports/Site Test
1 Accuarcy Measurment Detail Check 100 % Review records Yes
Calibration of Test/ Measuring Instruments
2a Material
Paints & Thinner Chemical Properties Review Detail Check 100 % Review records Yes Mfrs Test certificate
b Equipments
Compressor Workability Visual Detail Check 100 % Review records Yes Site Report
Blasting Equipments Workability Visual Detail Check 100 % Review records Yes Site Report
Spray Painting Equipments Workability Visual Detail Check 100 % Review records Yes Site Report
3 Take Over of Tank for painting Completeness Visual Detail Check 100 % Check/witness at random Yes Site Report
4 Surface Visual Detail Check 100 % Witness Yes Site Report
Surface Preparation / Grit Blasting
5 Primer application- DFT Check Thickness Measurement Detail Check 100 % Witness Yes Site Report
6 Final Painting -DFT Check Thickness Measurement Detail Check 100 % Witness Yes Site Report
7 Equipment Identification Numbering Visual Detail Check 100 % Witness Yes Site Report
E MECHANICAL COMPELETION Completeness Visual Detail Check 100 % Check/witness at random Yes Site Report
F FINAL INSPECTION Detail Check 100 % Witness Yes Site Report
Completeness,Cleanliness, Overall Verification of Documents

dimension, Plumbness,Orientation,
Radiography etc
Overall quality, Data keeping QA/QC Documents
G DOCUMENTATION Completeness Submit Review Yes
As Built Drawings.
Test Reports
WPS NO.:
DATE :
PQR NO.:
CLIENT : Hindustan Petroleum Corporation Limited
LOCATION :
QW-482 - WELDING PROCEDURE SPECIFICATION

(REF. SPECIFICATION : ASME SECTION IX)
JOINT DESIGN (QW 402) SKETCH / DETAIL : 1 (A)
Type : SQ BUTT
Backing : NO FIG 1 (A)
Backing Material Type / Grade : NA

WELDING PROCESS : SMAW TYPE : MANUAL
BASE METALS (QW 403)
Material Specification : IS 2062 / EQ. To IS 2062 / EQ.
Type / Grade No. : GR.B To GR.B

P. No. : 1 To 1
Group No. : 1 To 1
Thick of Coupon : 6 mm
Thickness Range : 6 mm
FILLER MATERIAL (QW 404)
Spec. No. (SFA) : 5.1 Filler Size : 3.15 mm
AWS No. (CLASS) : E 6013 Electrode Flux Type : -
A. No.: : 1 Backing / Storage : As per Manuf. Std.
F. No.: : 2 Consumable Insert : None
Make : ESAB/ADVANI/D&H
POSITION (QW 405)
Position of Groove : 3G Position of Fillet : NA
AWS No. (CLASS) : UPHILL
PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)
Preheat Temp. (Min) : NA Temperature : NA
Interpass Temp. (Max) : NA Time : NA
Preheat Maint : NA Other : NA
GAS (QW 408)
Shielding Gas : NA Flowrate : NA
Percentage Comp. : NA Gas Backing : NA
Trailing : NA Purging : NA
ELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)
Current Mode : DC String or weave Bead : String / Weaving
Volts : 18 to 30 Orifice or Gas Cup Size : NA
Electrical Polarity : STRAIGHT Initial / Interpass Cleaning : Wire Brushing
Amperage : 80 TO 140 Method of back gauging : Grinding
Tungsten Electrode Size & Type : NA Oscillation : NA
Mode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NA
Elect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : Multiple
Other : NA Multiple of Single Electrode : Single
Travel Speed Range : SEE TABLE
Peening : NA
WELDING PROCEDURE
Filler Material Current & Voltage Travel Speed Heat Input
Pass No. Welding Process
Class Dia Type & Pol. Amps Range Volts Range mm / min kJ / mm
ROOT SMAW E6013 3.15 STRAIGHT 80 to 120 20 to 24 85 to 100

SUB. PASS SMAW E6013 3.15 STRAIGHT 90 to 130 24 to 28 90 to 125
AFTER BACK CHIP - - - - - -
FINAL SMAW E6013 3.15 STRAIGHT 90 to 130 24 to 28 90 ot 125
APPROVAL HINDUSTAN PETROLUEM CORP. LTD
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

JOINT DESIGN (QW 402) SKETCH / DETAIL : 1 (B)
Type : SQ BUTT
Backing : NO FIG 1 (B)
P. No. : 1 To 1
Group No. : 1 To 1
Thickness Range : 6 to 8 mm
Spec. No. (SFA) : 5.1 Filler Size : 3.15 / 4 mm
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Current Mode : DC String of weave Bead : String / Weaving
Electrical Polarity : REVERSE Initial / Interpass Cleaning : Wire Brushing
Peening : NA
WELDING PROCEDURE

SUB. PASS SMAW E6013 4 STRAIGHT 120 to 190 24 to 28 100 to 150
SUB. PASS SMAW E6013 4 STRAIGHT 120 to 180 24 to 28 100 ot 150
FINAL SMAW E6013 4 STRAIGHT 120 to 180 24 to 28 100 ot 150
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : SINGLE "V"
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE

NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION : MAHUL TERMINAL

Type : SQ BUTT
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
GAS (QW 408)
Peening : NA
WELDING PROCEDURE

SUB. PASS SMAW E6013 3.15 STRAIGHT 90 to 130 24 to 28 90 to 125
FINAL SMAW E6013 3.15 STRAIGHT 90 to 130 24 to 28 90 ot 125
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

JOINT DESIGN (QW 402) SKETCH / DETAIL : 2(B)
Type : SQ BUTT
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE

NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

JOINT DESIGN (QW 402) SKETCH / DETAIL : 3
Type : T FILLET
Backing : NO FIG 3
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
Position of Groove : - Position of Fillet : 2F
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE
ROOT SMAW E7018 3.15 REVERSE 100 to 135 20 to 24 80 to 120

SUB. PASS SMAW E7018 4 REVERSE 120 to 190 24 to 28 90 to 150
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

JOINT DESIGN (QW 402) SKETCH / DETAIL : 3A
Type : T FILLET
Backing : NO FIG 3
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE

SUB. PASS ROOT 2 SMAW E7018 4 REVERSE 120 to 190 24 to 28 90 to 150
SUB. PASS ROOT 3 SMAW E7018 4 REVERSE 120 to 190 24 to 28 90 to 150
SUB. PASS 4 TO 5 SMAW E7018 4 REVERSE 120 to 190 24 to 28 90 to 150
NAME :
SIGNATURE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : T FILLET
Backing : NO FIG 4

P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE
INSIDE
SUB. PASS (2) SMAW E7018 4 REVERSE 120 to 190 24 to 28 90 to 150
OUTSIDE
1ST PASS SMAW E7018 3.15 REVERSE 100 to 135 20 to 24 90 to 120
FINAL (3) SMAW E7018 4 REVERSE 120 to 190 24 to 28 100 to 150
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : DOUBLE "V"
Backing : NO FIG 4

P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
Position of Groove : 3G Position of Fillet : 2F
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE
INSIDE
BACK SIDE
FINAL (3) SMAW E7018 4 REVERSE 120 to 190 24 to 28 100 to 150
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : SQUARE BUTT WITH BACKING STRIP & FILLET
Backing : YES FIG 5
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
Position of Groove : 1G Position of Fillet : 2F
AWS No. (CLASS) : -
GAS (QW 408)
Current Mode : DC String of weave Bead : String
Peening : NA
WELDING PROCEDURE
ROOT (1,2) SMAW E7018 3.15 REVERSE 100 to 135 20 to 24 90 to 120

FINAL (5,6) SMAW E7018 3.15 REVERSE 100 to 135 20 to 24 90 ot 120
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : LAP FILLET
Backing : NO FIG 6
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Electrical Polarity : Electrode-Straight Initial / Interpass Cleaning : Wire Brushing
Peening : NA
WELDING PROCEDURE

NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:

Type : LAP FILLET
Backing : NO FIG 7
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE
ROOT (1) SMAW E7018 3.15 REVERSE 80 to 120 20 to 24 80 to 120

FINAL (3,4) SMAW E7018 4 REVERSE 90 to 190 24 to 28 90 ot 150
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : T FILLET
Backing : NO FIG 8
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE

SUB. PASS SMAW E7018 4 REVERSE 90 to 190 24 to 28 90 to 150
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:

Type : T FILLET
Backing : NO FIG 9
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Electrical Polarity : Straight Initial / Interpass Cleaning : Wire Brushing
Peening : NA
WELDING PROCEDURE
ONE SIDE CONT.
ROOT (1) SMAW E6013 3.15 STRAIGHT 80 to 120 20 to 24 80 to 120
SUB. PASS (2) SMAW E6013 4 STRAIGHT 90 to 190 24 to 28 90 to 150
2nd STITCH FILLET 100 (100) 100
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : LAP FILLET
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE

NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : LAP FILLET
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE

NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : T FILLET
Backing : NO FIG 11
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE
ONE SIDE CONT.
SUB. PASS (2) SMAW E6013 3.15 STRAIGHT 90 to 190 24 to 28 90 to 150
2nd SITCH FILLET 100 (100) 100
NAME :
SIGNATURE :
DATE :
Note : 1) For 5mm to 16mm joint separate WPS has to be made using E7018 Rod
2) Inner joint bulk head shall have doublers plate
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : LAP FILLET
Backing : NO FIG 7


P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE
ONE SIDE CONT.

2nd SITCH FILLET 100 (100) 100
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : T FILLET
Backing : NO FIG 12
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE

NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : T FILLET
Backing : NO FIG 13


P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE
INSIDE
OUTSIDE
NAME :
SIGNATURE :
DATE :
Note : Joint at the point where Outer rim & Lap of Bottom Deck plate meet shall be like
a) Bottom deck has to be made Sq Butt joint for 100 mm length
WPS Pg (a) should be submitted separately
Hence Joggly not needed
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : T FILLET
Backing : NO FIG 14
WELDING PROCESS `` SMAW TYPE : MANUAL

P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE
ONE SIDE CONT.
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : DOUBLE V BUTT
Backing : NO FIG 15

P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
GAS (QW 408)
Peening : NA
WELDING PROCEDURE

SUB. PASS (2) SMAW E7018 3.15 REVERSE 90 to 130 24 to 28 90 to 125
SUB. PASS (3,4) SMAW E7018 3.15 REVERSE 90 to 130 24 to 28 90 to 125
AFTER BACK CHIP
FINAL SMAW E7018 3.15 REVERSE 90 to 130 24 to 28 90 to 125
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : LAP FILLET
Backing : NO FIG 16
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE

NAME :
SIGNATURE :
DATE :
Note : L 75 X 75 X 8 only has to be used

WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : T FILLET
Backing : NO FIG 17
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE
ONE SIDE CONT.
2ND SIDE STITCH FILLET 100 (100) 100
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : Single V Full Pen Butt Joint
Backing : NO FIG 18
Backing Material Type / Grade : Chip Back to Sound metal & reweld
P. No. : 1 To 1
Group No. : 1 To 1
Thickness Range : 1.76 to 20 mm
POSITION (QW 405)
GAS (QW 408)
Electrical Polarity : Electrode - Negative Initial / Interpass Cleaning : Wire Brushing
Peening : NA
WELDING PROCEDURE
ROOT SMAW E6013 3.15 STRAIGHT 90 to 95 22 to 24 65 to 90 0.275

HOT PASS SMAW E6013 3.15 STRAIGHT 90 to 95 18 to 20 85 to 90 0.238
FILLING SMAW E6013 4 STRAIGHT 100 to 120 18 to 20 85 to 90 0.238
CAPPING SMAW E6013 3.15 STRAIGHT 90 to 95 22 to 24 65 to 90 0.275
AFTER BACK CHIP
SUB PASS SMAW E6013 3.15 STRAIGHT 90 to 95 18 to 20 85 to 90 0.238
FINAL SMAW E6013 4 STRAIGHT 100 to 120 22 to 24 65 to 90 0.275
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : T FILLET
Backing : NO FIG 19
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE

NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : SQUARE BUTT WITH BACKING STRIP
Backing : YES FIG 20
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE

FINAL (5,6) SMAW E7018 3.15 REVERSE 100 to 135 20 to 24 90 ot 120
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : SQUARE BUTT W/BACKING PLT. FOR COD
Backing : YES FIG 21


P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
Position of Groove : 1G Position of Fillet : -
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE

FINAL (5 TO 10) SMAW E7018 3.15 REVERSE 100 to 135 20 to 24 90 ot 120
NAME :
SIGNATURE :
DATE :
Note : WPS for 10mm to insert plate joint should be submitted separately
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : SQUARE BUTT W/BACKING PLT. FOR COD
Backing : YES

Type / Grade No. : GR.B To GR.B ANNULAR TO CLEAN OUT BOTTOM JOINT
P. No. : 1 To 1
Group No. : 1 To 1
POSITION (QW 405)
Position of Groove : 1G Position of Fillet : -
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE

FINAL (3 TO 4) SMAW E7018 3.15 REVERSE 100 to 135 20 to 24 90 ot 120
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE :
PQR NO.:
LOCATION :

Type : T FILLET
Backing : NO FIG 9
P. No. : 1 To 1
Group No. : 1 To 1
Thickness Range : 6 mm OUTER RIM TO BOTTOM DECK LAP JOINT
POSITION (QW 405)
AWS No. (CLASS) : -
GAS (QW 408)
Peening : NA
WELDING PROCEDURE
ONE SIDE CONT.
NAME :
SIGNATURE :
DATE :
WPS NO.:
DATE
WPS NO.:
CLIENT : HINDUSTAN PETROLEUM CORPORATION LTD.
LOCATION :
JOINT DESIGN (QW-402) SKETCH / DETAIL:
Type SQ. BUTT
Backing NO FIG 1 (A)
Backing material Type / Grade NA
WELDINHG PROCESS SWAM TYPE MANUAL
Material Specification IS 2062 / EQ. To IS 2062 / EQ.
Type / Grade No. GR.B To GR.B
P. No. 1 To 1
Group No. 1 To 1
Thick of Coupon 6 mm
Thickness Range 6 mm
Spec. No. (SFA) 5.1 Filler Size : 3.15 / 4 mm
AWS No. (CLASS) E 6013 Electrode Flux Type : -
A. No. : 1 Backing / Storage : As per Manuf. Std.
F. No. : 2 Consumable Insert : Non
Make ESAB/ADVANI/D&H
POSITION (QW 405)
Position of Groove 3G Position of Fillet : NA
Weld Progression UPHILL
Preheat Temp.(Min) NA Temperature : NA
Interpass Temp.(Max) NA Time : NA
Preheat Maint Others : NA
GAS (QW 408)
Shielding Gas NA Flowrate : NA
Percentage Comp. NA Gas Backing : NA
Trailing NA Purging : NA
Current Mode DC String or weave Bead : String / Weaving
Volts 18 to 30 Orifice or Gas Cup Size : NA
Electrical Polarit STRAIGHT Initial / Interpass Cleaning: Wire Brushing
Amperage 80 TO 140 Method of back gauging : Grinding
Tungsten Electrode Size & Type NA Oscillation : NA
Mode of Metal Transfer (GMAW) NA Contact Tube to work distance
: NA
Elect. Wire - Feed,Speed,Range NA Multiple or Single Pass ( /: Side) Multiple
Other NA Multiple or Single Electrode: Single
Travel Speed Electrode : SEE TABLE
Peening NA
WELDING PROCEDURE
Filler Material Heat Input
Class Dia Type & Pol. Amps Range Volts Range mm / min kj / mm
AFTER BACK CHIP E6013

HINDUSTAN PETROLEUM CORPORATION LTD
JOB PROCEDURES
FOR
TANKAGE WORKS
JOB PROCEDURES FOR TANKAGE WORK

HINDUSTAN PETROLEUM CORPORATION LTD
!
"
#
$
%
%
&
JOB PROCEDURES FOR TANKAGE WORK

DOC NO
DATE
PAGE NO
03 OF 16
PROJECT TITLE
PROCEDURE FOR FABRICATION & ERECTION OF
TANKAGES BY JACKING UP METHOD
JOB PROCEDURE FOR FABRICATION & ERECTION OF TANKAGE

BY JACKING METHOD
1. SCOPE:
This procedure covers detailed activities for fabrication, erection and testing of the
storage tanks, and also equipment & manpower required for the same. All the tasks /
activities need to be carried out with atmost care with good workmanship and in
accordance with the specifications to achieve satisfactory completion of the whole
activities.
2. PURPOSE:
The purpose of this document is to follow proper methodology to carry out the
activities in a proper sequence for fabrication, Erection and Testing of the storage
tanks.
3. REFERENCE:
API 650
ASME Sec IX
ASME Sec V
Tender Specification.i.e. 18-3188-99-02-V-02-001-A4; VSS004; 18-3188-00/Z-00-
001; 18-3188-99-00-V.02-005-A4 etc
Approved Drawing / Specification.
4. RESPONSIBILITY:
The responsibility of implementation of this procedure rests with Construction
Manager of M/S Vishal Structurals Pvt. Ltd.
5. METHOD OF CONSTRUCTION:
5.1 IDENTIFICATION OF MATERIALS
Each Piece of Plates, fittings or any other component of tankage system shall be
clearly identified by marking heat no. on the part (e.g.: IS 2062 Gr.B, H.No.-XXX)
using hard punching.
Each weld joint shall be marked with joint Number with Welder Number.
5.2 FABRICATION WORK
All fabrication work involving material identification, marking, cutting, rolling and
welding shall be done in accordance with this job procedure, API 650 (Latest
edition), JE Spec and tender documents. The workmanship shall be good in every
respect meeting all safety, QC & NDT requirements, with the coordination of
Engineer-In-Charge.
Prepared by Concurred by Approved by
Name : Name :
Design: Design:
CONTRACTOR Hindustan Petroleum Crop. Ltd. Hindustan Petroleum Crop. Ltd

DOC NO
DATE
PAGE NO
04 OF 16
PROJECT TITLE
PROCEDURE FOR FABRICATION & ERECTION
OF TANKAGES BY JACKING UP METHOD
Lay all the plates, Structural & pipes in such a way prior to fabrication to
facilitate proper checking of dimensions & heat no.
Mark the components as per the drawings.
5.2.1 ANNULAR & BOTTOM PLATE FABRICATION:

Mark the plates as per drawing
Carry out the cutting operation after proper inspection.
All the cutting operation shall be carried out by Gas Cutting.
Grind the cut edges smooth to remove burrs and slag.
Stack the plates at designated place in the fabrication yard in proper
sequence.
Backing – strip shall be fitted and tacked with annular plate as per drg.
After completion of the fabrication under side of annular and bottom plates shall
be blast cleaned and painted as per the specification to the satisfaction of the
engineer-in-charge.
Check the Joint Position, Root gap for welding after welding Inspection by weld
visual & NDT as per API 650 / Tender document.
5.2.2 SHELL PLATE FABRICATION

Lay all the plates in the open area such a way easy for marking and cutting.
Mark the plates as per drawing and to the satisfaction of Engineer-in-charge.
The cutting operation includes beveling shall be carried out by gas cutting
method on all the four sides.
Grind the cut edges smooth to remove slag and burr.
The edge prepared plates shall be shifted by hydra crane to the rolling area.
The plates shall be fed to rolling m/c. by means of hydra crane & proper lifting
tools and tackles.
Name : Name :
Design: Design:
CONTRACTOR . Hindustan Petroleum Crop. Ltd. Hindustan Petroleum Crop. Ltd

DOC NO
DATE
PAGE NO
05 OF 16
PROJECT TITLE
The plate shall be rolled as per drawing details and the radius shall be checked
using Template.
Proper care shall be taken for the smooth curvature.
36’’ Long (5 to 6mm thk.) Template shall be used to check rolling curvature
accurately.
The Template shall be checked and cleared by inspection authority.
The rolled plates shall be inspected and shall be within 03mm. of tolerance
limit.
The rolled plates shall be shift to shot blasting yard to carryout the shot blast
as per JE specification.
Final profile and dimensions check shall be carried out before sent for rection.
5.2.3 ROOF PLATE FABRICATION
Mark the roof plate as per drawing

All the cutting operation as per requirement shall be carried out after getting
the clearance from the inspection authority.
All the cutting operation shall be carried out by gas cutting method on all the
four side.
Grind the cut edges smooth to remove burrs &slag.
Structural item of the roof shall be fabricated as per drawing.
These roof plates shall be shifted to blasting yard to carryout the blasting and
painting.
Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
06 OF 16
PROJECT TITLE
5.2.4 APPURTENANCES
Mark the required items of the Appurtenances as per the drawing. All the
cutting operation as per requirement shall be carried out after getting the
clearance from inspection authority.
All the cutting operation shall be carried out by gas cutting method.
Grind the cut edges smooth to remove burrs & slag.
Flanges face to be covered with a suitable cover to protect from damage
during handling, fabrication and transportation.
The entire shell nozzle, roof appurtenance, i.e. flanges, flanges to pipe
joint and other requirements etc. Shall be fabricated as per approved
drawings.
All the fabrication and welding activities shall be carried out after the stage
wise inspection wherever required.
The N.D.T requirements as per code specification.
5.2.5 SPIRAL STAIRWAY, HAND RAILING

All the structural items shall be straightened before marking and cutting.
Mark the components as per drawing.
All the cutting operation, as per requirement shall be carried out after getting
the clearance from inspection authority.
All the cutting operation shall be carried out by gas cutting method.
Grind the cut edges smooth to remove burrs & slag.
Fabrication such as fitting, welding, drilling, etc. Shall be carried out as per
drawing and after the clearance from inspection authority.
After fabrication all these structural items shall be blasted and painted as per
requirement.
5.3 ERECTION:
5.3.1. ANNULAR PLATE LAYING
Check the level of foundation as per specification API 650 clause 8.4.2. Latest
edition.
After getting clearance for annular plate laying, mark the 0o, 90o, 180o, 270o co-
ordinates on the foundation from the reference point.
Lay the annular plate as per approved drawing.
Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
07 OF 16
PROJECT TITLE
Out radius of the annular plate shall be in positive side (5 to 10 mm.) in order to
achieve the final required radius after weld shrinkage.
Orientation of the annular plate joint shall be as per approved -drawing.
Fit up of annular plate's joints shall be carried out using proper jigs and fixtures as
shown in drawing.
Care shall be taken while fit-up, such that there should not any gap between
annular plate and backing-strip.
Annular plates joints welding shall be carried out by welding alternative joint at four
quadrants.
Qualified welders shall be engaged for the welding work according to WPS.
If any defect found the defect weld shall be removed by grinding and re-weld and
conduct the LPT check test. Repeat the sequence until the defect cleared.
Complete the welding, clean the final weld surface by wire brushing and grinding.
Remove the jigs and fixtures which were used for fit-up of the annular joint and
grind the tack.
Radiography shall be taken as per API-650 Sec-6.
5.3.2 BOTTOM PLATE LAYING:

Lay the center plate on the foundation top as per drawing.
With co-ordination of Centre plate lay the bottom plates sequentially as per drg.
Laps shall be maintained while the fit-up of short seam and long seam as per drg.
Temporary tack weld to be carry out on the Long-seam to avoid uneven
movements, while the fit-up and welding of short-seam.
Short seam welding will be carried out alternatively to avoid distortion.
After the completion of short-seam welding, remove the temporary tacks on the
Long- seam by grinding to facilitate the long-seam fit-up.
Short seam welding will be carried out alternatively to avoid distortion.
After the completion of short-seam welding, remove the temporary tacks on the
Long- seam by grinding to facilitate the long-seam fit-up.

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
08 OF 16
PROJECT TITLE
Minimum laps shall be maintained while the fit-up of long-seam as per approved
drg.
Joggling shall be carried out by hammering wherever it necessary. (Three plate
Joining junction.)
Before starting the welding, channels shall be tacked along the long-seam to avoid
the distortion.
After completion of shot seam welding long seam welding will be carried out
alternatively to avoid distortion.
Qualified welder shall be engaged and welding shall be carry out as per approved
WPS.
After Completion of welding thoroughly clean the weld ‘joint by wire brushing and
grinding.
Sketch to annular plate joint shall be welded only after shell to bottom joint welding.
All the bottom plate' s joints vacuum box test shall be carried out as per approved
procedure and code specification.
If any defect found the defect weld shall be removed by grinding and re-weld and
conduct the vacuum box test. Repeat the sequence until the defect cleared.
5.3.3. SHELL COURSE ERECTION

After the completion of welding of Annular plates and bottom plates, mark the tank
inner radius on the annular plates.
Fix 25 Nos. of erection stools at the equal interval on the annular plates & transfer
the inside tank diameter on the stools.
The top one shell courses shall be erected by conventional method.
Balance shell courses shall be erected by hydraulic jack method.
The rolled shell plates shall be shifted to the tank foundation area stacked around
the periphery by using hydra crane.
Proper care shall be taken while handling the rolled plates.
Care shall be taken that the shell plate erected to the diameter marked on the
annular plate.
Jigs and fixtures shall be use to align the shell plates.
Complete the fit up except the final joint which shall be fitted and weld after
completion of the welding of the other joints. (To avoid the shrinkage)

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
09 OF 16
PROJECT TITLE
Peaking to be checked after the fit-up of the vertical joints. Peaking shall be within
the tolerance as per API - 650. (Tolerance 1/2")
Peaking shall be checked at top, middle and bottom of the vertical joints using a
Sweep board of 36” long.
Plumbness shall be checked for the verticality of the shell course at every 60° and
shall be within the tolerance (tolerance 1/200 of the total shell height)
For perfect verticality, channels shall be provided at the regular interval inside of
the shell course (3 to 5 meters) Providing the channels shall be facilitates the
alignment last shall course.
Tack welds of the fitted vertical joints shall be ground smooth.
Offer for inspection and get clearance from Engineer-in-charge for the vertical
fit-up Complete the first side welding by using qualified welders.
Care shall be taken while the welding to avoid the peaking and the roundness
distortion
After completion of first side welding, back-chip shall be carried out for sound metal
from other side of the weld by grinding.
Back-chipped grooves shall be offered for inspection before starting the welding.
Complete the 2nd side welding using qualified welders.
Joint Nos. & welder No. shall be marked on both side of the weld .joint.
Care shall be taken to avoid the peaking and roundness distortion.
Clean weld joints from both sides by wire brushing and grinding.
After completion of welding from both sides remove all the temporary jigs and
fixtures and flush grind the tacks. (Do the weld fill up wherever required) and the
portion checked by D.P.test.
Check the peaking, plumb ness, circumference and the radius, offer for inspection
to the satisfaction of the Engineer-in-Charge.
Erect last shell course plate on top of the erected shell plate, 3mm thick spacers
shall be kept between first and last but one shell course plates to maintain
horizontal seam gap.
Erection channels shall be fixed between last but one shell course plates and
last shell course plates at regular intervals to align and hold the last shell in
vertical position.

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
10 OF 16
PROJECT TITLE
After all the shell plates for last shell course is erected, fit-up the vertical joint using
jig plates which has been fixed during erection and tack weld the joints.
Check peaking at vertical joints of shell using a sweep board of 36" wide,
acceptable tolerance shall the as per API-650 clause 5.5.4 (local deviation shall
not exceed 1/2")
Complete welding of last course vertical seam inside after getting clearance from
the Engineer-in-charge.
Back chip & welding shall be carried out following as same as for other shell
course to the satisfaction of Engineer - in - Charge.
After completion of welding, weld visual, peaking & circumference shall be
checked out and recorded to the satisfaction of Engineer - in-Charge.
Fit up the Horizontal seam between top shell courses and tack welded, remove the
spacers provided during erection, tack weld shall be ground smooth and ensure
that the tacks are sound and there are no defects like cracks and porosity etc.
Check peaking at vertical joints of shell using a sweep board of 36" wide,
acceptable clearance shall be as per API 650 clause 5.5.4 (local deviation shall
not exceed 1/2") Using a vertical sweep board 36" long, check banding at
horizontal joints. Deviation shall not exceed 1/2".
Check Verticality of the last shell course, Verticality (plumb ness) tolerance shall
be as per API - 650 clause 5.5.2 (max. out of plumbness at the top of the shell
relative to the bottom of the shell not to exceed 1/200 of total shell height from top
of last shell to Bottom)
While welding care shall be taken for banding and the roundness.
Back-chip shall be carried out by grinding for the sound metal and to the
satisfaction of Engineer-in-Charge.
Complete the 2nd side welding and clean the joint thoroughly from both sides by
grinding and wire brushing.
Check banding, plumb ness and recorded in the approved format to the
satisfaction of Engineer - In-Charge.
Offer weld visual to the satisfaction of Engineer-In-Charge. .
Mark the RT spots as per the instruction of the Engineer -In-Charge, and complete
the RT as per API - 650 Sec-6 requirements.

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
11 OF 16
PROJECT TITLE
Offer the RT film for reviewing to the Engineer-In-Charge, and if any repair occurs
the repair spot shall be repaired by grinding for the sound metal, Re- weld the
repair spot as per code API -650 sec-6 requirements.
Take the repair spot RT and re offer for the inspection to the satisfaction of
Engineer-In- Charge
Spiral staircase Erection shall be carried out as per drawing including brackets.
Remove all the temporary cleats and tacks by grinding.
Install jacks as per requirement and the distance between the jacks shall not be
more than 3.5 meter. Connect the power pack and check the total system is ready
for erection of the shell.
Install the jacking cleats on the bottom shell course (inside) and weld soundly the
cleats to the shell. Roof structure & Roof shall be erected then start jacking.
Start jacking of the assembly of top two shell course along with the wind girder.
Lift till the required space for the lower shell course plate width + Erection chair
height. (400~450 mm)
Erect the lower shell course by using the Hydra crane for shifting and position the
plates.
Alignment and fit up shall be carried out by using jigs and fixture and as per
drawing offer the fit up for inspection.
Followed by welding, weld visual, peaking and plumb ness before and after as
mentioned above for the top two shell courses.
After completion of the welding lower down the jacked up assembly on top of 3rd
shell from top.03 mm thick spacer shall be kept between 3rd and 2nd shell from top
to maintain the Horizontal joint gap.
Fit up the Horizontal joint between 3rd and 2nd shell courses from top using jigs
and fixtures and tack weld, remove the spacers provided during erection. Tack
shall be ground smooth, check the banding and record. Offer fit up and banding to
the satisfaction of Engineer-In-Charge.
Followed by welding, banding & plumb ness before and after welding shall be
carried out as mentioned for the above Horizontal joint.
RT shall be carried out and cleared before the next lifting
Portion of the spiral stairway shall be erected as per drawing

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
12 OF 16
PROJECT TITLE
After clearance from inspection, the jacking cleats shall be fitted to 3 rd shell from
top course plates and the total assembly shall be jacked up by required height for
erection of the all the shell courses.
In the same manner erect all the shell courses and spiral stairway.
The 1st shell course plates shall be erected, provide min. 6 mm thick packing plates
at required location in each shell plate to facilitate proper welding of the bottom
most portion of the vertical joint. This packing plate shall not be removed until
commencement of shell to annular fit up. Leave the final shell plate open by
providing angular frame in order for deck plate shifting and working.
After completion of welding of vertical seams of the 1st shell course by following
abovementioned process and the Horizontal joint between the shell courses 1 and
2 shall be aligned by lowering the jacks and the fit up shall be carried out.
Follow the above-mentioned process for the horizontal joint welding and
clearance.
RT shall be carried out as per API-650 Sec.6
Shell to annular plate joint shall be carried out using jigs and fixture.
After getting fit up clearance for welding, root weld shall be carried out from
inside.
After completion of inside welding clean the weld thoroughly by wire brushing,
grinding and buffing.
The shell to bottom joint area from both sides shall be cleaned thoroughly to carry
out the chalk-diesel test.
Apply chalk solution from inside. Apply diesel by a hand spray pump from out side.
Hold it as per instruction of the Engineer-In-Charge and check the root weld for
any defect.
If any defect found the defect shall be repaired by grinding the defect area for the
sound metal plus 150mm from both end of the defect.
Conduct the chalk - diesel test on the repair spot. Carry out the whole process until
the repair cleared to the satisfaction of Engineer - In – Charge.

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
13 OF 16
PROJECT TITLE
After completion of shell to bottom out side welding visual inspection will be
carried out to the satisfaction of the Engineer-In-Charge.
On completion of shell to bottom welding / NDT and having completed all erection
and welding work on the tank inside related to the roof and roof structure, all
unwanted materials and scrap shall be removed from inside of the tank.
RT of vertical and horizontal joint shall be completed.
Sketch to annular plate joint fit up shall be carried out and complete the welding.
Vacuum box test the shall be carried out for the bottom plate short seam, long
seam and sketch to annular plate joint.
If any repair occurs the same shall be repaired and re-tested as per the approved
procedure and API-650.
5.3.4 ERECTION OF CONE ROOF PLATES AND STRUCTURES
After completion of the Top two shell courses erection, fit up, welding and curb ring
fit up & welding shall be done.
Erect the fabricated Centre Drum, Roof Truss, and cross girders as per drawing.
Complete the welding of Roof structure by approved welders and as per approved
WPS.
Erect and Lay the Roof plates on the structure as per the Drg.
While fit up of the short seams and long seams Lap to be maintained as per Drg
Weld the short seams by welding alternative joint or sequence mentioned in the
Drg.to prevents the distortion.
Provided proper support lengthwise of the long seam and weld the joints as per
Drg. sequence.
Roof Nozzles and top shell nozzles fit-up and welding shall be carryout as per the
approved drawing and subsequently it has to be correlated with the concern piping
drawing.

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
14 OF 16
PROJECT TITLE
5.3.5 APPURTENANCES INSTALLATION

Flanges to pipe joint shall be prefabricated and required NDT shall be completed
before erection.
Mark the nozzle location as per drawings. Cut the openings by gas cutting after
proper Inspection-by-inspection authority.
Erect the nozzles as per the orientation & the elevation shown in the drawing.
Install RF. pads wherever required before nozzle erection
Suitable jigs & fixtures shall be provided to prevent the distortion during the
welding.
After completion of bottom shell course welding shell nozzles shall be marked as
per drawing and offer for inspection.
Cut open the nozzle opening, install the RF. Pads and erect the nozzles
(prefabricated) as per drawing.
Orientation, elevation & projection shall be maintained as per drawing and offer for
the inspection clearance.
Proper care shall be taken for the welding by providing jigs & Fixtures to prevent
distortion.
Welding shall be as per WPS and to be welded by the qualified welder.
Man-Hole neck shall be fabricated and the longitudinal joint shall be radio
graphed.
All the RF Pad weld shall be pneumatically tested at an pressure of 1.05 Kg/Cm2
RF. Pad pneumatic test shall be carried out to the satisfaction of the engineer-in-
charge.
All the shell nozzles final weld from both sides and RF. Pads welds shall be
inspected by visually and by LPT, to the satisfaction of the engineer-in-charge.

Name : Name :
Design: Design:
CONTRACTOR . Hindustan Petroleum Crop. Hindustan Petroleum Crop.
Ltd. Ltd
DOC NO
DATE
PAGE NO
15 OF 16
PROJECT TITLE
6. PROPOSED PLANT AND MAJOR EQUIPMENT

PLANT /EQUIPMENT /TOOLS / TACKLES
Hydra 10MT / 12MT capacity.
Welding transformers /Rectifiers 400 a & 600 a Welding generators.
Radiography source Ir 192.
Test Pump.
Water pump
Transporting Equipment.
Plate bending Machine.
Pipe Bending Machine
Hydraulic Jack 12 MT [with power pack & accessories] and other
required equipment.
Grinding machine [AG - 7, AG - 4, GQ – 4 & FF2]
Gas cutting equipment [Pug cutting m/c & hand cutting m/c]
Vacuum pump and vacuum box with Gauge.
Vernier Caliper
Lifting Tools & Tackles and Derrick
Mother & Portable Oven
All Measuring Tape (30 M, 15 M, 5M, 3M.)
Piano Wire, Plumbob (Heavy weight)
Viewer
Aluminum Ladder -4 Nos.
12v Hand lamp set for all four tanks.
Exhaust fan for all four tanks.
DG set with panel board separately for welding Rectifiers and Grinding.
Elcometer Pr.Gauge, Air-Compressor etc.
7. MAN POWER
AS PER REQUIREMENT

DOC NO
DATE
PAGE NO
16 OF 16
PROJECT TITLE
8. QUALITY ASSURANCE & QUALITY CONTROL
This shall be followed and maintained with the compliance / adherence to the drawings,
procedure and code specification. Records shall be kept in the relevant check sheet and
formats duly signed by all the concerned departments.
9. SAFETY
Tested & certified Lifting equipments should be used for lifting and shifting
purpose.
Safety Precautions should be followed during fabrication and erection as per JE
specification.
Welding cables and power cables to be laid properly as per IE rules and local state
govt. rules.
Proper house keeping and clean condition shall be maintained in the fabrication
shop and site as per requirement.
10. RECORDS
Foundation hand over report
Material Inspection Records
Electrode, Consumables etc. verification record
Welding Inspection report
NDT reports
Test reports

Name : Name :
Design: Design:
DOC NO
V
DATE
PAGE NO
03 OF 17
PROJECT TITLE
RADIOGRAPHIC EXAMINATION PROCEDURE.
RADIOGRAPHIC EXAMINATION PROCEDURE

1. SCOPE:
The scope of this procedure shall apply to all radiographic examinations carried
out during the execution of the Tankage Re-Erection work Phase-II with a special
emphasis on radiation safety.
2. PURPOSE:
The purpose of this procedure is to ensure that the radiographic images produced
are acceptable quality and that all radiographic examinations are performed in a
safety policy, project specifications, quality control plan (SEP-Q1-001) and
applicable codes.
3. REFERENCE:
ASME V Nondestructive Examination-Boiler & pressure vessel Code
ASME B31.3 Process Piping
ASME IX Welding and Bracing Qualification
API 650 Welded Steel tanks for Oil Storage.
SNT-TC-1A Recommended Practice for Nondestructive Testing Personnel
Qualification & Certification.
API 1104 Standard for welding pipelines and related facilities.
4. RADIATION SAFETY
4.1 General
The radiographic technician (radiographer) shall be fully trained / qualified, and
shall be fully aware of the hazards of radiation.
Human body tissue will be severely damages if they are over exposed to
radiation and even small amount of exposure on a daily basis, with insufficient
recovery periods, will eventually produce a serious deterioration in health.
All possible safety precaution shall always be taken to avoid unnecessary
exposure.
Prior to commencing any radiation work on site, emergency procedures shall be
established.
All radiographic discipline personnel who are involved with working with ionizing
Radiation shall
Take all reasonable safety precautions.
Not knowingly expose either themselves or any other person to radiation
greater than is absolutely necessary for the purposes of their work.
Name : Name :
Design: Design:

DOC NO
DATE
PAGE NO
04 OF 17
PROJECT TITLE
Make full and proper use of all personal protection equipment provided.
Report any defects to radiographic equipment to his employer immediately
upon discovery.
4.2 Controlled areas
Radiography shall only be undertaken in designated and clearly identified
”controlled areas”.
These areas shall be identified and sealed by the use of the following as a
minimum
Radiation tape Barriers-which surround and seal off the controlled area in its
entirety.
Radiation Hazard Warning Signs in English.
The sign shall be a minimum size of 450 x 450 mm.
These shall be positioned every 30 meters around the periphery of the
controlled area.
Flashing yellow lights to indicate radiation hazard area, these shall be
positioned adjacent to warning signs.
Under no circumstances shall non radiographic discipline (unclassified)
personnel cross or enter the barriers to a controlled area.
Any infringement of this safety rule / regulations concerning controlled areas will
result in the immediate removal of the individual concerned and expulsion from
the Tankage Project.
4.3 Radioactive isotope
The container in which radioactive isotopes are housed shall be lockable and
sealed. They shall be manufactured from expended uranium or similar
materials, to international safety standards.
These containers shall be re-certified as safe to use every of 26 months
(maximum).The senior radiographic technician on site shall hold the keys at all
times (other than usage).The whereabouts of all radioactive isotopes on site
shall be logged and known at all times.
5. QUALIFICATION OF EXAMINATION PERSONNEL

The qualification of examination personnel shall be in accordance with SNT-TC-
1A or an alternative system specifically accepted by owner.

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6. EQUIPMENT AND MATERIALS

6.1 Film
Radiographs shall be made using industrial radiographic films that are available to
meet the required quality of radiographs. AGFA /KODAK made D4 or equivalent
film to be used for 6 mm to 19 mm thick materials.
6.2 Identifying screen

The function of the lead intensifying screens is to reduce exposure times by the
emission of electrons and secondary radiation in reaction to the primary radiation
source and at the same time reduce film fogging by acting as a filter for the
absorption of back scattered radiation.
The lead screens used shall be clean and in good condition, with a thickness of
0.125 mm (front) and 0.25 mm (rear), and shall be in direct contact with the
radiographic film.
6.3 IQI (Image Quality Indicator)

Pentameter shall be either the hole type or the wire type and shall consist of those
in Table 1 for hole type and those in Table 2 for wire type.
6.4 Radiation source

Iridium 192 will be used as a radiation source.

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Table .1.Hole Type IQI Designation, Thickness and Hole Diameters, in
Penetrameter Penetrameter 1T Holes 2T Holes 4T Holes

Designation Thickness Diameter Diameter Diameter
5 0.005 0.010 0.020 0.040
7 0.007 0.010 0.020 0.040
10 0.010 0.010 0.020 0.040
12 0.012 0.012 0.025 0.050
15 0.015 0.015 0.030 0.060
17 0.017 0.017 0.035 0.070
20 0.020 0.020 0.040 0.080
25 0.025 0.025 0.050 0.100
30 0.030 0.030 0.060 0.120
35 0.035 0.035 0.070 0.140
40 0.040 0.040 0.080 0.160
45 0.045 0.045 0.090 0.180
50 0.050 0.050 0.100 0.200
60 0.060 0.060 0.120 0.240
80 0.080 0.080 0.160 0.320
100 0.100 0.100 0.200 0.400
120 0.120 0.120 0.240 0.480
160 0.160 0.160 0.320 0.640
200 0.200 0.200 0.400 …….

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Table .2. Wire IQI Designation and Wire Diameters, in
ASTM Wire
Set Diameter
0.032
0.004
A 0.005
0.006
0.008
0.010
0.013
0.016
B 0.020
0.025
0.032
0.040
C 0.050
0.063
0.080
0.100
0.126
0.160
0.200
D 0.250
0.320

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7.PROCESSING REQUIREMENTS
7.1 Quality of radiographs
All radiographs shall be free from mechanical, chemical or other artifacts to be
extent that they cannot mask or be confused with the image of any discontinuity in
the object being radiographed. Such artifacts include but are not limited to:
[a] Fogging
[b] Processing defects such as water or chemical marks.
[c] Scratches, Finger marks, crimps, static smudges or tears
[d] Loss of details due to poor film Contrast.
[e] False indication due to defective screens.
7.2 Processing Manual (According to SE-94)
7.2.1 Preparation :–
No more film should be processed that can be accommodated with a
Minimum separation of ½ “. Hangers are loaded and solutions stirred before
starting development.
7.2.2 Start of development :-
Start the timer and place the films into the developer tank. Separate
to a minimum distance of ½ “ and agitate in two directions for about 15
seconds.
7.2.3 Development:-
Normal development is 5 to 8 minutes at 68° F (20° C)
7.2.4 Agitation:-
Shake the film horizontally and vertically, ideally for a few seconds each
minute during development. This will help develop evenly.
7.2.5 Rinsing:-
Rinse the films with vigorous agitation in clear water.
7.2.6 Fixing:-
The Films must not touch one another in the fixer. Agitate the hangers
vertically for about 10 seconds and again at the end of the first minute, to
ensure uniform and rapid fixation. Keep them in the fixer until fixation is
complete (i.e. at least twice the clearing time),but not more than 15 minutes
in relatively fresh fixer. Frequent agitation will shorten the time of fixation.
7.2.7 Fixer Neutralizing:-
Use hypo eliminator or fixer neutralizer between fixation and washing.

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7.2.8 Washing:-
Washing is very slow below 60° F(16° C).When washing at temperature above
85° F(30° C),care should be exercised not to leave films in the water too long.
The films should be washed in batches without contamination from new film
brought over from the fixer. If pressed for capacity, as more films are put in the
wash, Partially washed film should be moved in the direction of the inlet.
7.2.9 Wetting Agent:-
Dip the film for approx. 30 seconds in a wetting agent added clear water.
7.2.10 Drying:-
Take Precaution to tighten film on hangers, so that it cannot touch in the dryer.
Too hot a Drying temperature at low humidity can result in uneven drying and
should be avoided.
8.EXAMINATION PROCEDURE:-
8.1. Surface Preparation
The weld ripples or weld surface irregularities on both the inside (where
accessible) and outside shall be removed by any suitable process to such a
degree that the resulting radiographic image due to any irregularities cannot mask
or be confused with the image of any discontinuity.
8.2. RT request
Upon completion and visual acceptance of a weld that is subject to radiography,
the controlling engineer shall make a request for radiographic examination.
The request shall be entered into the schedule for radiographic examination and
forwarded to the radiographic technicians for execution.
8.3. Controlled area

Radiography shall only be performed at such times as the work site is clear of all
non radiographic discipline personnel and the area of exposure shall be
designated a ‘ controlled area’
Prior to commencing exposure of the isotope, all safety precautions and
requirements as stated in 4.0 radiation safety shall be implemented.
The area in which the isotope is to be exposed shall be treated as a ’controlled
area’ and only classified personnel may enter.

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The boundaries of this ‘controlled area’ shall be identified with radiation tape
barriers, warning signs (in both English and Hindi) and flashing lights.
8.4.Marking on the weld

The radiographer shall identify the weld to be radiographed and mark the weld.
8.5. Film identification

Each radiograph shall be uniquely identified by means of lead numbers and
letters. The lead letters and numbers shall not encroach into the weld area and
shall not interfere with the interpretation of the radiograph in any way.
The following information shall be displayed on each radiographic film as a
minimum:
--- Project name
--- Company name
--- Line number, drawing number or piece number.
--- Weld number
--- Repair identification number(where applicable)
--- Welder identification number
--- Date of radiograph
--- Joint thickness and diameter
8.6. Location markers

Location markers, which are to appear as radiographic images on the film, shall
be placed on the part, not on the exposure holder.
Their location shall be permanently marked on the surface of the part being
radiographed when permitted, or on a map, in a manner permitting the area of
interest on a radiographed to be accurately traceable to its location on the part.
8.7. Direction of radiation

The direction of the central beam of radiation should be centered on the area of
interest whenever practical.

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8.8. Film handling

Care shall be taken to ensure that both exposed and unexposed films are kept
segregated and are stored in such a manner as that they shall not be subjected
to radiation, excessive heat, dirt, fumes, etc.
8.9. Radiographic technique

8.9.1 Single wall technique
In the single wall technique, the radiation passes through only one wall of the
weld, which is viewed for acceptance on the radiograph.
8.9.2 Double wall technique

When it is not practical to use a single wall technique, one of the following
double wall techniques shall be used.
[a] Single wall viewing
For welds in components, technique may be used in which the radiation
passes through two walls and only the weld on the film side wall is viewed
for acceptance on the radiograph.
When complete coverage is required for circumferential welds, minimum of
three exposures taken 120 deg. to each other shall be made.
[b] Double wall viewing
For welds in components 3.1/2 in. or less in nominal outside diameter, a
technique may be used in which the radiation passes through two walls and
the weld in both walls is viewed for acceptance on the same radiograph.
For double wall viewing, only a source side penetrameter shall be used.
[1] For welds, the radiation beam may be offset from the plane of the weld at an
angle sufficient to separate the images of the source side and film side
portions of the weld so that there is no overlap of the areas to be interpreted.
When complete coverage is required, a minimum of two exposures taken 90
deg. To each other shall be made for each joint.
[2] As alternative, the weld may be radiographed with the radiation beam
positioned so that the images of both walls are superimposed.
When complete coverage is required, a minimum of three exposures taken
at either 60 deg. To 120 deg. To each other shall be made for each joint.

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8.10. Geometric unsharpness

Unless otherwise specified in the applicable job order or Contract, the geometric
unsharpness shall not exceed the following limits:
Material Ug
Thickness (in.) Maximum (in.)
Under 2 0.020
2 trough 3 0.030
Over 3 trough 4 0.040
Greater than 4 0.070
8.11. IQI Selection

The designed hole penetrameter with essential hole or designed wire diameter
shall be as specified in Table 3.
8.11.1.Weld with reinforcements

The thickness on which the penetrameter is based is the nominal single wall
thickness plus the estimated weld reinforcement not to exceed the maximum
permitted by the referencing Code Section.
Backing rings or strips are not be considered as part of the thickness in
penetrameter selection.
The actual measurement of the weld reinforcement is not required.
8.11.2.Weld without reinforcements

The thickness on which the penetrameter is based is the nominal single wall
thickness.
Backing rings or strips are not to be considered as part of the thickness in
penetrameter selection.

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Table.3 IQI Selection

Penetrameter
Normal
Single-wall Source Side Film side
Material
Thickness Hole Type Essential Wire Hole Type Essential Wire Diameter, in
Range, in. Designation Hole Diameter, Designated Hole
in
Up to 0.25 incl. 12 2T 0.008 10 2T 0.006
Over 0.25 through 0.375 15 2T 0.010 12 2T 0.008
Over 0.375 through 0.50 17 2T 0.013 15 2T 0.010
Over 0.50 through 0.75 20 2T 0.016 17 2T 0.013
Over 0.75 through 1.00 25 2T 0.020 20 2T 0.016
Over 1.00 through 1.50 30 2T 0.025 25 2T 0.020
Over 1.50 through 2.00 35 2T 0.032 30 2T 0.025
Over 2.00 through 2.50 40 2T 0.040 35 2T 0.032
Over 2.50 through 4.00 50 2T 0.050 40 2T 0.040
Over 4.00 through 6.00 60 2T 0.063 50 2T 0.050
Over 6.00 through 8.00 80 2T 0.100 60 2T 0.063
Over 8.00 through 10.00 100 2T 0.126 80 2T 0.100
Over 10.00 through 12.00 120 2T 0.160 100 2T 0.126
Over 12.00 through 16.00 160 2T 0.250 120 2T 0.160
Over 16.00 through 20.00 200 2T 0.320 160 2T 0.250

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CONTRACTOR . Hindustan Petroleum Crop. Hindustan Petroleum Crop. Ltd

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8.11. Placement of penetrameters

8.11.1.Source side penetrameter(s)
The penetrameter(s) shall be placed on the source side of the part being
examined, except for the condition described in 8.11.2
8.11.2. Film side penetrameter(s)

Where inaccessibility prevents hand placing the penetrameter(s) on the
source side, the penetrameter(s) shall be placed on the film side in contact
with the part being examined.
A lead letter ”F” , at least as high as the penetrameter indication number(s),
shall be placed adjacent to or on the penetrameter(s), but shall not mask the
essential hole where hole penetrameters are used.
8.11.3.Penetrameter location for welds—hole penetrameters

The penetrameter(s) may be placed adjacent to or on the weld.
The identification number(s) and, when used, the lead letter ”F” shall not be
in the area of interest.
8.11.4. Penetrameter location for welds—wire penetrameters

The penetrameter(s) shall be placed on the weld so that the length of the
wires is perpendicular to the length of weld.
The identification number(s) and, when used, the lead letter ”F” shall not be
in the area of interest.
8.12. Number of penetrameters

For components where one or more film holders are used for an exposure,
at least one penetrameter image shall appear on each radiographed except
as outlined in 8.12.2.
8.12.1. Multiple penetrameters

If the requirements of 9.3.2 are met by using more than one penetrameter,
one shall be representative of the lightest area of interest and the other the
darkest area of interest: the intervening densities on th radiograph shall be
considered as having acceptable density.
Prepared by Concurred Approved by Concu

by Name : by
Name : Design: Name
Design: Design
CONTRACTOR Hindustan Petroleum Crop. Ltd
. Hindustan Hindus
Petroleum Petrole
Crop. Ltd. Crop. L
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8.12.2. Special cases

[1] For cylinder vessels where the source is placed on the axis of the object
and one or more film holders are used for a single exposure of a complete
circumstance, at least three penetrameters shall be spaced approximately
120 deg.apart.
[2] For cylinder vessels where the source is placed on the axis of the object
and four or more film holders are used for a single exposure of section of
the circumference, at least three penetrameters shall be used.
One penetrameter shall be in the approximate center of the section
exposed and one at each end
When the section of the circumference exposed exceeds 240 deg. the
rules of [1] above apply. Additional film locations may be required to obtain
necessary penetrameter spacing: otherwise at least one penetrameter
image shall appear on the each radiograph.
[3] For spherical vessels, where the source is located at the centre of the
vessel and one or more film holders are used for a single exposure of a
complete circumstance, at least three penetrameters shall be spaced
approximately 120 deg. apart.
For other welds radiographed simultaneously, one additional parameter is
shall be placed on each other weld.
[4] For segments of spherical vessels where the source is located at the
centre of the vessel and four or more films holders are used for a
circumferential weld, at least three penetrameters shall be used. One
penetrameter shall be in the approximate centre of the portion exposed
and one each end.
When the portion exposed exceeds 240 deg., the rules of [3] above apply.
Additional film locations may be required to obtain necessary penetrameter
spacing; otherwise, at least one penetrameter image shall appear on each
radiograph.
8.13. Shims
A shim of material radiographically similar to the weld metal shall be placed
between the part and the penetrameter, if needed, so that the radiographic
density throughout the area of interest is no more than minus 15 % from
the radiographic density through the penetrameter.
The shim dimensions shall exceeds the penetrameter dimensions such
that the outline of at least three sides of the penetrameter image shall be
visible in the radiograph.

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9. EVALUTION
9.1. Quality of radiographs
All radiographs shall be free of mechanical, chemical, handling related or other
blemishes to the extent that they do not mask and are not confused with the
image of any discontinuity in the area of interest of the object being
radiographed. If any doubt exists as to the true nature of an indication
exhibited by the film, the radiograph shall be rejected and re-shot.
9.2. Viewing facilities for radiographs
Viewing facilities shall provide subdued background lighting of an intensity that
will not cause troublesome reflections, shadows or glare on the radiograph.
Equipment used to view radiographs for interpretation shall provide a variable
light source sufficient for the designated wire to be visible for the specified
density range.
9.3.Radiographic density
9.3.1 Density Limitations
The transmitted film density through the radiographic image of the body of
appropriate hole penetrameter or adjacent to the designated wire of a wire
penetrameter and the area of interest shall be 2.0 minimum and 4.0 maximum.
9.3.2 Density variation
[a] General
If the density of the radiograph anywhere through the area of interest varies by
more than minus 15% or plus30 % from the density through the body of the
hole penetrameter or adjacent to the designated wire of a wire penetrameter
within density limitations, then an additional penetrameter shall be used for
each exceptional area or areas and the radiograph taken.
[b] With Shims
When shims are used the plus 30 % density restriction of [a] above may be
exceeded, provided the required penetrameter sensitivity is displayed and the
density limitation are not exceeded.
9.4. IQI sensitivity
Radiography shall be performed with a technique of sufficient sensitivity to
display the hole penetrameter image and the specified hole, or the designated
wire of a wire penetrameter, which are essential indication of the image quality
of the radiograph. The quality levels required using wire Penetrameters shall
be equivalent to the 2-2T level of method E 142/ or practice E1025, ASME Sec
V Article 22 for hole type penetrameters. The table T-276 Article 2 Sec V
Provides a list of various hole type IQI’s and the diameter of the wires of
corresponding EPS (Equivalent Penetrameter Sensitivity) with the applicable
2T holes in the IQI.
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9.4. Excessive scatter

A lead letter “B” shall be attached to the back of each film holder during each
exposure to determine if backscatter radiation is exposing the film
If a light image of the “B” appears on a darker background of the radiograph,
protection from backscatter is insufficient and the radiograph shall be
considered unacceptable.
10. ACCEPTANCE CRITERIA

Radiographs shall be interpreted only in those areas in which Penetrameter(s)
have established that a suitable radiographic technique has been used
The following acceptance criteria shall be applied according to applicable code
section.
[a] ASME B 31.3
[b] ASME Sec VIII Div 1 UW- 51 or UW- 52
[c] ASME Sec VIII Div.2 AI-510
[d] API 650 XI th Edition cl.8.1.5
11. RECORDS
The following radiographic records shall be maintained as agreed upon between
the client and Visual
11.1 Sketch
11.2 Weld repair documentation
11.3 Film used
11.4 Thickness of material
11.5 Source to film distance
11.6 Film interpretation record shall contain as the minimum following information
11.6.1. Disposition of each radiograph (acceptable or rejected)
11.6.2. If rejected, cause for rejection (slag, crack, Porosity, LOP,LOF etc)
11.6.3. Surface indication verified by visual examination (grinding marks, weld ripple,
spatter etc.)
11.6.4. Signature of the film interpreter
12. ATTACHMENTS
12.1 Sketch showing location markers and arrow markers
12.2 Radiation warning Sign Board.
12.3 Sample radiographic Report.

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PROJECT TITLE
PROCEDURE FOR VACUUM BOX TEST
VACUUM BOX TEST PROCEDURE

1. SCOPE
The objective of the vacuum box technique of bubble leak testing is to locate
leaks in a pressure boundary that cannot be directly pressurized. This is
accomplished by applying a solution to a local area of the pressure boundary
surface and creating a differential pressure across that local area of the
boundary causing the formation of bubbles as leakage gas passes through the
solution.
2. PURPOSE
The purpose of this procedure is provide a guide line to carry out the Vacuum
box test to check soundness of annular joints, bottom( long seam & short seam)
and welding joints for annular plates.
3. REFERENCE CODE
1. API-650 (Latest edition) 7.3.4 & 8.6 Eleventh edition
2. ASME Sec-V
.
4. EQUIPMENT
4.1. The Vacuum box test is performed by using a box with visible window of
fiber glass (i.e.6” Wide by 30” long metallic box with a fiber glass). The
open bottom is sealed against the tank surface by a sponge rubber gasket.
The test scheme shall have suitable connections, necessary valve and
calibrated Vacuum gauge. The gauge shall have a range of 0 psi to 15 psi
or equivalent Pressure limits such as 0 in.Hg to 30 in.Hg.
4.2. The Test scheme shall be demonstrated with sample test block by
application bubble solution at site before conduction the test on the job.
The bubble forming solution shall produce a film that does not break away
from the area to be tested, and the bubbles formed shall not break rapidly
due to air drying or low surface tension, soaps or detergents designed
specifically for cleaning shall not be used for the bubble forming solution.

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4.3. A vacuum can be drawn on the box by any convenient method, such as
connection to a gasoline or diesel motor intake manifold or to an air ejector
or special vacuum pump. The gauge shall register a partial vacuum of at
least 2 psi ( 4in.Hg)(15KPa) below atmospheric pressure.
4.4. Bubble forming solution (Brand name / Type will be furnished prior to
execution) to be established vide 4.2 & to be recorded.
5. PERSONAL
The personnel shall be competent and have through knowledge in performing
this method.
6. SURFACE PREPARATION
The surface to be examined and all adjacent areas shall be cleaned thoroughly
and free from all dirt, grease, lint, scale, welding flux, weld spatters, paint, oil
and other extraneous matter that could obstruct surface openings or otherwise
with the examination.
Prior to vacuum testing all joints shall be checked visually.
7. PROCEDURE
The temperature of the surface of the part to be examined shall not be below
400F( 50C) nor above 1250F( 500C)
The weld seam on the test shall be applied with a bubble solution for detecting
leaks prior to placing vacuum box.
The foaming shall be minimized by means of uniform application of bubble
solution.
The gauge shall at least register a partial Vacuum of 21 Kpa or 3 Lbf/in2 for
inspection of the joints
An Overlap of 2” minimum for adjacent placement of the Vacuum box shall be
given for each subsequent examination.
The required partial vacuum shall be maintained for at least for 10 seconds
examination time stop watch to be used after reaching the 21 KPA / Designated
vacuum.

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8. EVALUATION
Bubbles produced by air sucked through the welded seam can detect the
presence of defect.
The tested areas are accepted only when no continuous bubbles formation is
observed.
A minimum light intensity of 1000 lux is required for conducting the
examination.
9. REPAIR/RETEST
Defects in welds shall be repaired by chipping, grinding or melting out the
defects from one side or both sides of the joints, as required and rewelding.
Only the cutting out of defective joints that is necessary to correct the defects
is required.
After repairing retest of Vacuum box test shall be carried out.
10. CLEANING
After test the area shall be thoroughly cleaned for the further activities.
11. INSPECTION REPORT

The test shall be carried out in presence of the HPCL Engineer.
Upon satisfactory inspection, a report shall be prepared as per HPCL
approved format.
12. SAFETY
Safety shall be followed as per HSE specification during test.

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LIQUID PENETRANT EXAMINATION
PROCEDURE.
LIQUID PENETRANT EXAMINATION PROCEDURE
1. SCOPE:
The scope of this procedure shall apply to all liquid penetrant examinations
carried out during the execution of Tankage Ph II Mahul
2. PURPOSE:
The purpose of this procedure is to ensure that liquid penetrant examinations
are performed in accordance with the project specification, quality control
plan (SEP-QI-001) and applicable codes.
3. REFERENCE:
ASME V Nondestructive Examination - Article 6.
ASME B31.3 Process Piping
API 650 Welded Steel tanks for Oil Storage.
SNT-TC-1A Recommended Practice for Nondestructive Testing Personnel
4. QUALIFICATION OF EXAMINATION PERSONNEL

The qualification of examination personnel shall be in accordance with SNT-
TC-1A or an alternative system specifically accepted by owner.
5. MATERIALS
Penetrant materials used shall belong to the same manufacturer and family
of particular type of Penetrant used batch Certificates for Penetrant materials
shall be maintained.
5.1. Visible, solvent-removable penetrants

5.2. Solvent removers
5.3. Developers

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PROCEDURE.
6. PROCEDURE
6.1. GENERAL
The liquid penetrant examination method is an effective means for detecting
discontinuities which are open to the surface of nonporous metals and other
materials.
6.2.TEMPERATURE LIMIT
It shall be ensured that the temperature of penetrant materials and the surface
of the materials to be tested shall be between 600 F to 1250 F(160 F to 520 F)
6.3. SURFACE PREPARATION
The surface to be examined and all adjacent areas shall be dry and free of all
dirt, grease, lint, scale, welding flux, weld spatter, paint, oil and other
extraneous matter that could obscure surface openings.
6.4.DRYING AFTER PREPARATION
After cleaning, drying of surfaces to be examined shall be accomplished prior
to application of the penetrant.
6.5. APPLICATION OF PENETRANT
The penetrant is applied on the surfaces to be examined by spraying. A liquid
fluorescent or visible dye Penetrant is applied evenly over the surface being
tested and allowed to enter discontinuities open to surface.
6.6. PENETRATION TIME
Penetrant dwell time shall be minimum 10 min. and maximum 60 min.
Ref. Table T-672 ASME Sec V Article 6.
6.7. REMOVAL OF EXCESS PENETRANT
Excess solvent removable penetrants shall be removed by wiping with a cloth
or absorbent paper, repeating the operation until most traces of penetrant
have been removed.
The remaining traces shall be removed by lightly wiping surface with cloth or
absorbent paper moistened with solvent.
To minimize removal of penetrant from discontinuities, care shall be taken to
avoid the use of excess solvent.
Flushing the surface with solvent, following of the penetrant and prior to
developing, is prohibited

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PROCEDURE.
6.8. DRYING AFTER EXCESS PENETRANT REMOVAL

Following the removal of excess penetrant, the surface will dry quickly by
normal evaporation.
6.9. DEVELOPING
Prior to applying non-aqueous developer to the surface, the developer shall be
thoroughly agitated to ensure adequate dispersion of suspended particles.
Developer shall be applied by spraying.
6.10. DEVELOPING TIME AND INTERPRETATION
The developer causes the bleed-out of the entrapped Penetrant out of the
discontinuity staining the developer. The surface is then examined visually to
determine Presence or absence of indications.
Final interpretation shall be made within 7 to 30 min. after a wet developer
coating is dry. Adequate illumination is required to ensure adequate sensitivity
during the examination and evaluation of indications.
7. ACCEPTANCE CRITERIA
All indication shall be evaluated in terms of the following applicable
acceptance criteria.
[a] ASME B 31.3
[b] ASME Sec VIII Div 1,APPENDIX-VIII
[c] API 650
[d] T-676 Article 6 ASME Sec V
8. SAFETY
Penetrant materials are highly volatile, relatively toxic and may cause skin
irritation. Use adequate ventilation at all times and avoid prolonged skin
contact. Penetrant materials aerosol cans should be kept out of direct sunlight
or areas in excess of 1300F.

Name : Name :
Design: Design:
DOC NO
R0
DATE
PAGE NO
01 OF 02
PROJECT TITLE
PROCEDURE FOR OIL-CHALK TEST
OIL-CHALK TEST PROCEDURE

1. SCOPE:
This test procedure shall be used to check the weld joint of shell to annular
plate.
2. PURPOSE:
The purpose of this procedure is provide a necessary guide line to carry out oil-
chalk test to check the weld joint of shell to annular plate.
3. SURFACE PREPARATION:
The surface to be examined and the adjacent area within at least 1” shall be
cleaned thoroughly, must be dry and free from dirt, oil, grease, scale, welding
flux, spatters, paint and other foreign matter that could obstruct surface
openings or otherwise interfere with the examination.
4. APPLICABLE CODE:
API 650 Sec (Clause 7.2.4 (d)) / ASME Section V article 6).
5. PROCEDURE:
After completion of root weld from inside of the shell to bottom joint, apply wet
chalk solution by brush on the root weld uniformly.
Allow the weld joint to dry thoroughly and then spray diesel/ kerosene on the
opposite side of the weld (outside) by using the hand spray pump.
6. INSPECTION AND ACCEPTANCE CRITERIA:

After the application of the penetrant oil, hold it as per the instruction of the
Engineer-in-charge. (Duration time - 4 hrs for light diesel ,high flash point
penetrating oil) API 650 Cl 7.2.4 (d) Edition XIth.
Examine the root weld visually for the evidence of wicking.

DOC NO
R0
DATE
PAGE NO
02 OF 02
PROJECT TITLE
PROCEDURE FOR OIL-CHALK TEST
7. REPAIR AND RETEST:

If any defect found then the same shall be repaired as per the approved
procedure.
Re examine the repair spot and additionally minimum 150mm. for repair spot on
both directions.
Repeat the process until there is no evidence of leaking.
After completion of the test thoroughly clean the joint from both sides for the
further welding.
8. INSPECTION REPORT:
Test shall be carried out jointly and to the satisfaction of the Engineer-in-charge.
Test to be recorded in the approved format.
CONTRACTOR
Hindustan Petroleum Crop. Ltd. Hindustan Petroleum Crop. Ltd
DOC NO
DATE
PAGE NO
01 OF 03
PROJECT TITLE
PROCEDURE FOR PNEUMATIC PRESSURE TEST
PNEUMATIC PRESSURE TEST
1. SCOPE
The objective of the pneumatic pressure testing is to locate leaks in the welds
of the reinforcement plates to shell plates and pontoons of floating roof .This
is accomplished by applying a soap solution to a local area of the pressure
boundary surface and creating a differential pressure across that local area of
the boundary causing the formation of bubbles as leakage gas passes through
the solution.
2. PURPOSE
The purpose of this procedure is provide a guide line to carry out the
Pneumatic pressure test to check soundness of welds of the reinforcement
plates to shell plate and the welds of roof seam of cone roof tank.
3. REFERENCE CODE
1. API-650 (Latest edition) (7.3.4) Eleventh Edition
2.TABLE I-1021 of ASME Section V, July 1, 2008 Edition.
4. EQUIPMENT
4.1. The test scheme shall have suitable connections, necessary valve and
calibrated pressure gauge. The gauge shall have a range of 0 psi to 15
psi or equivalent Pressure limits such as 0 in.Hg to 30 in.Hg.
4.2. An air pressure can be created by any convenient method, such as

connection to a gasoline or diesel motor intake manifold or to an air
ejector or pump.
4.3. Gases: The test gas will normally be air; however inert gases may be
used.
4.4. Bubble solution: As per ASME-V, I-1032.
5. PERSONAL
The personnel shall be competent and have thorough knowledge in
performing this method.

DOC NO
DATE
PAGE NO
02 OF 03
PROJECT TITLE
LONI REVAMPING PROJECT PROCEDURE FOR PNEUMATIC PRESSURE TEST
The surface to be examined and all adjacent areas shall be cleaned
thoroughly and free from all dirt, grease, lint, scale, welding flux, weld spatters,
paint, oil and other extraneous matter that could obstruct surface openings or
otherwise with the examination.
Prior to pneumatic pressure testing, joint shall be checked visually.
7. PROCEDURE
SHELL APPURTENANCES-
REINFORCEMENT PLATES TO SHELL PLATES WELDS
The temperature of the surface of the part to be examined shall not be
below 400F( 50C) nor above 1250F( 500C)
Make 6mm diameter-screw threaded Tell tale hole in the reinforcement
pads before its welding to shell and shell appurtenances.
The reinforcements pads shall be tested by applying up to 2 psi in the
pressure gauge between the tank shell and reinforcement plates on each
opening using tell tale hole
Use soap suds on welds between reinforcement plate to shell,
reinforcement plate to appurtenances to shell plate if any defect noticed.
Repair the defective weld and repeat the test till entire satisfaction.
Close the tell tale with a bolts or screw.
8. INDICATION OF LEAKAGE: The presence of continuous bubble growth on the

surface of the material indicates leakage through an orifice passage(s) in the region under
examination.

DOC NO
DATE
PAGE NO
03 OF 03
PROJECT TITLE
LONI REVAMPING PROJECT PROCEDURE FOR PNEUMATIC PRESSURE TEST
A minimum light intensity of 1000 lux is required for conducting the

examination.
9. REPAIR/RETEST
Defects in welds shall be repaired by chipping, grinding or melting out the
defects from one side or both sides of the joints, as required and rewelding.
Only the cutting out of defective joints that is necessary to correct the defects
is required.
After repairing retest of Pneumatic pressure test shall be carried out.
10. CLEANING
After test the area shall be thoroughly cleaned for the further activities.
11. INSPECTION REPORT
The test shall be carried out in presence of the Engineer In charge /HCPL
Inspector.
Upon satisfactory inspection, a report shall be prepared as per HPCL
approved format.
12. SAFETY
Safety shall be followed as per HSE specification during test.
13. Acceptance Criteria:
The area under test is acceptable when no continuous bubble formation is

observed.
Vishal Structurals Pvt. Ltd. Hindustan Petroleum Crop. Ltd. Hindustan Petroleum Crop. Ltd
DOC NO
V
DATE
PAGE NO
03 OF 05
PROJECT TITLE
JOB PROCEDURE FOR HYDRO TEST / WATER FILL
UP TEST
JOB PROCEDURE FOR HYDROTEST/WATER FILLUP TEST

1. SCOPE
This test procedure shall be carried out to detect the leak in shell weld joints and to
observe the load stabilization of liquid in interval level height.
2. PURPOSE
The purpose of this procedure is providing the guideline and sequential steps for the
hydro test / water fill up test for the tank.
3. CHECK LIST
After completion of the erection, welding and NDT the following points shall be
checked before testing.
All the mechanical activities completion in respect of the drawing and HPCL
Specification and code requirements.
Radiography completion including repairs.
The entire NDT test like chalk-diesel test, LPT, RF .Pad pneumatic test, vacuum box
test completion.
Finally mechanical clearance from the Engineer-In-Charge shall be taken before
Hydrotest in approved format
4. TEST MEDIA
Test media shall be in iron free water, which is clean and free of silt i.e.; Portable
water
5. PROCEDURE
Proper arrangement shall be carried out for the water filling (pipe connection from
the water resource point and providing valves and NRV wherever required.
markers shall be provided on the shell, 500 mm from the bottom to check tank
settlement. Size shall be 50 X 50 X 6mm angle and 100 mm long. The nos. of
setting marker shall be minimum 8 Nos or as per the approved Drg.
Code : API 650 (7.3.6) Eleven Edition

Name : Name :
Design: Design:
DOC NO
VS
DATE
PAGE NO
04 OF 05
PROJECT TITLE
UP TEST
Settling markers shall be provided at every 300 outside the tank at a height of 500
mm from the top of annular plate.
Setting marker shall be welded and initial level reading shall be taken with respect
to the permanent benchmark using dumpy level / Total station
Shell settlement measurements shall be made after tank erection, prior to
hydrotesting and during water filling at 1000 mm intervals up to maximum filling
height of tank.
The levels taken before water filling called as initial level of the tank and shall be
record in an approved format.
The water filling height shall be restricted to the max. Liquid Level or up to the
curb angle.
The water filling shall be carried out in four stages (25%, 50%, 75% & 100% of the
max liquid level of the tank)
Any leaks observed in the shell joint during the hydro test shall be noted and
repaired with the water level min. of 300mm below the leak spot.
The repaired shall be carried out as per the procedure and tank test shall be
recommenced.
After each stage of filling, a load stabilization period shall be observed as
minimum 24 hours max between each stage of filling.
During the stabilization period the settlement reading shall be observed and
recorded jointly with HPCL Engineer-In-Charge through dumpy level only.
Filling rate shall be not exceed 5 meters per day.
After completion of the water filling the water load shall be maintained for 24
hours. After 24 hours the final settlement reading shall be recorded jointly with
engineer-In-Charge.
Tank shall be emptied at a maximum water level variation rate of 5 meters per
day. Care shall be taken that top manholes are open during empty operation of
conical roof tanks.
If salt water is used then corrosion inhibitor should be sprayed (mixed) prior to
filling / after hydro test the tank should be thoroughly cleaned with sweat water.

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
05 OF 05
PROJECT TITLE
UP TEST
6. CLEANING
After draining the water the tank shall be thoroughly cleaned, free from dirt and
foreign materials and shall be dried by air.
7. RECORDS
Records shall be prepared and submitted to Engineer in-charge for approval.
8. SAFETY
All Safety precaution shall be taken during water fill up test.
9. REFRENCE
(A) API 650
(B) OISD 129
(C) PO Tech Specification
Note : Permanent B M shall be min. 50Mtr away from Tank shell

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
01 OF 04
PROJECT TITLE
JOB PROCEDURE FOR SURFACE PREPARATION BY
SHOT BLAST CLEANING AND APPLICATION OF
PAINTS
JOB PROCEDURE FOR SURFACE PREPARATION

BY COPPER SLAG BLAST CLEANING AND APPLICATION OF
PAINTS
1. SCOPE
This procedure defines the requirements for surface preparation, selection &
application of paint on external surface of pipes & structural steel, ducts, Tanks
and other items to be installed / constructed at LONI revamping project.
2. PURPOSE
The purpose of this procedure is to carry out the shot blasting & primer painting of
all the tanks structures & pipes, ducts etc. in a systematic way to minimize
available errors and to provide guide lines for best achievement in shot blasting &
primer painting at LONI revamping project.
3. STANDARD & SPECIFICATION

1. Surface preparation standard should be Swedish Standard Institution SIS-05
5900-1967/ SA 2 ½.This standard contains photographs of the various standards
which is required for inspection purpose by the Engineer-In-Charge.
2. Painting Specification ( as per the technical specs of tender document)
4. EQUIPMENT
To perform this above work the following Equipment / Materials are required from
our end.
1. All Tools
2. Spray Gun
3. Air Hose
4. Hopper
5. Air Filter Compressor of capacity

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
02 OF 04
PROJECT TITLE
PAINTS
6. EIcometer
7. Abrasive Paper such as good quality surface with an abrasive powder glass,
sand/Flint/emery paper of different rating shall be used
8. Cu Slag
9. Air Compressor of capacity 5.6 m3 - 7 m3
10. Brushes (Good quality Nylon bristles with long & flexible bristles shall be used)
11. Paints
All the tack weld should be grinded and welding slag, spatters should be
cleaned. The Surfaces shall be Cu Slag blast cleaned by using Cu slag
blasting. All other contaminants: oil, grease etc. shall be removed by use of
an aromatic solvent. The surface shall be cleaned using copper slag of
approved quality meeting tender specifications, at appropriate distance and
angle depending of nozzle size maintaining constant velocity and pressure.
The blasting nozzle should be venturi style with tungsten carbide or boron
carbide as the materials for liners. Nozzles orifice may vary from 3/16 ” to 3/4
” .On completion of blasting operation, the blasted surface shall be clean and
free from any scale or rust and must show a grey white metallic luster. Primer
or first coat of paint shall be applied within maximum 4 hrs of surface
Preparation. Compressor will be oil less compressor. Air pressure will be 7.00
Kg/Sq. Cm, distance & angle of the nozzle will depend on nozzle size
maintaining constant velocity & pressure. Compressed air shall be free from
moisture & oil. There will be one barricading in between sand blasting &
painting yard. Cu slag blasting work will not be performed when relative
humidity beyond 85 %. After blasting, surface will be inspected by photograph
in SIS-05 5900-1967 Code of SA 2 ½.

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
03 OF 04
PROJECT TITLE
PAINTS
6. SELECTION OF PAINT
Selection of Paint system shall be as per Tender Specification
7. PAINT APPLICATION
7.1 PRIMER PAINTING
Blasted surface will be primed with one complete application of primer within 4
hrs of blasting. Primer paint will be Approved Vendor make as per painting
specification. Application of each coat will be continuous and uniform. Primer
application will be performed by Spray Gun. Primer painting DFT thickness will
be checked as per specification.
7.2 INTERMEDIATE AND FINAL COAT.

Each coat shall be in proper state of cure or dryness before the application of
succeeding coat. Manufacturer instruction shall be followed for inter coat
interval and application.
8. REPAIR OF DAMAGE PAINT SURFACE

8.1. Quickly remove the Primer from damaged area by emery paper and
mechanical scrapping to expose the white metal.
8.2. Paint application as per specification.
9. DOCUMENTATION
9.1. A written QAP with Procedure qualification trials and for the actual work.
9.2. Results of measurements of temperatures, relative humidity, surface Profile,
Film thickness, holiday detection, adhesion tests with signature of
appropriate authority.
9.3. Type of testing equipments and calibration.
9.4. Code & batch numbers of paint material used.

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
04 OF 04
PROJECT TITLE
PAINTS
10. INSPECTION AND TESTING

10.1. All painting materials including Primers and thinners brought to site by Contractor
for application shall be produced directly from manufactures as per specification
and shall be accompanied my manufacture’s test certificates.
10.2.The Painting work shall be subject to inspection by HPCL at all times. In particular
following stage wise inspection will be performed and Contractor shall offer the
work for inspection and approval at every stage before proceeding to the next
stage. The record of inspection shall be maintained in the registers / report.
Stages of inspection as follows:
[a] Surface Preparation
[b] Primer application
[c] Each Coat of Paint.
D.F.T shall be checked and record after application of each coat and extra coat of
paint should be applied to make up the D.F.T specified without any extra cost to
owner.
11. FINISH COAT COLOUR & COLOUR CODING

Finish coat and colour coding shall be applicable as per HPCL approved
documents.
12. SAFETY
Safety Precaution shall be followed as per HSE manual / specification.
13. Acceptance Criteria

a) Surface Preparation: surface will be inspected by photograph in SIS-05
5900-1967 Code of SA 2 ½. ( contractor shall manage the photograph).
b) Painting : DFT readings using digital Elcometer ( calibration certificate to

be submitted to HPCL) as per the tender technical specifications.

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
03 OF 04
PROJECT TITLE
PROCEDURE FOR BITUMEN CARPETING
1. SCOPE
This work shall consist of construction in Anticorrosive layer, layer of
Premixed Carpet and a layer of Seal Coat over the tank foundation pad.
2. PURPOSE
The purpose of this document is to state the requirement of material,
workmanship and construction procedure to be followed during the execution
of tank pads works.
3. MATERIALS
Bitumen:
Bitumen to be used for bitumen macadam shall conform of 60 / 70 grade as per IS:
73
4. PROCEDURE
Anti – corrosive layer will consist of screened coarse sand mixes with 155/6
bitumen or equivalent (8 to 10 % by volume).
Sand shall be clean, dry coarse, hard, sharp, free from all impurities and shall
conform to IS: 383.
Bitumen shall be heated to a temperature 1750 C to 1900 C with 3% kerosene
if required and sand shall be thoroughly mixed with it in mixing drums to give a
uniform mixture and shall be laid over the pad in line, grade and levels as
shown on drawings.
The anti- corrosive layer shall be then tamped to form hard mass of uniform
50 mm thickness.
For Premix Carpet, Sand shall be as per specification. The stone chipping
shall be of hard black trap. It shall be obtained from approved quarry. The
grading of stone shall be 12 mm and down size.

Name : Name :
Design: Design:
Ltd. Ltd
DOC NO
DATE
PAGE NO
04 OF 04
PROJECT TITLE
PROCEDURE FOR BITUMEN CARPETING
Bitumen required for the work shall be 60/70 grade as per IS: 73 or its
equivalent quality used for premix work.
The anti- corrosive layer on which the premix is to be laid shall be thoroughly
cleaned of all dust and loose materials. A coat of heated bitumen at the rate of
1 Kg / m2 shall be uniformly applied.
The binder bitumen 60/70 shall be heated to required temperature with 3 % to 4

% kerosene if required and mixed with some chipping of size as given below at
a rate of 6 m3 of stone chips per 100 m2 area and shall be mixed until the
asphalt is well coated over all the particles of aggregate.
The grading of stone chips shall be normally 3:2 (60% of aggregate of 12 mm

size and 40 % of aggregate of smaller size upto 6 mm).
The premix carpet shall be laid in 2 layers of 45 mm & 30 mm thickness and 12

mm thick seal coat layer. Each layer shall thoroughly rolled and compacted to
the satisfaction of the owner/ consultant. After compacting and laying the first
layer of 45 mm, a tack coat of hot bitumen at the rate of 1 kg/m2 shall be
uniformly applied to the surface by means of sprayer and the second layer of 30
mm thick shall be laid tamped and compacted to the satisfaction of Owner /
Consultant.
Sand shall be spread evenly on the final surface at the rate of 0.5 m3 per 100
m2.
A seal coat 12 mm thick shall be laid over Premix Carpet layer using bitumen
60 / 70 @ 100 kg / 100 m2 of surface area & mixing with stone chips of size 6
mm @ 0.92 m3 / 100 m2 of surface area as per correct grade and camber and
compaction of the layers done using plate compactor.

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
02 OF 07
PROJECT TITLE
INSPECTION TEST PLAN FOR TANK FABRICATON
1.0 GENERAL
The enclosed ITPs shall be followed for the works to be performed by the Contractor
under this Tender. The provisions indicated for stagewise inspection by HPCL are a
minim um and the contractor shall develop a detailed ITP and obtain approval for the
same prior to commencement of work. Contractor to carry out 100% examination of all
activities.
2.0 LEGEND
HP: Hold point;

A point which require sin section / verification and acceptance by HPCL before any
further processing is permitted. The Contractor shall not process the activity/ item
beyond a Hold point without written approval by HPCL.
W: Witness Point;
An activity which requires witnessing by HPCL when the activity is performed.
Rw: Review of Contractor’s documentation.
S: Surveillance Inspection by HPCL;

Monitoring or making observations to verify whether or not materials/ items or
services conform to specified requirements. Surveillance activities may include
audit, inspections, witness of testing, review of quality documentation & records,
etc.
WC: 100% examination by Contractor.
Responsibility for execution of the inspection/ testing is with the Contractor.

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
03 OF 07
PROJECT TITLE
S. No. ACTIVITY VISHAL HPCL
STORAGE TANKS
A. PRIOR OF FABRIATION
1. Acceptance of the tanks foundation WC HP
2. Incoming Material
Owner’s Supply WC Rw WC Rw
Contractor’s supply, including check testing WC HP
3. Welding Filler Material Approval /Qualification

a) Manufacturing Test Certificate/Documents WC* Rw*
b) Testing, if any
i) Carbon Steel WC W
4. WPS/PQR(Sample Copy attached from Previous HPCL Site

Records)
a) Procedure:
i) WPS to be written for all the Weld Joints for
for Bottom /Shell/Fl. Roof/A ppertunance etc
b) Testing :
i) Carbon Steel WC HP
c) Approval of Final WPS / PQR WC HP
5. a) Welder performance Qualification Test WC W

b) Certification& Approval of welder WC HP
6. Review of joint numbering in drawings mention

Reference of 4.a.i. WC HP
7. Suitability of plate bending machine WC Rw
8. Fabrication, erection, testing procedure for job WC HP
B FABRICATION / ERECTION OF BOTTOM WC HP
1. Plate size, marking and cutting WC W
2. Blast cleaning & painting of underside of bottom plates WC HP

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
04 OF 07
PROJECT TITLE
3. Plate layout, overlap and fit up WC S
4. Sequence of welding WC S
5. Size and positioning of backing plate for annular plates WC W
6. Banking of electrodes WC S
7. Inter-pass cleaning WC S
8. Visual check of welding WC W
9. DPT/RADIOGRAPHY of annular plate butt welds and WC HP

bottom plate butt welds (As applicable)
10. Vacuum box test for bottom plate welding WC HP
SHELL
1. Plate size, marking and cutting WC Rw
2. Plate binding, curvature check, stacking WC W
3. Shell course alignments and fit-up of vertical and WC W

circumferential joints before welding
4. a)Check Shell diameter @0,45,90,135,180,225,270,315,360 WC HP

& circumference for circularity with strapping tap,
perpendicularity, straight edge before welding and
documenting (Each Shell wise & w.r.t. precede & ascend)
5. Visual check of welding and back chipping WC W
6. a) inner side welding visual check WC W

b) Check shell diameter @0,45,90,135,180,225,270,315,360 WC HP
& circumference for circularity with strapping tap,
perpendicularity, straight edge before welding and
documenting (Each Shell wise & w.r.t. precede & ascend)
7. Location size and alignment of nozzles and other openings WC HP

Name : Name :
Design: Design:
Ltd.
DOC NO
DATE
PAGE NO
05 OF 07
PROJECT TITLE
8. R.F. pads fit-up / welding WC W
9. PWHT of shell, RF pads, nozzles, manhole etc (If Applicable) WC W
10. Radiography marking (for random radiography only) WC HP
11. Curb angle and Wind girder fit-up / welding WC W
12. DPT of Nozzles, etc. (as applicable) WC W
13. RF pads pneumatic test WC HP
14. Shell to bottom fit-up WC HP
15. Shell to bottom I/S welding root run visual/ oil chalk test WC HP
16. Shell to bottom O/S welding visual and PT WC W
17. Fabrication and erection of stair ways WC S
18. Radiography
a) Radiography interpretation WC HP
b) Check shot for Radiography WC HP
FLOATING ROOF
1. Temporary staging, spacing and levels WC Rw
2. Plate size, straightening and cutting WC Rw
3. Plate layout, overlap, fit-up welding WC Rw
4. Availability of approved calculations for design of buoys WC HP
5. Buoys / pantoon fabrications WC S
6. Vacuum testing of roof – plates welds WC HP

Name : Name :
Design: Design:
CONTRACTOR . Hindustan Petroleum Hindustan Petroleum Crop. Ltd
Crop. Ltd.
DOC NO
DATE
PAGE NO
06 OF 07
PROJECT TITLE
7. Location of sleeve support WC S
8. Pad plate welding with roof and sleeve support WC S
9. Fixing and welding of Buoys WC W
10. Initial – Lift WC W
11. Support Fixing through sleeve WC S
12. Seal welding of support sleeve from beneath after WC S

dewatering
13. Air test of Buoys / Pantoons WC HP
14. Pantoon welding WC S
15. Location, fixing and welding of man-holes, drains etc. WC W
16. Shell to pontoon clearance WC HP
17. Air Test of Pontoons for Leakproofness WC HP
18. Seal fixing WC HP
19. Floating Roof testing, as required e.g. flooding etc. WC HP
20. Primary roof drains installation & testing WC HP
C. TESTING
1. Correctness testing arrangements especially size of WC HP

Blind Flanges / vents/ drains/ temporary piping
2. Mechanical/ Inspection clearance WC HP
3. Earthing of ladder & shell WC W
4. Settlement reading through Dumpy Level during water filling WC HP

Name : Name :
Design: Design:
Ltd.
DOC NO
DATE
PAGE NO
07 OF 07
PROJECT TITLE
5. Hammer test WC HP
6. Air pressure test WC HP
7. Vacuum test WC HP
8. Roof collapsibility test in case of floating roof ranks WC HP

Vis-a-vis to FR Dessign approved
9. Calibration of tanks from statutory authorities WC Rw
INSPECTION & TEST DOCUMENTS
Review Test and Inspection documents WC Rw

Name : Name :
Design: Design:
JOB PROCEDURE
H.P.C.L
1. SCOPE:
The scope of this procedure shall apply to all reinforced cement

concrete works carried out during the execution of the civil works
Tankage Erection job.
2. PURPOSE:
The purpose of this procedure is to ensure the high quality of
the concrete casted and thus it shall meet all the strength
requirements as per tender specifications and all relevant IS codes,
the casted structures have perfect geometry as per the approved
drawings etc all complete.
3. REFERENCE:
IS 456
4. JOBS PRIOR TO RCC WORKS:
Getting the constructional drawings approved from HPCL EIC.

Fixing of Centre line & levels with respect to HPCL coordinates &
Bench Marks with Total Station.
Carrying out of Excavation up to required depth and proper rolling
and compaction of virgin soil up to maximum satisfaction of HPCL
EIC and getting it tested.
Supply and filling of murrum as per specifications in layers of 200
mm and compaction of each layer to 95% modified proctor density.
Machine mixing of aggregates, sand, cement and water as per mix
proportion specified in tender specifications, carrying out of PCC
to specified thickness, compaction using plate vibrator and curing.
SUBMITTED BY CHECKED BY APPROVED BY

(FOR HPCL) (FOR HPCL)
JOB PROCEDURE
H.P.C.L
5 RCC WORKS:
A) MARKING
Marking points and measuring the slope of Apron and beam slope
(it should be towards the drain connection point in 1:100) getting
hold point clearance from HPCL.
B) FORM WORK
Submission of design/plan for shuttering and props.
Approved quality formwork to be provided as per HPCL approved
drawings. The forms shall be butting with each other in straight
lines, the corners of the boards being truly at right angles.
Maximum care shall be taken to make the form work watertight.
The contactor shall be permitted reuse of forms brought new on the
work for exposed concrete work as specified below.
Plywood Forms 6 Reuses (Max.)
Steel Forms 10 Reuses (Max.)
The Engineer – in – Charge may, at his absolute discretion, order
removal of any forms considered unfit for use in the work
irrespective of the number of uses specified above.
Inside dimensions to be marked
C) REINFORCEMENT STEEL.
Visual inspection of the steel supplied for manufacturing defects at

field.
The sample piece will be taken out from above supplied steel; the
same will be tested at designated laboratories for all the tests as
given in attached specifications. The test reports have to be
submitted before the placement of concrete.
Note: Tests shall be repeated for every 02 MT of each size (dia).
Submission bar bending schedule prepared by contractor for
approval to HPCL EIC
JOB PROCEDURE
H.P.C.L
Reinforcement shall be straightened, cut and bent to shape and
dimension as shown in the bar bending schedule approved by
HPCL. Straightening, Cutting and bending of bars shall be as per
IS 2502.
All reinforcement shall be fixed in the correct position, adequate
no. of cover blocks/ spacers have to be provided and shall be
properly supported to ensure that displacement will not occur when
the concrete is placed and compacted.
The reinforcement shall be tied at every intersection by two
standards of 20 SWG black soft annealed binding wire
Note: cover blocks should have the same cement sand contents as
the concrete which shall be placed and have a size of 40 X 40 mm
and thickness equal to the specified cover.
Note: When reinforcement bars are placed in two or more layers,
the vertical distance between the horizontal bars shall be
maintained by introducing spacer bars at 1 to 1.2 m center to
center.
Counting authorized laps and chairs.
Tolerance: Unless otherwise directed by the Engineer-in-Charge,
reinforcement shall be placed within the following tolerance:
For effective depth 200mm or less + 10

For effective depth more than 200mm + 15 mm
D) CONCRETING
Mix design
The mix shall be designed to produce the grade of concrete having
the required workability and characteristic strength.
The design mix shall be conforming to the guidelines of IS: 10262
Mix design with supportive laboratory tests shall be submitted to
the Engineer-in-Charge for approval
Batching

JOB PROCEDURE
H.P.C.L
During proportioning concrete, based on the results from Design
Mix, the quantity of both cement and aggregate shall be determined
by mass.
Note: a reasonable number of bags shall be weighed periodically to
check the net mass.
Water shall be either measured by volume in calibrated tanks or
mass;
All measuring equipment shall be mentioned in a clean serviceable
condition, and their accuracy periodically checked
Mixing
The mixing of concrete shall be strictly carried out in an approved
type of mechanical concrete mixer.
Mixer shall comply with IS: 1791
The mixing shall be continued until there is a uniform distribution
of the material and the mass is uniform in colour and consistency
Mixing time shall be as indicated in the following table
Capacity of Mixer Minimum Mixing Time
3
2 m or less 1 ½ minutes
3 m3 2 ½ minutes
5 m3 3 minutes
All records and charts for the batching and mixing operation shall
be prepared and maintained by the Contractor as per the
instructions of the Engineer-in-Charge
Hand mixing of concrete shall be permitted with the addition of
10% more cement.
For highly lean concrete, hand mixing may be permitted by the
Engineer-in-Charge as a special case. Ten percent (10%) extra
cement shall have to be added to the normal mix when mix by hand
Transportation & Placing

The entire concrete placing program including transportation
arrangements, deployment of requirement lay out proposed
JOB PROCEDURE
H.P.C.L
procedures and methods, shall be submitted to the Engineer-in-
Charge 24 hours prior to concreting, for approval
No concreting shall be placed until his approval has been received
Concrete shall not be placed until the formwork, the placement of
reinforcing steel, embedded parts, pockets etc. have been inspected
and approved by the Engineer-in-Charge
Concreting shall not be started unless the electrical conduits, pipes,
fixtures etc. wherever required are laid by the concerned agency
Before concreting, the Contractor shall provide, fabricate and lay in
proper position all metal inserts anchor bolts, pipes etc as per
relevant drawings and directions of Engineer-in-Charge.
All concrete shall be conveyed from the mixer to the place of final
deposit as rapidly as possible in suitable buckets, dumpers,
containers or conveyors which shall be mortar leak tight.
Concrete shall be discharged by vertical drop only and the drop
height shall not normally exceed 1.5 meter
Unless otherwise approved concrete shall be placed in single
operation to the full thickness of foundation rafts, slabs, beams and
similar members. Concrete shall be placed continuously until
completion of the part of the work between approved construction
joints or as directed by the Engineer-in-Charge.
Compaction
Concrete shall be thoroughly compacted with vibrators of pin
dimensions 3” and 4” and fully worked around the reinforcement,
embedded fixtures and into corners of form work before setting
commences and shall not be subsequently disturbed
The vibrators shall be of immersion type with operational
frequency ranging between 8,000 and 12,000 vibrations per
minute.
All vibrators shall comply with IS: 2505.
Screed board concrete vibrators or concreting vibrating tables or
form vibrators conforming to IS: 2506, 2514 and 4656,

JOB PROCEDURE
H.P.C.L
respectively may also be used where specifically required and
directed by Engineer-in-Charge.
The vibrator shall be withdrawn slowly.
The spacing shall provide some overlapping of the area vibrated at
each insertion.
Curing
Concrete shall be cured by keeping it continuously moist wet for
the specified period of time.
Curing shall be started after 8 hrs. of placement of concrete, and in
hot weather after 4hrs.
The water used for curing shall be of the same quality as that used
for making of concrete.
Curing shall be assured by use of an ample water supply under
pressure in pipes with all necessary appliances such as hose,
sprinkles etc.
A layer of sacking, canvas, Hessian, of other approved materials
which will hold moisture for long periods and prevent loss of
moisture of the concrete shall be used as covering
Exposed surfaces of concrete shall be maintained continuously in
damp or wet conditions for at least the 1st 7/10 days after placing of
concrete.
For curing the concrete in pavement floors, flat roofs or other level
surfaces, the ponding method of curing is preferred after the expiry
of first 24hrs during which (i.e. 1st 24 hrs) the concrete shall be
cured by use of wet sacking, canvas Hessian etc.
E) ACCEPTANCE CRITERIA
The concrete shall be deemed to comply with the strength

requirements if:

JOB PROCEDURE
H.P.C.L
every sample has a test strength not less than the characteristic
value;
The strength of one or more samples though less than the
characteristic value, is in each case not less than the greater of:
1. The characteristic strength minus 1.35 times the standard

deviation;
And
2. 0.80 times the characteristics strength; and the average strength
of all the samples is not less than the characteristics strength plus
{1.65 -- (1.65/(n)1 / 2)} x S.D.
Rebound hammer test and compressive strength test of extracted

cores meet strength requirements as per mix design.

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DOC NO
V
DATE
PAGE NO
03 OF 05
PROJECT TITLE
TANKAGE JOB AT LONI TERMINAL JOB PROCEDURE FOR Puncture TEST / Rain water
FILL UP TEST
JOB PROCEDURE FOR PUNCTURE/FLOATATION/RAIN WATER

ACCUMULATION TEST
1. SCOPE
This test procedure shall be carried out to check the buoyancy and design of floating
roof vis-à-vis fabrication and under conditions of testing:
a. Single deck and any two adjacent pontoon compartments punctured and flooded in
single deck pontoon roofs and any two adjacent compartments punctured and
flooded in double deck roofs, both roof types with no water or live load.
b. 250 mm of rainfall in a 24 our period over the full horizontal tank area with the roofs
intact.
2. PURPOSE
The purpose of this procedure is to check the design compatibility w.r.t. fabricated
and erected roof under testing.
3. CHECK LIST
After completion of the erection, welding and NDT, Pneumatic testing, diesel chalk
testing of outer rim, visual checking of welds (100%) and rectification if any the
following points shall be checked before testing.
All the mechanical activities completion in respect of the drawing and HPCL
Specification and code requirements.
NRV in central roof drain to be checked.
The entire NDT test like chalk-diesel test, LPT, RF .Pad pneumatic test, vacuum box
test completion.
Punctures with couplings fitted in the deck and adjacent pontoons to be ensured
before commencing of Hydrotesting.
Puncture test to be carried out when roof is in highest position.
Finally mechanical clearance from the Engineer-In-Charge shall be taken before
Puncture test in approved format.
4. TEST MEDIA
Test media shall be in iron free water, which is clean and free of silt i.e.; Portable
water.
5. PROCEDURE
For puncture test:
Initial reading of
a. RIM SPACE (atleast at 08 POINTS) to be taken.
b. Location of rolling ladder (drum) w.r.t. shell to be taken and spirit level on ladder
staircase.
c. Deck immersion and rim position w.r.t. tank shell should be noted.
d. Water fill height to be noted.
Out of two adjacent pontoons one to be punctured and time to be noted along with
the height of water column coming out of hole ( this shall help in evaluating the final
height of water after fillup).
Again after the water settles down and no more significant change seen note the
time taken and check for any leakage in adjacent pontoon, then repeat the points ( a
to d) and puncture next ( adjacent) pontoon.
Again note the readings (repeat as above).
After that puncture the central deck and repeat the procedure and steps a to d.
For Rain water fill:
1. Blind the NRV and fill the central deck till 10” and keep the same for one day without
Puncture test condition and with puncture test condition.
NOTE: NRV to be opened thereafter to see the water flow afterwards from roof drain and
time taken to remove the water.
Code: API 650 APPENDIX C.
6. CLEANING
After draining the water the tank shall be thoroughly cleaned, free from dirt and
foreign materials and shall be dried by air.
7. RECORDS
Records shall be prepared and submitted to Engineer in-charge for approval in
approved format.
8. SAFETY
All Safety precaution shall be taken during the test.
9. REFRENCE
(A) API 650
(B) PO Tech Specification

Name : Name :
Design: Design:
DOC NO
VS
DATE
PAGE NO
04 OF 05
PROJECT TITLE
TANKAGE JOB AT LONI TERMINAL JOB PROCEDURE FOR HYDRO TEST / WATER FILL
UP TEST
ACCEPTANCE CRITERIA:
1. At each stage of water filling the time taken in water settling and Tilting should be in
conformance to the approved floating roof design within the mentioned tolerances of all the
variables like RIM SPACE, TILTING, TIME TAKEN TO WATER FILL.
2. For rain water fill test the water filled should overflow on ED and for the period of 24 hrs the
water should in no case come out of deck outer rim (i.e. immersion should be as per design
for water).
3. The time taken by the roof drain water to come out from central roof drain sump should be in
conformance to the design and code requirements ( Appendix C, API 650).
NOTE:
After the completion of test the punctures should be blinded and DP tested for leakage when
roof at lowest position( after Hydrotesting if welded, else coupling should be seal tighted.

Name : Name :
Design: Design:
DOC NO
DATE
PAGE NO
05 OF 05
PROJECT TITLE
TANKAGE JOB AT LONI TERMINAL JOB PROCEDURE FOR HYDRO TEST / WATER FILL
UP TEST
Name : Name :
Design: Design:
QUALITY
ASSURANCE
PROGRAMME
CONTENTS
______________________________________________________________
CLAUSE DESCRIPTION
1.0 INTRODUCTION
2.0 DEFINITIONS
3.0 SCOPE OF WORK BY CONTRACTOR
4.0 QUALITY ASSURANCE SYSTEM REQUIREMENTS

1.0 INTRODUCTION
This specification establishes the Quality Assurance requirements to be met

by Contractors (including turnkey contractors) and vendors.
In case of any conflict between this specification and other provisions of the
contract / purchase order, the same shall be brought to the notice of HPCL,
at the stage of bidding and shall be resolved with HPCL, prior to the
placement of order.
2.0 DEFINITION
2.1 Bidder
For the purpose of this specification, the work “Bidder” means the
person(s), firm, company or organization who is under the process of being
contracted by HPCL/Owner for delivery of some products (including service).
The word is considered synonymous to supplier, contractor or vendor.
2.2 Correction
Action taken to eliminate the detected non-conformity.
2.3 Preventive Action
Action taken to eliminate the causes of a potential nonconformity, defect or

other undesirable situation in order to prevent occurrence.
2.2 Process
Set of inter-related resources and activities which transform inputs into
outputs.
2.3 Special Process

Process requiring pre-qualification of their process capability.
1.0 SCOPE OF WORK BY CONTRACTOR
1.1 Prior to award of contract
1.1.1 The bidder shall understand scope of work, drawings, specifications and
standards etc., attached to the tender / enquiry document, before he
makes an offer.
1.1.2 The bidder shall submit milestones chart showing the time required for
each milestone activity and linkages between different milestone activities
along with overall time period required to complete the entire scope of
work.
1.1.3 The bidder shall develop and submit manpower and resource deployment
chart.
1.1.4 The bidder shall submit, along with the bid, a manual or equivalent
document describing / indicating / addressing various control / check points for
t he purpose of quality assurance and the responsibilities of various
functions responsible for quality assurance.
2.0
2.1 After the award of contract
The bidder shall submit the schedule for submission of following

documents in the kick-off meeting or within two weeks of the placement
of order, whichever is earlier.
• Quality plan for all activities, required to be done by the bidder,

to accomplish offered scope of work.
• Inspection and test plans, covering various control aspects.
• Job procedures as required by HPCL/Owner.
Various documents submitted by the bidder shall be finalized in

consultation with HPCL. Here it shall be presumed that once a bidder
has made an offer, he has understood the requirements given in this
specification and agrees to comply with them in totality unless otherwise
categorically so indicated during pre-award stage through agreed
deviation / exception request. All quality assurance documents shall be
reviewed by concerned HPCL functional groups and the bidder shall be
required to incorporate all comments within the framework of this
specification at this stage of the contract. It is also obligatory on the
bidder that he obtains approval on every quality assurance document,
before he starts using a particular document for delivery of contracted
scope of work. Participation of HPCL/Owner in review / approval of
quality plan / QA documents does not absolve the contractor of the
contractual obligations towards specified and intended use of the product
(or service) provided by him under the contract.
2.2 During job execution
4.2.1 During job execution, the bidder shall fully comply with all quality
documents submitted and finalized / agreed against the requirements of
this specification. Approval of HPCL on all these documents shall be
sought before start of work.
4.2.2 Bidder shall produce sufficient quality records on controlled / agreed

forms such that requirements given in this specification are objectively
demonstrates.
4.2.3 Bidder shall facilitate HPCL/Owner during quality / technical audits at his
works / sites.
4.2.4 Bidder shall discharge all responsibilities towards enforcement of this

specification on all his sub-contractors for any part of the scope which
is sub-contracted.
3.0 QUALITY ASSURANCE SYSTEM REQUIREMENTS
5.1 The bidder shall nominate an overall in-charge of the

contract titled as “Project Manager” for the scope of work of agreed
contract. The name of this person shall be duly intimated to HPCL,
including all subsequent changes, if any. HPCL shall correspond only
with the project manager of the bidder shall be responsible for co-
ordination and management of activities with bidder’s organization and
all sub-vendors appointed by the bidder.
5.2 After award of work the bidder may review augmentation of manpower
and resources deployment chart (submitted earlier), detail it out, if so
consented by HPCL/Owner and resubmit the same as “Issued for
implementation”.
5.3 The bidder shall plan the contract scope of work on quality plan format
such that no major variation is expected during delivery of contract
scope of work. These quality plan shall be made on enclosed format
complete in all respect. The quality plan shall be assumed to be
detailing bidder’s understanding and planning for the contract / offered
scope of work. The bidder shall plan the type of resources including
various work methodology which he agrees to utilize for delivery of
contract scope of work.
5.4 The bidder is required to review the contract at all appropriate stages to
evaluate his capabilities with respect to timely and quality completion of
all activities pertaining to contracted scope of work and shall report to
HPCL/Owner of constraints, if any.
5.5 The design activities, if any, performed during delivery of contract scope
of work shall be so controlled that the output is reliable enough. It is
expected that during development of design, the bidder shall take
recourse to detailed checking, inter departmental reviews and documented
verification methods.
5.6 For all documents which the bidder is likely to utilise for delivery of
contract scope of work, a system must exist which assures that latest /
required version(s) of the document(s) is available at all location / point
of use.
5.7 In case the bidder decides to sub – contract any part / full of the contract
scope of work (without prejudice to main contract condition), the bidder
shall
- Evaluate the technical and financial capabilities and past performance of
the sub-contractor(s) and their products and/or services before awarding
them with the sub-contracted scope of work. Selection of a sub-
contractor should meet HPCL approval in documented form.
- Requirement of this specification shall be enforced on sub-contracted
agency also. The bidder shall choose sub-contractor based on their
capability to meet requirements of this specification also.
NOTE : It may so happen that, in a given situation, a sub-contractor may not

have a system meeting the requirements of this specification. In all such
eventualities, bidder may lend his system to sub-contractor for the
contract such that sub – contractor effectively meets the requirements of
this specification. In all such cases HPCL shall be duly informed.
5.8 Bidder shall establish methodology such that the materials supplied by
the owner / HPCL shall be suitably identified in such a manner that
either through identification or some other means, sufficient traceability is
maintained which permits effective resolution of any problem reported in
the outputs.
5.9 Critical activities shall be identified and the bidder is required to have
documented methodologies which he is going to utilize for carrying out
such activities under the contract scope of work. Wherever it is difficult
to fully inspect or verify the output (special process) bidder shall pre-
qualify, the performers and methodologies.
5.10 All inspections carried out by the bidder’s surveillance inspection staff
shall be in conformity to quality plans and / or inspection and test plans.
All inspection results shall be duly documented on controlled / agreed
forms such that results can be co-related to specific product, that was
inspected / tested.
5.11 All inspection, measuring & test equipments (IMTEs) shall be duly
calibrated as per National / International standards / codes and only,
calibrated and certified IMTEs shall be utilized for delivery of contract
scope of work.
5.12 All outputs / products delivered against contract scope of work shall be
duly marked such that their inspection status is clearly evident during all
stages / period of the contract.
5.13 All non-conformities (NCs) found by the contractor’s inspection / HPCL

surveillance staff shall be duly recorded, including their disposal action.
The deficiencies observed during stage of the product, shall be recorded
and resolved suitably. Effective corrective and preventive action shall be
implemented by the bidder for all repetitive NCs, including deficiencies.
5.14 All deficiencies noticed by HPCL’s representative(s) shall be recorded on

a controlled form such deficiencies shall be analyzed by the bidder and
effective and appropriate correction, corrective and preventive actions
shall be implemented. Bidder shall intimate HPCL/Owner of all such
corrective and preventive action implemented by him.
5.15 Bidder shall establish appropriate methodologies for safe and effective
handling, storage, preservation of various materials / inputs encountered
during delivery of contract scope of work.
5.16 Bidder shall prepare sufficient records for various processes carried out
by him for delivery of contract scope of work such that requirements of
this specification are objectively demonstrate. In case HPCL/owner finds
that enough objective evidence / recording is not available for any
particular process, bidder shall be obliged to make additional records so
as to provide sufficient objective evidence. The decision of HPCL/owner
shall be final and binding on such issues.
5.17 The bidder shall arrange internal quality audits at quarterly intervals, to
independently assess the conformance by various performers to the
requirements of this specification. The findings of such assessment shall
be duly recorded and a copy shall be sent to HPCL/owner for review.
For all special processes, bidder shall deploy only qualified performers. Wherever HPCL
observes any deficiency, the bidder shall arrange the adequate training to the
performer(s) before any further delivery of work.
QUALITY ASSURANCE PLAN FOR CONSTRUCTION OF STORAGE TANKS
CUSTOMER : DATE :
CONTRACTOR : QAP NO. :
PROJECT : PAGE :
SL. CHARACTERISTICS TO TYPE/METHOD EXTENT OF REFERENCE ACCEPTANCE FORMAT OF AGENCY

DESCRIPTION OF ITEMS CAT REMARKS
NO. BE CHECKED OF CHECK CHECK DOCUMENTS STANDARDS RECORDS P W V
MATERIAL IDENTIFICATION
1. Plate for tanks, nozzle neck 10" and 1 Physical, chemical M Physical & As per APPD DRGS/ IS 2062 GR. B,C MILL TC 3 3/1 1,2 For IOC supplied
above and structurals properties, heat Chemical Tests. Specification DATA SHEET & GR. A for material
treatment. structurals SA
370
2 Dimensions and M Meas. & Visual 100% APPD DRGS/ ASTM A 6,A20 IR 2 1
surface quality DATA SHEET
3 Lamination free M Visual, UT/MPT (if All edges API 650 ASME Sec. VII MFTRS TC & 3 1 Not reqd. for
reqd.) Div. I IR structurals.
2. Pipes for nozzle 1 Physical, chemical M Physical & As per APPD DRGS/ A 106GR B/C, MFTRS TC 3 1* 1,2 *If specified in WO
properties, heat Chemical Tests specification DATA SHEET API 5L Gr. B
treatment
2 Dimensions and M Meas. & Visual 100% APPD DRGS/ ANSI B IR 2 1

surface quality DATA SHEET 36.10/API 5L
3. Flanges for nozzles 1 Physical, chemical M Physical & As per APPD DRGS/ ASTM A 105 & A MILL TC 3 3/1 1,2
properties, heat Chemical Test specification DATA SHEET 181
treatment
2 Dimensions & surface M Meas. & Visual 100% APPD DRGS/ ANSI B 16.5 IR 2 1 1,2
quality DATA SHEET
4 Pipe fittings 1 Physical, chemical M Physical & As per APPD DRGS/ As per WO/ MFTRS TC 3 3/1
properties, heat Chemical Tests specification DATA SHEET ASME SA 234
treatment
2 Dimensions & surface M Meas. & Visual 100% APPD DRGS/ ANSI B 16.9 IR 2 1 1
quality DATA SHEET
5 Bolts, nuts for nozzle flanges & 1 Physical, chemical M Physical & As per APPD DRGS/ ASTM A 193 & MFTRS TC 3/2 2,1
structurals properties, heat Chemical Tests specification DATA SHEET 194/ IS 1367
treatment C. L. 4.4.6
2 Dimensions & surface M Meas. & Visual 100% APPD DRGS/ ANSI B 1.1/B IR 2 1 IOC to witness 10%
quality DATA SHEET 1.2/ B 18.2.2 random meas &
100% visual.
SL. DESCRIPTION OF ITEMS CHARACTERISTICS TO CAT TYPE/METHOD EXTENT OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
IN PROCESS:
6. Welding procedure specification Correctness M Scrutiny 100% WPS WPS-ASME WPS 2 1 To be checked
proposed SEC. IX and approved by
IOC before tests.
7 Welding procedure qualification Desired property of M Physical & 100% WPS ASME – SEC ASME WPS & 2 1,2
test and record welding, establishing Chemical Tests IX PQR Formats
correctness of
welding variables
8 Welders Performance Ability of welders to M Radiography 100% WPQ ASME SEC IX ASME WPQ 2 1,2
Qualification make sound weld format
9 Plate cutting for bottom, shell & Dimensions, M Meas. & Visual 100% Cutting Layout APPD. DRGS. IR 2 2 1
roof checking diagonal & Plan
squaring
10 Rolling of Plates Dimensions & M Meas./ Visual 100% APPD. DRGS. APPD. DRGS. IR 2 2 1
Shape
11 Fittments of weld joints Alignment, Edge CR Visual, Meas, 100% APPD. DRGS. APPD. DRGS. IR 2 2,1 H
preparation, root Plumpness
gap, cleanliness
along seam
12 Root run after back gauging of Free of flaw M Visual 100% API 650 API 650 IR 2 2,1
Butt weld joints
13 Finished Butt weld joints 1 Smoothness and M Visual 100% API 650 API 650 IR 2 2,1
Reinforcement
2 Internal Flaws CR Radiography API 650 & API 650 & WO ASME Sec. VIII IR 2/3 2,1 1 H
WO Div. I, UW-51b
3 Peaking/ Banding/ M Meas/Plump 100% API 650 API 650 IR 2 2,1
Circularity
14 All Lap Joints of Bottom Plates 1 Lay out, Edge Prepn M Visual 100% API 650 API 650 IR 2 2,1
2 Welding M Visual, Vacuum 100% API 650 API 650 IR 2 2,1
Test, Pneumatic
Test
15 Bottom plates sand blasting 1 Cleanliness/ Surface M Visual / Meas. 100% WO Painting Spec. IR 2 1,2
underside painting Profile
2 Coating thickness M DFT, Elcometer 100 % WO Painting Spec. IR 2 1,2
16 Nozzle to flange & nozzle to Dimension, M Visual, Plumb, 100% APPD. DRGS/ API 650/ IR 2 1,2
shell Orientation of Meas API 650 APPD. DRGS
nozzle, projection,
elevation, fittment
17 RF Pad/ Nozzle to Shell Leak tightness M Pneumatic soap 100% API 650 API 650 IR 2 1,2
suds
18 Shell to Annular plate 1 Weld soundness M Visual/ Meas. 100 % APPD DRGS API 650 IR 2 1,2
2 Leak tightness M Penetrant/ 100% API 650 API 650 IR 2 1,2
19 Deck plate lap joints 1 Fitment, dimensions M Visual/ Meas. 100% APPD DRGS API 650 IR 2 1,2
Slope
2 Weld Soundness M Visual/ 100% API 650 API 650 IR 2 1,2
Penetrant
20 Rim bulk head compartment 1 Fitment / Dimension M Visual & Meas 100% APPD DRGS API 650 IR 2 1,2
2 Welding M LPT/Pneumatic 100 % API 650 API 650 IR 2 1,2
21 Splice joints of rafters/columns Dimensions & M Visual & Meas. 100% APPD DRGS/ API 650 IR 2 1,2
Welding API 650
22 Appurtenances, leg supports Alignment, M Visual /Meas. 100% APPD DRGS API 650 IR 2 1,2
fabricated appurtenances Dimension, Weld
soundness
23 Central Sump 1 Fitment M Visual / Meas. 100% APPD. DRGS. API 650 IR 2 1,2
2 Weld soundness M DPT/ & Visual 100% API 650 API 650 IR 2 1,2
24 Piping for fire water/foam system 1 Layout & fitment M Visual, Meas. 100% APPD. DRGS. APPD. DRGS. IR 2 1,2
2 Welding quality M Root DPT & 100% APPD. DRGS. APPD. DRGS. IR 1 1,2 1 10% of DPT shall
Final welding be witness by 1
Visual
NO. BE CHECKED OF CHECK CHECK DOCUMENTS STANDARDS RECORDS
P W V
25 Inspection prior to release for Completeness, CR Visual, Random 100% APPD. DRGS, APPD. DRGS. IR 2 1
hydro-test, Inside/Outside cleanliness, overall Meas., DATA SHEET DATA SHEET,
welding surface, External dimension, Verification of all API 650
Internal attachment plumpness records
orientation,
radiography etc.
26 Final inspection during hydrotest Leak tightness CR Hydrotest 100% APPD. DRGS API 650 IR 2 1,2
verticality M Plump Every 30° APPD. DRGS API 650 IR 2 1,2
27 Final assembly Settlement M Meas. Every 30° APPD. DRGS OISD 129/ BS IR 2 1,2
3659
28 Buoyancy test, Floatation test, Smooth Floatation CR Hydrotest 100% APPD. DRGS API 650 IR 2 1,2
Deck puncture test leak tightness M Submersion 100% API 650 API 650 IR 2 1,2
Measurement
29 Rain water test Deck CR Water filling on 100% API 650 Spec. API 650 Spec. IR 2 1,2
deck
30 Calibration Capacity wrt Filling M Meas. & 100% APPD. DRGS IS 2007/2008 Cali. Chart 3 1,2
height Certification IS 2007/2008
31 Cleaning Cleaning external & M Visual 100% Technical Technical IR 2 2,1

internal after Specification Specification
hydrotest
32 Painting/ Stamping 1 Surface Preparation M Visual 100 % Approved Approved IR 2 2,1

2 Surface Finish M Mech. Gauge Random Procedure Procedure
3 Coating Thickness M Elco. Meter Random
33 QA & QC Documentation Overall quality, Data M Review of all 100% Technical Technical IR 2 1
Keeping TC, IR for Specifiation Specifications
previous stages & applicable
codes
SL. CHARACTERISTICS TO TYPE/METHOD EXTENT OF REFERENCE ACCEPTANCE FORMAT OF AGENCY
DESCRIPTION OF ITEMS CAT Remarks
STANDARD BOUGHT-OUT
ITEMS
34 Gauge hatch 1 Physical & Chemical M Physical, Random AS PER As per spec. MFTRS TC 3,2 1,2
Properties Chemical Tests SPEC. APPD. DRGS
APPD. DRGS.
2 Dimension M Visual & Meas. 100% APPD. DRGS. APPD. DRGS. MFTRS TC 3,2 1,2
DATA SHEET DATA
SHEETS
35 Sprinkler nozzle/ Foam maker Dimension & M Physical & Random APPD. DRGS APPD. DRGS MFTRS TC 3,2 1,2
Surface Quality Chemical Tests & SPEC. & Spec.
36 Foam seal & Accessories 1 Physical & Chemical M Physical & Random APPD. DRGS APPD. DRGS MFTRSTC 2 1
Properties Chemical Tests & SPEC. & Spec.
2 Dimension M Meas. & Visual 100% APPD. DRGS APPD. DRGS MFTRS TC 3,2 1,2
& SPEC. & Spec.
37 Flame arrestor/ Breather valve 1 Physical & Chemical M Physical & Random APPD. DRGS APPD. DRGS MFTRSTC 2 1
Properties Chemical Tests & SPEC. & Spec.
2 Dimension M Meas., Visual 100% APPD. DRGS APPD. DRGS IR 2 1

& SPEC. & Spec.
P PERFORMED BY 1. HPCL AUTHORISED REPRESENTATIVE CR : CRITICAL

W WITNESSED BY 2. VENDOR QC M : MAJOR
V VERIFIED & REVIEWED BY 3. SUB AGENCY/ SUB VENDOR (IF APPLICABLE & APPROVED) IR : INSPECTION RECORD TO BE MAINTENED BY STS
H HOLD TILL CLEARED BY 1 MEAS. : MEASUREMENT

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CONSTRUCTION OF PETROLEUM OIL STORAGE TANKS AT PARADEEP

HINDUSTAN PETROLEUM CORPORATION LIMITED

PETROLEUM OIL STORAGE TANKS

PARADEEP POL TERMINAL

TENDER COVER PAGE

PROJECT DESCRIPTION, SCOPE OF WORK & SCHEDULE OF

6 SPECIAL CONDITIONS OF CONTRACT 1 24

7 TENDER TECHNICAL SPECIFICATIONS

7.1 TECHNICAL SPECIFICATION

7.1-A GENERAL SCOPE OF WORK FOR TANKS 1 27

7.1- SPECIFICATION FOR STAINLESS STEEL ARMOURED HOSE 1 3

7.3.10. INSPECTION TEST PLAN FOR TANK FABRICATION 1 6

8 TENDER DRAWINGS 39 nos

9 SAFETY, HEALTH & ENVIRONMENT(SHE) POLICY 1 8

10 PARADEEP TERMINAL LAYOUT 1 1

PROJECT DESCRIPTION/ SITE INFORMATION

S. No. Size of Tank Product Capacity No. of Type

The site addresses is as below:

Hindustan Petroleum Corporation Ltd

Opposite Paradeep Railway Station,

Ph : (06722) 229225/ 229226

Scope of the job involves but not limited to the following:

1. Design, Construction and testing of above ground steel storage tanks.

5. The complete requirements shall be executed comprehensively with single point

Drawings required to be submitted by the Party:

IMPORTANT NOTES TO SCHEDULE OF QUANTITIES

ITEM DESCRIPTION OF ITEM UNIT QTY

CONSTRUCTION OF PETROLEUM OIL STORAGE TANKS

2.0 Murrum Filling Cubic 2000

Supplying and filling murrum of approved quality with PI of 7-17(Medium

3.0 Rubble Soling Cubic 75

4.0 Plain Cement Concrete 1:2:4 Cubic 50

5.0 RCC M 20 - Tank Apron Cubic 135

6.0 RCC M 20 - Ring Beam for above ground tanks Cubic 75

Designing of Mix, Providing and laying Reinforced Cement Concrete of M-20

REINFORCEMENT STEEL Metric 12.5

Supply, fabrication and laying in position steel reinforcement conforming to

ANTI CORROSIVE LAYER Square 3000

Providing and laying 100mm thick (compacted thickness) anti-corrosive layer

FABRICATION, ERECTION & WELDING – BOTTOM, SHELL, PONTOON

from HPCL Storage yard to Work site/ Contractor's fabrication yard,

NOTE : (for Item Nos9 to11)

All the Testing/Design/Third party inspection/vetting requirements as per

All appurtenances to be fabricated in line with requirements of API 650.

24.0 WATER DRAW OFF NOZZLE Each 16

Water draw off nozzles of 80 mm dia with reinforcement pad plate,

26.0 PRESSURE TRANSMITTER NOZZLE Each 4

Pressure transmitter nozzles of 80 mm dia with reinforcement pad plate,

FLOATING ROOF APPURTENANCES

reinforcement pad plates as per drawing complete as per specifications. For

27.0 DECK THROUGH MANHOLES-600mm NB Each 2

600 mm NB deck through manhole with 6 mm sleeve, manhole cover, bolting

28.0 DECK THROUGH MANHOLES- 750mm NB Each 2

750 mm NB deck through manhole with 6 mm sleeve, manhole cover, bolting

Fabrication and erection of 500 NB and 1.5 mt long MS ERW sleeve

30.0 PONTOON MANHOLES Each 56

31.0 AUTO BLEEDER VENT Each 4

Supply, fabrication, erection of 300 mm dia pipe conforming to ASTM A 105

32.0 RIM VENT Each 4

33.0 EMERGENCY DRAIN Each 2

Supply, fabrication, erection of 150 mm nominal dia emergency drain with

CENTRAL ARTICULATED ROOF DRAIN ASSEMBLY

Roof Drain: Design, sizing, Preparation of drawings, submission of design

shoes, guides and guards, if any as per Manufacturer's instructions; Supply,