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GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED

50000 MTA PAC PROJECT


ANNEXURE 6.4 SECTION 5
CONSTRUCTION PHILOSOPHY

5.1

OVERALL CONSTRUCTION PHILOSOPHY

1.0

Scope:
This document outlines the overall philosophy for Construction work for PAC
Project at GNFC, Bharuch.

2.0

Equipment / piping / machinery / structural material & all other components forming a
part of the Project shall be safely received, unloaded, transported & stored by the
Contractor.

3.0

Installation of static equipment shall be as outlined in Section 4.5.

4.0

Installation of pumps, compressors and drives as per the Section 4.5.

5.0

Fabrication and erection of above ground / underground piping including piping


support, will be according to respective Section.

6.0

Removal of site office, workshop & other temporary facilities arranged by


Contractor after acceptance of plant by GNFC.
Contractor shall follow all the safety rules & regulations of GNFC. Safety Manual is
attached.

8.0

GNFC shall provide construction utilities like construction power & water at one point.
Distribution of the same shall be the Contractors responsibility.

9.0

Supply of manpower for assistance during commissioning for small activities without
any additional cost is included.

10.0

House Keeping:
The contractor should ensure cleaning of area on daily basis & should follow ISO
14001 Guidelines

5.2

PLANNING

1.0

SCOPE
This specification provides guide line for activities of Site Planning, Progress Control,
and reporting at site.
The Contractor shall mobilize at site, adequate number of Computers for proper
planning, scheduling, material control, progress reporting & execution of the Project.

GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED


50000 MTA PAC PROJECT
ANNEXURE 6.4 SECTION 5
CONSTRUCTION PHILOSOPHY

2.0

DETAILED SCHEDULE
The Contractor shall prepare detailed schedule using Project Monitoring Soft wares like
PRIMA VERA, etc.

3.0

FABRICATION AND ERECTION

3.1

The following information shall be clearly indicated for each activity:


Reference quantities
Estimated Erection duration
Weight percentage assigned to that activity
Starting date
Completion date
Monthly expected progress by activity and by work area
The actual progress of the activities shall be monitored weekly/monthly
compared with the planned one and update in the schedule.

and shall be

The following information shall be clearly indicated for each activity.


Weekly/monthly and cumulative planned quantities to be executed
Weekly/monthly and cumulative actual quantities executed
3.2

REPORTING
In addition to the above referenced schedules, Contractor shall produce daily, weekly,
monthly reports.
Format of the report shall be as per mutual understanding between Contractor , and
Owner.
However format of reports shall be produced by contractor and approved by Owner.

4.0

CONTRACTORS DAILY REPORT

4.1

Contractor shall submit a daily report of manpower and major activities as follows:
Consolidated Daily Labor Report
AThis report relevant to actual manpower in site split up by discipline, work area,
main activities has to be submitted by Contractor to Manager before 10 a.m. each
morning for same day.
BDaily Production (Fitup, Welding, NDT, Erection etc.) Records along with NDE
data, if any
C-

4.2

Welders Work Records.

Contractor shall sequentially number the daily reports for each calendar day of site
activities.
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GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED


50000 MTA PAC PROJECT
ANNEXURE 6.4 SECTION 5
CONSTRUCTION PHILOSOPHY
5.0

CONTRACTORS WEEKLY REPORT

5.1

Contractor shall submit weekly progress report to Owner as per agreed cut off and
submission date as per agreed format.
The contents of the report shall be generally the same as described and the following:
Weekly
Production (Welding) Records along with NDE data, if any.
The records on progressive evaluation of welders weekly performance.
Such weekly report shall be discussed during a weekly progress meeting to be held at
site between Contractor and owner, if required.

6.0

DOCUMENT SCHEDULE
Contractor shall submit all documents to Owner as per the document schedule.
Document schedule shall be the part of the ITB.
Documents to be submitted by Contractor shall be in the format approved by Owner.

5.3

EQUIPMENT

1.0

General Scope
This document shall outline Contractors scope of work for static equipment erection.
Following activities will be carried out by the Contractor:
Check & make good Civil foundation for equipment.
Prepare Erection Scheme for the Heavy Lifts.
Check vertical alignment using Theodolite only.
Shall arrange for testing of Crane.

2.0

Contractor shall not use any column or member of foundation for dragging or
the equipments. Foundations and Columns are not designed for the same.

3.0

The actual dimensions taken during alignment such as heights, deviations from the
horizontal and vertical etc. shall be recorded on forms supplied to Contractor by the
Owner.

4.0

TOLERANCES
Following tolerances are valid for fine alignment:
Height tolerance for vertical equipment :
+ / - 1 mm measured at the base ring or foot plat
Height tolerance for horizontal equipment:
+/- 1 mm when supports are fixed to the foundation
+/- 3 mm for sliding supports
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lifting

GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED


50000 MTA PAC PROJECT
ANNEXURE 6.4 SECTION 5
CONSTRUCTION PHILOSOPHY
Vertical deviation shall not exceed:
0,2 mm/Mt. for columns
0,3 mm/Mt. for separators, heat exchangers etc.
As a measurement datum the average from various measurements taken of the vessel
shall be used. Any deviations over the tolerances needs the written approval of the
GNFC.
5.0

LIFTING EQUIPMENT AND TOOLS


All construction equipment which is to be used for the execution of the equipment
erection shall be in first-class operating condition, safe, fit for the uses for which
intended and suitable for the safe and efficient performance of the work.
Crane shall not be loaded over 85% of the permitted limit.
The load on a rope shall not exceed 25% of the breaking load for shackles and slings.
The allowable load for shackles and slings are restricted from 10% to 12,5% of the
breaking load.
Cables with strands and wires wound in the same direction (long lay) shall only be for
guided loads.
Two cranes are to be used if length, weight or another special feature predominates.
Cross ties are to be used in the event when a tall upright item has to be lifted by 2
Cranes.
There shall be no removal or transfer of any of the lifting equipment from the site
without the prior written approval of the GNFC.
For unloading or lifting the equipment use the weight from the Collie/ Packing list and
not the weight stated in the drawing or Inquiry.

6.0

ERECTION PROCEDURE
Equipment nozzles shall not be used for lifting.
A crane shall not be used for back movement during lifting.
When lifting non-ferrous or painted vessels and equipment, hemp ropes, special
supports or cross ties shall be used to avoid damage.
In the range of the steel wire rope the corner of the aluminum heat exchanger must be
protected against damaging with angles out of la-sheet-metal.
Prior to lifting thin walled vessels or soft material vessels such as aluminum, all
necessary action shall be taken to avoid crushing of the vessel during lifting.
Care shall be taken that the guide rope can move unrestricted while lifting equipment.
Guidelines shall be used for each piece of equipment during lifting.
Shim sheets or plates shall not protrude out past base plates or foot flanges.
Shim sheets or plates shall be deburred and planed.
Wedges and temporary packing shall be removed after equipment is leveled.

GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED


50000 MTA PAC PROJECT
ANNEXURE 6.4 SECTION 5
CONSTRUCTION PHILOSOPHY
5.4

MACHINERY

1.0

Scope
Scope includes Installation of a machinery item in accordance with the
Installation Instructions of the supplier of the Machine.

2.0

Assembly & installation of the coupling and alignment of the machinery.


Alignment shall be carried out using Dial Gauges only.
The alignment of the machinery shall not get disturbed more than +/-0.03 mm
(unless otherwise specified by the manufacturer) in both directions(axial &
radial) during assembly and disassembly of the piping connections.

3.0

Progress Report & Data

Contractor shall submit to GNFC all information regarding the activities


of the machinery erection, on a weekly basis.
This information shall consists of:
Date of receipt of machinery
Date of machinery erection;
Date of first preservation;
Date of rotation by hand (at least alternate days, unless otherwise stipulated in
the manufacturers instructions);
Date of first alignment;
Date of checking the stress relieving of the piping connections and final
machinery alignment;
Date of motor or machine test run;
Date of last renewal of preservation agent;
Date when machinery is ready for operation.
Date of acceptance of machinery by owner
4.0

Records

4.1

After completion, a certificate of final alignment acceptance report shall be


issued for each machinery.

The certificate shall contain the following data:


4.1.1 The values of the first and final alignment;
4.1.2 The actual tolerances of the connecting flanges;

5.0

ERECTION PROCEDURE

5.1

In case anchor bolts are not installed, bolts shall be unpacked and anchor bolt
pockets shall be cleaned. Dosing pump foundation shall be checked for
accessibility of oil drainage plug and bottom cover of dosing pump.
The machinery is to be placed onto the foundation in accordance with the
appropriate X-Y-Z coordinates.

5.2

GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED


50000 MTA PAC PROJECT
ANNEXURE 6.4 SECTION 5
CONSTRUCTION PHILOSOPHY
5.3

Shim plates or sheets shall not protrude out of base plates or foot flanges.
Shim shall not be stacked in more than three (3) layers.
Wedges and temporary packing shall be removed after machinery is leveled.
After the proper alignment the base plates shall be grouted after the shuttering
by planking boards on each side of the foundation.
After the hardening time of the grout, the machine must be realigned and all
anchor bolts shall be tightened according to the manufacturers instructions.
Observe special instructions of the machine manufacturer.
The grouting shall equally distribute the static and dynamic forces from the
machine to the foundation . Only non-shrinking, non-metallic, free of chloride,
oil-resistant and easy fluidity grout (size 0-3 mm, crushing strength after 28
days ca. 70-90 N/mm2, deflection strength after 28 days ca. 10-15 N/mm2) shall
be Used.

6.0

ALIGNMENT OF MACHINES

6.1

Machine to driver shaft alignment must be set to the values given by the
machine manufacturer.
Stress free connection of the piping must be assured.
During check of the rotation, motor has to be disconnected from pump,
compressor etc.
During the check of the over speed trip, turbine has to be disconnected from
pump, compressor, generator etc.
Alignment shall be accepted and documented on prescribed format only after
ensuring stress free piping connection with machine.
Alignment readings shall be recorded when piping is disconnected and when
piping is connected to the machine.
Factors of influence:
Elevation of base frame, Bearing from base to sectional joint, Diameter of
journal, Oil film thickness
Limits of alignment:
Final alignment shall be executed acc. the different conditions between each
machine from the manufacturer.
Alignment and checking of alignment shall be made several times to ensure the
most possible accuracy.
Measuring devices:
Dial gauges (scale 0,01 mm) with supports, filler gauges and high precision
instruments.

6.2

7.0

All outside connected machine parts that may be damaged during the erection
shall be removed, marked and stored properly.
FINAL ALIGNMENT
The acceptance protocol for the final alignment can only be signed if the pipes
are bolted up.
An acceptance protocol has to be provided with disconnected and connected
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GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED


50000 MTA PAC PROJECT
ANNEXURE 6.4 SECTION 5
CONSTRUCTION PHILOSOPHY
pipes.
Stress free connection of the connection piping must be assured.
During check of rotation, motor has to be disconnected from pump, compressor
also.
During check of overspeed trip, turbine has to be disconnected from pump,
compressor, generator a.s.o.
Machine to driver shaft alignment must be set to the values, given by the
machinery manufacturer.
5.5 - PIPING
1.0

SCOPE:This specifications outlines the scope of work for the fabrication, installation and
testing of the above ground piping.
The scope shall includes but not limited to the following activities:
Identification of the Material as per the Pipe Class indicated on the drawing.
Identification of the Shop & Field Joints.
Ensuring availability of WPS / PQR for the relevant pipe classes.
Prefabrication.
NDT for prefabricated spools & attending repairs.
Shifting prefabricated spools to site, erection, & field joints.
NDT for field joints and attending repairs.
Mechanical completion, including installation of all supports, inline
instrumentation, etc.
Removal of inline instruments & providing spools for Hydro Test & flushing.
Preparation for & completion of Hydro Testing.
Draining of Hydro Test Water.
Flushing & Drying.
Card Board Blasting, for Process Piping.
Removal of licking devices from Spring supports.
Preparation of Loop Files in triplicate.
Handing over for further activities.

2.0

Performance of radiographic examination of weld on all types of piping including


provision of all necessary equipments with radioactive source, developing room
with air conditioner, consumables and whatever else even though not expressly
mentioned here in but required to perform the work up to radiography
interpretation as per specifications and instructions of GNFC / Third Party
Inspection Agency. Film quality should be D4 for S.S. material while for C.S. it
shall be D7/D4 or its equivalent of approved make to obtain quality of image.
Contractor shall arrange higher curry source to take radiography in limited time.

GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED


50000 MTA PAC PROJECT
ANNEXURE 6.4 SECTION 5
CONSTRUCTION PHILOSOPHY
3.0

Contractor shall also provide all facilities for evaluation of films.

4.0

Contractor shall use welding electrodes, filler wire, flux etc. from
following manufacturers only.

Advani Oerlikon
D & H Secheron
ESAB

5.0

Stress reliving (PWHT) of the weld joints as per specifications & code
requirement.

6.0

Statutory Approval
All activities related to statutory approvals shall be as per Annexure 4.8.

7.0

PROGRESS REPORT SCHEDULE AND DOCUMENTATION

7.1

Contractor shall schedule and coordinate all planning, supervision and progress
activities.
Contractor shall promptly submit such schedules, reports to the GNFC .

7.2

Contractor shall prepare & submit complete documentation, as built drawings


and isometrics to GNFC.

7.3

The final documentation shall consist of As built marked drawings / plans /


isometrics.

7.4

Contractor shall prepare Test Loop File for individual test loop. Each loop
file will consist of :
Section of P & I D of the loop.
As Built piping isometric with joint numbers & welder number duly marked.
Line History sheet comprising of fit up release, weld joint visual clearance,
correctness as per Isometric, etc.
NDT Records such as DP / MP / RT.
PWHT * PWHT hardness recods, if any.
Final Hydro Test report.
Flushing / drying / card board blasting reports.

8.0

Welders will be qualified under relevant ASME Codes.

9.0

QA / QC activities by the Contractor will be done under Third Party Inspection


agency, as appointed by GNFC during the Project Execution.

5.6

FLUSHING

1.0

SCOPE
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GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED


50000 MTA PAC PROJECT
ANNEXURE 6.4 SECTION 5
CONSTRUCTION PHILOSOPHY

2.0

This specification defines the basis for cleaning and flushing operations in
connection with hydrostatic testing as outlined in the Specification for testing in
the field of equipment and piping
FLUSHING MEDIUM
Stainless steel piping shall be flushed with potable water or raw water with a
pH-value not over 7.0.
Carbon steel and alloy piping shall be flushed with potable or raw water.
In special cases piping shall be blown out with oil-free air.

3.0

DURATION FOR FLUSHING


In an open system, flushing shall be continued until flush water leaving the
system is clear and free from all foreign debris.
In a closed system, flushing shall be continued until circulating pump strainer is
free from foreign debris and circulating water is clear.
Unless otherwise agreed, flushing and cleaning operations shall be performed
during normal working hours.

4.0

General Requirement:
Flushing and blow-out operations shall be performed by qualified and skilled
personnel acquainted with the technology of flushing.
Contractor is responsible for all damages occurring during flushing - or blow
out activities
GNFC shall be informed before the start of any flushing or blow-out activity. A
work schedule shall be submitted to GNFC for approval.
Contractor shall prepare an adequate number of spool pieces for
temporary replacements.
Flushing operations shall be carried out in connection with hydrostatic testing of
complete system. Wherever possible, flushing should be arranged prior to the
start of pressure test.
The above practice minimizes the number of flange connections to be opened
after successful pressure testing.
In order to avoid wastage of expensive gaskets, all temporary connections for
the flushing operation will be installed using temporary gaskets, resistant
against the pressure and temperature of flushing operations.
Contractor shall restore all systems to their original condition after flushing as
required by GNFC.
Contractor shall provide suitable connections to hydrants and
drainage to sewers for circulating water.
Contractor shall provide circulation and/or flushing pumps.
Contractor shall provide suitable temporary pipe connections, hose
connections, blind flanges, temporary gaskets, temporary strainers and dummy
spools as required for flushing and steam blowing.

5.0

REQUIREMENTS CONCERNING INSTRUMENTS AND EQUIPMENT

5.1

Control instruments : In general all instruments in the system to be flushed must


be isolated from the test by test blinds or removed unless otherwise permitted by
GNFC.
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GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED


50000 MTA PAC PROJECT
ANNEXURE 6.4 SECTION 5
CONSTRUCTION PHILOSOPHY
Relief valves and rupture discs shall be removed or blanked off from equipment
or piping system prior to flushing/ testing.
Contractor shall ensure that instrument removal for flushing is performed by
skilled craftsmen.
Orifice plates flow nozzles or other similar restrictions normally shall not be
installed until the system is flushed.
Control valves DN < 200 (8) will be removed.
If there is no by-pass a spool piece shall be installed.
All control valves not removed (welded or diameter nominal > 200 (8) will be
opened prior to flushing at 100% and stay open during flushing activities.
Line mounted instruments such as Rotameters and positive displacement meters
shall be removed and spool pieces shall be installed instead. In case of an
existing by-pass, the open ends will be flushed shortly and blinded.
Locally mounted pressure gauges shall be blocked off or removed and their
connections to be plugged during flushing.
Level instrument floats located inside vessels or float cages shall be blocked off
and opened to the air.
5.2

Vessels :
Vessels may only be flushed if the feed line has been thoroughly cleaned
before.
To flush into columns, special permission from GNFC will be necessary.
Where possible, all connecting pipes should be flushed starting from the vessel
in order to avoid disassembling of flange connections. Filling of those vessels
will be done using the deepest possible point for flushing connection.
Flushing into tanks is only allowed providing the tank will be thoroughly cleaned
after flushing.

5.3

Rotating equipment
Pumps, compressors, turbines will never be flushed. Flange connections of
these equipments will be disconnected prior to flushing and the above
equipments must be protected with blinds.

5.4

Heat Exchangers :
Heat Exchangers may be flushed through if the feed line is thoroughly cleaned
before.
Exception : Plate heat exchangers shall always be blanked off.

6.0

RECORDING
The flushing or blowing-out shall be recorded in the test documents, the socalled Pressure circuits.
After the flushing or blowing-out is finished, the documents shall be signed by
all parties concerned to certify that the system is satisfactorily flushed/blown out
and clean.

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GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED


50000 MTA PAC PROJECT
ANNEXURE 6.4 SECTION 5
CONSTRUCTION PHILOSOPHY
4.5.7

SAFETY

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

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