Part-III

Section – 1

1.0 GENERAL

1.1 Site Survey

The following site survey shall be carried out by the Contractor.

i) Route survey.

ii) Bench mark - Establishing bench marks / control points at site

and maintaining the same till completion of work.

The objective of survey to be conducted is to verify the relative grade

levels, connecting roads, pavements and drainages in relation to the
scope of work to be carried out.

Contractor shall carry out detailed Route survey of entire pipe line and
shall verify the existing underground facilities referring the available
drawings documents, site survey etc in order to work out details of
crossings of such facilities by the pipe lines.

1.2 Soil investigation :

The contractor shall carry out soil investigation at pumps location in

order design the pump foundation within allowable soil bearing
strength.

1.3 Calculations & Design

1.3.1 Design Calculations and Drawings

The Contractor shall submit all design calculations and all

construction and fabrication drawings for CPCL’s review /
comments / approval. Upon review / approval by CPCL, the
documents shall be issued to Contractor for incorporation of
comments or with no comments stamp.

1.3.2 Design :

a) Units

Metric units shall be used.

b) Design Loads

i) Wind – As per Indian standard BIS 1893.

ii) Earthquake – As per Indian standard BIS 875.

Offsite Automation
1
 Part-III
Section – 1

c) Reinforced Concrete Design standards.

d) Steel Structure Design standards.

1.4 Materials and Workmanship :

1.4.1 All materials used for permanent installation in the works shall
be new and shall conform to the relevant specifications. The
manufacturers specification and origin of all materials shall be
made available to the Engineer-in- charge for approval, prior to
their use in the works. Samples shall be provided, if required.
The Contractor shall carry out all tests and supply all tests
certificates as required by the Engineer-in- charge, to ensure
that materials are in compliance with the relevant specifications
and standards. In addition, the Contractor shall supply as many
samples of materials as may be required to enable the
Engineer-in- charge to carry out any independent testing.

1.4.2 All workmanship shall conform to the relevant specifications and

standards and be executed to the satisfaction of the Engineer-
in- charge with regard to both quality control and project
schedule.

1.5 Setting Out :

The works shall be set out from existing Datum Points (benchmarks)
located within the Refinery. Further temporary benchmarks shall be
established by the Contractor in each work area as necessary and as
agreed by the Engineer-in- charge.

2.0 SCOPE OF WORK

2.1 General

2.2.1 Demolishing works :

a) The Contractor shall cut & remove the existing redundant

pipe lines of various sizes at the LSHS loading facilities
near the fuel oil tanks (TK- 201-205 &212).

b) Demolishing of existing north, east & west side earthen

dike and reconstruction of RCC dike wall for the above
existing fuel oil tanks.
Chennai Petroleum Corporation Limited
Offsite Automation Project
-2-
 Part-III
Section – 1

c) Any other existing facilities like walkways, cross over

platforms etc. shall also be demolished and re
constructed to suit new facilities.

The above demolishing works shall be carried out in order to

create space for the new blending headers & control valves
station.

2.2.2 New pumps:

a) R.C.C (Reinforced cement concrete) foundations for the

new pumps.

b) Reinforced concrete paving around the pumps shall be

provided.

c) Pump drain and floor wash for extended part shall be

connected to nearby existing OWS system and storm
water as required without disturbing the performance of
existing system.

d) Steel structure/ pipe cross over stairs, operating platforms

and pipe supports as required.

2.2.3 New blending headers:

a) For ease of operation and maintenance, provide

necessary structural platforms, walkways, pipe cross-
overs, staircase, ladders etc. as per applicable
engineering Standards.

b) Necessary pipe supports shall be provided for the

blending headers as well as connected piping & control
valves.

d) All drain points shall be connected to the existing OWS

system.

2.2.4 Control room extension & modification

The civil / structural works for satellite house shall comprise but
not limited to the following :-

Chennai Petroleum Corporation Limited

Offsite Automation Project
-3-
 Part-III
Section – 1

i) Refer conceptual layout of OM&S control room drawing

no. 20-E-41341 showing the lay out for guidance purpose
only. The Contractor shall prepare detailed drawings and
submit for CPCL approval. Also, refer to OISD-STD-163
and Instrumentation specification for the facilities to be
provided in the Control room.

ii) The minimum inside dimensions shall be as shown in the

conceptual drawings. The building shall be designed &
constructed suitable for packaged type air condition
system with pressurization as specified in Electrical
HVAC technical specifications. Refer to OISD-163 for the
pressurization requirements.

iv) The building shall be designed as RC framed building. It

shall consist of reinforced concrete foundations, columns,
floor slab and roof slab. The design of the ‘control room’
shall conform to the requirements of OISD – 163
(latest/amended revision).

v) False flooring shall be with minimum 1" thick wooden

board (600 x 600mm) completely encased with
galvanized steel plates. It shall be covered with vinyl tiles
of minimum thickness of 3mm.

vi) False ceiling shall be of Gypsum tiles supported by

suspended ceiling system except in battery room.

viii) Roof finish shall consist of plaster alkyd primer, enamel

paint finish from inside for battery room and roof top shall
be terrazzo tile over approved weather proofing system
which shall include light weight concrete screeds. Roof
drainage shall be connected to near by existing drainage
network.

x) All materials and apparatus for room finish shall be of first

class category and shall be subjected to CPCL approval.

xi) 3'-0" wide RCC plinth protection shall be constructed

around the control room.

Chennai Petroleum Corporation Limited

Offsite Automation Project
-4-
 Part-III
Section – 1

xii) The floor and inner walls of battery room shall be

protected by acid / alkali resistant tiles to a height of 5 ft.
from floor level.

xiii) EPC Contractor shall design and submit the architectural

/ civil / structural drawings for CPCL's approval. The
specification of undefined items shall be similar to the
latest Refinery practices and good civil engineering
practices.

xiv) The control room shall be provided with the Fire

protection system, as specified in OISD-163. The type of
fire protection system and the type of fire extinguishing
agent shall be subject to CPCL’s approval.

2.2.5 Dye Injection Facilities :

The scope of work involved in the construction of new dye

injection facilities shall comprise, but not limited to the following :

a) The Contractor shall provide a steel framed and sheet

metal clad shelter for dye injection facilities complete with
Reinforced concrete foundations for the dye pot, pump,
pipe supports, platforms, stairs etc.

b) The minimum inside dimensions shall be finalised during

detailed engineering as required. The shelter for the new
dye injection facility shall have operating platforms / stairs
and free moving space for maintenance activities.

c) Provide heavy duty RCC paving minimum 6” thick for

maintenance and operations facility.

d) Cladding & roofing shall be 24 gauge pre-coated galv

anized steel panels. The colour shall be decided at the
time of detailed engineering.

e) Standard roof eaves gutter with down takes pipes for

storm water drainage shall be provided. Storm water
Chennai Petroleum Corporation Limited
Offsite Automation Project
-5-
 Part-III
Section – 1

drain will be provided along with 3'-0" wide RCC plinth

protection and will be connected suitably to existing
drains.

f) Painting of all structural steel members shall be as per

painting standard.

g) Minimum thickness for any structural element main

members shall be 6mm.

h) Girt cladding shall be provided on three sides of the

shelter for complete protection against sun and rains.

i) Provide complete civil / structural works necessary for

electrical and instrumentation installations.

j) Horizontal deflection of shelter shall be limited to

height/200.

l) 3 feet wide PCC plinth protection shall be constructed

around the dye injection facility shelter.

m) EPC Contractor shall design and submit the civil /

structural drawings for CPCL's approval. The
specification of undefined items shall be similar to the
latest Refinery and good civil engineering practices.

2.2.6 Pipe crossings at road & tank dike :

a) RCC culverts shall be provided for all new pipelines at

road crossings. The culvert size shall be minimum 2.5
meter clear width. Refer to Standard specification doc. #
6-65-1021.

b) The pipe culvert shall be designed in such a way that no

water shall accumulate inside the culvert.

c) Pipe crossings at dike wall of tanks shall be provided with

pipe sleeve as per drawing No. 00-E-22774.

d) Additional space requirement for all new pipe culverts

shall be minimum 50%. In any case, the clear width of the
culvert shall not be less than 2.5 meters.

Chennai Petroleum Corporation Limited

Offsite Automation Project
-6-
 Part-III
Section – 1

2.2.7 PIPE SUPPORTS, SLEEPERS, CROSS OVERS & BRIDGES

a) The work shall comprises of providing pipe supports,

sleepers, cross-over and bridges of different size and
lengths as required for the new as well as affected
existing facilities. The work shall include necessary
excavation, levelling, cutting dykes and making it good
etc and shall comply with applicable engineering
standards.

b) Additional space requirement for all new pipe racks and

sleepers shall be 15%.

c) Modification of existing pipe cross over bridges fouling

with new pipe routings and provision of new pipe cross
over bridges, wherever necessary.

d) Provision of pipe protection sleeves / pipe culverts at road

crossings and dyke crossings.

2.2.8 Excavation for laying underground pipeline

a) Excavation for laying the pipe line shall be carried out in

all types of earth like asphalt roads, RCC / PCC flooring
etc.

b) Refer Clause No. 3.1 of Technical specification of this

document for work specification.

2.3 MISCELLANEOUS

2.3.1 Fire Proofing

Fire proofing design & construction for all Motor operated valves
(MOV) and cables (upto 25 meters from MOV) etc. shall be
carried out as per engineering standards. Material for fire
proofing shall be approved by CPCL.

2.3.2 Road Crossings

Contractor shall design and install under ground road crossings

such as culverts, pipe sleeves. All damaged roads shall be
resurfaced to original size and design.

Chennai Petroleum Corporation Limited

Offsite Automation Project
-7-
 Part-III
Section – 1

Where it is necessary for cables to cross road or areas exposed

to heavy loads, reinforced concrete duct bank shall be provided.
2 nos. 6" dia. extra sleeves shall be provided in each duct bank
for future use.

2.3.3 Materials, Equipment & manpower

All materials, consumables, equipment, tools, manpower,

transport etc. required for the full and proper execution of the
works shall be supplied by the Contractor and shall be approved
by the CPCL.

2.3.4 Kerbs, edgings, guard posts and crash barriers for the pipe lines
near the roads vulnerable for traffic shall be designed and
provided.

3.0 TECHNICAL SPECIFICATIONS – CIVIL / STRUCTURAL

The standard specification for general civil works doc. # 6-65-0066 shall be
followed

3.1 Earth Work

3.1.1 Existing Ground Levels

The existing ground levels are to be checked by Contractor and

to be verified with respect to those shown on drawings. In case
of any discrepancy, the same to be resolved with CPCL
Engineer before starting any excavation works.

3.1.2 Approval of Excavation

a. All excavations and foundations shall be approved by

CPCL Engineer before concrete is placed or piping is laid
in position. The Contractor shall notify CPCL Engineer in
writing when formation levels are reached stating the date
and time that such formation is ready for inspection.

b. Prior written approval of CPCL Engineer shall be

obtained before Contractor carries out any excavation.

Chennai Petroleum Corporation Limited

Offsite Automation Project
-8-
 Part-III
Section – 1

3.1.3 Excavations and Backfilling

Excavation / earth work within Refinery shall be carried out as

below :

a) In any type of ground including filled areas, hard soil,

running sand, asphalt or concrete pavements and at road
crossings.

b) Excavations inside refinery shall be carried out by hand

only. The Contractor shall take utmost care while
excavation as live underground facilities may be
available.

c) The Contractor shall take all necessary steps and

observe maximum precaution to protect all existing
services, utilities, landmarks, drains, water and gas
mains, power and telephone cables which are likely to be
damaged during excavations and / or due to slips and
falls of stacked earth. Any damages caused shall be
immediately notified to the CPCL and necessary repairs
shall be quickly carried-out at Contractor's expenses.
Contractor shall be fully responsible for all damages
caused and for the claims arose thereafter. All
equipment and materials delivered to site shall be
approved as per CPCL rules and regulations for safety
aspects.

d) No backfilling of pipe line trench shall commence without

the approval of the Engineer.

e) All other surplus excavated materials / debris shall be

cleared away from the site and deposited in a CPCL
approved dump area

f) All materials arising from the excavations shall remain

the property of CPCL.

3.1.4 Excessive Excavation

When excavation is made in excess of the depth of the

permanent work for which it is intended, the void so formed shall

Chennai Petroleum Corporation Limited

Offsite Automation Project
-9-
 Part-III
Section – 1

be filled with plain cement concrete class 2, 1:3:6 mix as per

standard at Contractor ’s own expense.

3.1.5 Dewatering

Efficient dewatering methods shall be adopted where work is to

be carried out under high ground water table areas.

3.2 Concrete Work

All concrete works including materials, mixing, placing, curing, testing

etc. shall comply with Standard Specification No. 6-65-1019.

All concrete in contact with soil shall be applied with two coats of
approved bituminous paint.

3.2.1 Cement

Cement shall be sulphate resisting cement conforming to ASTM

C-150 for the concrete elements which are in contact with earth
and Portland cement conforming to ASTM C-50 for other
concrete works.

3.2.2 Concrete Mix and Types

- The design of concrete shall be in accordance with ACI

Building Code requirements for concrete ACI-318 latest
revision and its commentary. Concrete mix shall be designed
to meet the compressive strength requirements of concrete.
All structural and foundation concrete shall have a 28 days
compressive strength of 3000 pounds per square inch (21.0
N/mm 2) cylinder strength.

- All blinding concrete under the foundation footings shall have

a 28 days compressive strength of 1500 pounds per square
inch, cylinder strength

- Freshly placed concrete shall be kept constantly wet for a

minimum period of 7 days.

- Samples of concrete shall be taken at the mixer and test

specimen made, cured and tested in accordance with the
requirements of B.S. 1881. The testing shall be made in an
approved testing laboratory in the presence of CPCL
representatives.
Chennai Petroleum Corporation Limited
Offsite Automation Project
- 10 -
 Part-III
Section – 1

3.2.3 Reinforcement

a) All main reinforcement steel bars shall conform to ASTM

A615, Grade 60, Type S deformed bars.

b) Reinforcing bars used for ties, and stirrups shall be ASTM A

615 Grade 40.

c) All reinforcement shall be placed and maintained in the

correct position on or as directed by the Engineer’s
Representative at site, ensuring the adequacy of ‘ cover’ as
indicated.

d) All reinforcement shall be inspected and approved by the

Engineer’s Representative before the concrete is placed.

e) All reinforcement at the time concrete shall be free of mud,

oil, rust, paint, grease, or any other foreign matters that may
adversely affect or reduce the bond.

3.3 Anchor Bolt

Anchor bolts shall be supplied by the Contractor and shall conform to

IS : 2062 / ASTM A307, carbon steel threaded standard fasteners

3.4 Structural Steel Work and Painting

3.4.1 General

The Contractor shall prepare all shop detail drawings and take
full responsibility for the accuracy thereof.

All materials shall be free from scale, rust, damage or defects.

All steel works shall be provided and fixed complete with all
plates, cleats, bolts, etc., cut to lengths and sizes and drilled, not
punched or gas cut. All steel members in contact with the soil
shall be painted. All items shall be given at least one coat of rust
inhibiting paint of an approved brand.

3.4.2 Rolled Mild Steel Joists, Channels, Angles and Tees

Rolled steel, mild steel joists, channels, angles and tees shall
comply with IS : 2062 / ASTM A36.
Chennai Petroleum Corporation Limited
Offsite Automation Project
- 11 -
 Part-III
Section – 1

3.4.3 Planing to Plates and Bars

The plates and bars used in structural work shall be straight and
bent to forms required and the ends planed so as to form sound
joints. Fabrication and erection shall be in accordance with the
AISC specification for the design, fabrication and erection of
structural steel for building and bridges and the AISC code of
standard practice for steel buildings and bridges.

3.4.4 Wrought Iron, Nuts and Washers

Bolts shall be of sufficient length to show at least one full thread

beyond the nut after tightening. Washers shall be with a
tolerance of 1.5mm on the diameter of the hole. When bolting to
diminishing sections, tapered washers shall be used.

3.4.5 Welding

Welding of all connections between steel members shall comply

with American Welding Society Structural Steel Welding Code
D1.1., latest edition or equivalent. All butt welds used in splicing
members shall be full penetration welds.

3.4.6 Steel Cutting

a. All steel parts shall be accurately set out, cut, framed,

and executed using proper bolts or welding with
electrodes. All cut parts shall be sawn cut. No oxygen
burning shall be permitted, except where allowed by the
CPCL Engineer. All cut parts and welded sections shall
be ground even and filed smooth with rounded edges.

b. Main members of structural columns, platforms

and gable frames shall be ‘whole’ members (no
splice), not welded portions.

3.4.7 Pipes

a. Pipes used as structural members shall be carbon steel

pipes in accordance with BIS 1239 / ASTM A53 Grade B.

Chennai Petroleum Corporation Limited

Offsite Automation Project
- 12 -
 Part-III
Section – 1

b. Pipes used for hand railing shall be as per BIS : 1239

carbon steel painted.

3.4.8. Painting of Structural Steel

For preparation of surfaces, priming and finishing paint and

inspection, refer to enclosed Engineering standard 6-44-0004.
The CPCL Engineer’ s final approval is to be obtained before
applying the paint / colour of the final coat.

3.4.9 Grating

a. The Contractor shall supply and erect all metal gratings of

applicable type as per engineering standard. The gratings
shall be hot dip galvanized as per Indian standard BIS 2629.

b. Grating panels arrangement diagrams with a piece mark

index shall be prepared by the Contractor before fabricating
the grating panels

b. The metal grating stair treads shall be provided with

perforated or chequered plate standard nosing.

3.4.10 Hand railing :

Hand railing shall be provided for platforms/ walkways / cross

overs / stairs etc. The design shall be as per existing at CPCL
and approved by CPCL.

3.5 Grouting

Grouting shall be carried out with approved non-shrink cement grout.

Before grouting, CPCL’s approval for the material and the method of
grouting shall be obtained.

4.0 APPLICABLE DRAWINGS / DOCUMENTS

The applicable and reference documents / drawings and engineering

standards & specifications are listed & enclosed in Part – IV of this Tender
document. Any other relevant documents, drawings and standards &
specifications mentioned there in shall also be form part of this document.

Chennai Petroleum Corporation Limited

Offsite Automation Project
- 13 -