GENERAL SPECIFICATION FOR SPEC.NO.

ROS:6204
GRP PIPING SYSTEM REV: 00

BHARAT HEAVY ELECTRICALS LIMITED,

RANIPET- 632 406.

GENERAL SPECIFICATION

FOR

GRP PIPING SYSTEM

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 GENERAL SPECIFICATION FOR SPEC.NO.ROS:6204
GRP PIPING SYSTEM REV: 00

TABLE OF CONTENTS

PAGE
S.No. DESCRIPTION
No.
PART-1: SUPPLY OF GRP PIPE & FITTINGS
1.0 Scope
1.1 General 4
1.2 Project Information
1.3.0 Scope of Supply
1.3.1 Fluid Details 4
1.3.2 GRP Pipes & Fittings
1.3.2 Marking Details 5
1.4.0 General Requirement
1.4.1 Applicable Codes And Standards
1.4.2 Manufacture
1.4.3 Resin 5-7
1.4.4 Pipe Liner / Pipe Structure
1.4.5 Joints
1.4.6 Fittings
1.5 DOCUMENT REQUIREMENTS
1.5.1 Documents / Details To Be Submitted Along With Bid 7
1.5.2 Documents / Service After Order
1.6 Inspection & Testing 8
1.7 Packing And Despatch 9

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PART-2: INSTALLATION AND TESTING

2.0 Scope
2.1 Scope Of Work
2.2 Erection, Commissioning and Testing of GRP Pipes and Fittings
2.3 Exclusions

2.4 Specification, Standards & Codes

2.5 Tools And Tackles
2.6 Flushing
2.7 Disposals Of Supports & Un-used Items
9-19
2.8 Inspection
2.9 Hydrostatic Testing
2.10 Testing Records
2.11 Additional Requirements
2.12 General Requirement to the Bidder
2.13 Site Cleanliness And Safety Requirements
2.14 Other Statutory Requirements
2.15 Time Of Completion
2.16 Engagement of Labour
2.17 Compliances With Labour Laws & Rules 19
ANNEXURE-A Data Sheet For GRP Pipe And Fittings 20
ANNEXURE-B Form for Technical Deviation 21
Tentative List of BHEL supplied Valves, Rubber Expansion
ANNEXURE-C 22
Bellows etc,

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PART-1: SUPPLY OF GRP PIPES & FITTINGS

1.0 SCOPE of WORK

This specification is intended for supply of Glass Fibre Reinforced Plastic (GRP) pipes and
fittings, Erection and Installation (E&C). The E&C includes collection of materials, Laying,
Joining by own supplied joining materials, fitting of BHEL supplied Valves, Rubber Expansion
Bellows, Static Mixer, Fasteners, Gaskets, etc., and hydro testing of complete GRP piping
with complete system to ensure to meet performance guarantee of system.

1.1 GENERAL

a. Item : GRP piping system

b. Application : Conveying of Sea water, corrosive fluid
at low pressure in RO-DM plant.
c. Surroundings : Hot, dusty & humid atmosphere
d. Installation : Indoor/Outdoor
e. Ambient Temperature : 45 °C Maximum & 15 °C Minimum
f. Operation : Continuous/Intermittent

1.2 PROJECT INFORMATION

1. Owner : TNGENCO
2. Project Title : Ennore SEZ 2x660 MW TPS
3. Location : BHEL Site Office, Ennore SEZ 2x660MW
4. Nearest Railway Station/Access by Road : Attipattu Puthunagar, North Chennai

1.3 SCOPE OF SUPPLY

GRP Pipes & Pipe Fittings as per annexure of Indent RWT70617 Rev latest
1.3.1 FLUID DETAILS
a. Medium Handled : Sea water, corrosive fluid
b. pH of Fluid : 2 to 12.
c. Operating Temperature : 20 – 40 ˚C.

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1.3.2 GRP PIPES & FITTINGS DETAILS

a) Pipe Design Data : Refer drawing No. 2-WT-240-00277 R00
and Annexure-A
b) Pipe Type : ID series pipe
c) Pipe Fittings : Elbows, Tees, Reducers, Fixed Flanges,
flange stub and blind flanges
d) Pipe Thickness : Vendor to provide detailed calculation for
Verification.
e) Outer Surface Finish : Smooth and glassy finish
f) Inner Surface Finish : Hazen-William flow coefficient, C = 150
g) Pressure Rating : PN10
h) Tolerance on pipe ID : as per standard IS12709
i) Tolerance on Pipe Thickness : 0 to + 0.5 mm.
j) Pipe Length :6m (Minimum)

1.3.3 MARKING:

Marking shall be done in all pipes and fittings. In pipes, marking shall be done at intervals
not more than 3 meters. The marking shall show the following:
a) Manufacturer's name
b) Pipe size and pressure rating
c) Batch number

1.4.0 GENERAL REQUIREMENTS FOR PIPE SPECIFICATION

1.4.1 APPLICABLE STANDARDS

 AWWA C950 : Fibre glass pressure pipe

 AWWA M-45 : Fibre glass pipe design manual
 ASTM D 2996 : Pipe wall thickness standards
 ASTM D 3567 : Dimensional control
 ASTM D 5421 : GRP flange dimension standards
 BS 5480 : Hydrostatic pressure test/ pipe stiffness test
 IS 12709 : GRP pipes and fittings for potable water

1.4.2 MANUFACTURE
GRP pipes shall be manufactured by filament winding of continuous fibreglass strand roving in
a dual helical predetermined pattern under controlled tension. All fittings such as Bends, Tees,
Elbows, Flanges, Blind Flanges etc are to be manufactured using the same materials as that of
pipe by contact moulding process. Standard GRP bends can be supplied factory made. GRP
pipes shall be supplied in a standard length of 6 metre (minimum).
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The internal and external surfaces shall be clean and free from defects such as protruding
fibres, voids, bubbles, pin holes, cracks, blisters, tackiness and foreign objects. Cut laminate
surfaces are coated with liner resin and have a smooth finish.

The design shall be performed to meet the required pressure class, PN 10. A minimum pipe
stiffness of 2500 N/m2 shall be selected.

1.4.3 RESIN

The resin used for the internal liner of the pipes and fittings is of an unsaturated resin that
can provide the required corrosive resistance. The resin in the structural wall of the pipes
and fittings is of the unsaturated Polyester type incorporating styrene as the polymer
monomer, but other resins may be used depending on the application. The vendor shall use
only approved polyester resin system for which they can provide documented performance
in this particular application.

1.4.4 PIPE LINER / PIPE STRUCTURE

a) The inner surface of GRP Pipe shall have a resin rich chemical resistant barrier
with a thickness of minimum 2.0 mm vinylester resin of ratio 90 % suitably
reinforced with “C” glass fibre of 10%.
b) Structural layer is made by filament winding of angle 54.7° consists of E- Glass
Chopped roving strand Mat of 60% by weight.
c) The outer surface of the GRP pipes shall be provided with UV stabilized barrier
made of 70% of resin & outer surface of the GRP pipe shall be glassy finish.

1.4.5 JOINTS

GRP pipes for above ground applications shall be joined by butt & wrap or flanged joint. For
connecting of equipment (pumps, tank etc.), valves & bellows flanges shall be used. For
instrumentation, flanged stubs are to be used. Typical instrumentation branch details are
indicated in the attached drawing.

1.4.6 FITTINGS

Fittings shall be supplied as per approved drawing. Only swept design shall be used for bends.
GRP flanges shall be contact mould in accordance with ASTM D 5421. Flange shall be flat faced
and drilled as per ANSI B 16.5 # 150.
ID chamfered flanges shall be used for wherever Wafer type Butterfly valve & Check valve
assembly with matched GRP flanges to facilitate Valve Disc full opening . Please refer typical
flange ID chamfered in Drg. No. : 2-WT-240-00277 R00 and Annexure –C (Tentative list of BHEL
supplied valves).
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Any rework arising out of this due to the interference of butterfly valve disc shall be carried out
by vendor only without any financial/commercial implications.

1.5 DOCUMENTATION REQUIREMENTS

The documentation during bid and post order stage shall meet the following requirements.

a. All documents and drawings shall be submitted in English.

b. Hard copies of all documents and drawings during bid stage to be submitted in
duplicate.
c. Hard copies of all documents for approval to be submitted in triplicate.
d. Hard copies of all final documents, drawings, manual etc., shall be submitted in bound
folder in duplicate.
e. Soft copies of all final documents in MS office/PDF shall be submitted through email.
f. Soft copies of all fitting drawings in AUTOCAD/PDF, latest version shall submitted
through email.

1.5.1 DOCUMENTS / DETAILS TO BE SUBMITTED ALONG WITH BID

a. Duly filled up data sheet Annexure-A in the enclosed format.
b. List of applicable standards for shop test.
c. Applicable Quality plan for supply of the above piping system.
d. Pipes & fittings Catalogues.
e. Confirmation on the dimensional details for the GRP pipe and fittings as given in the
enclosed drawing.
f. Hydraulic test procedure & details for testing the pipes, fittings, joints etc. at site after
installation.
g. Any deviation to this specification shall be specifically mentioned in the enclosed
deviation format Annexure-B.
h. In case of any deviation, to this specification the Bidder shall indicate the deviation,
clause by clause in the deviation format attached in Annexure-B. If there is no
deviation “NIL” statement shall be furnished. In the absence of Annexure-B, it will be
construed that the bid confirms strictly to this specification. Acceptance or rejection of
the offer with or without deviations (either fully or partially) is sole discretion of the
purchaser without seeking further clarification from the bidder.

NOTE: Bidders to note that failing to submit the above documents in class 1.4, the bid shall

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be considered as incomplete and may be liable for rejection.

If required, suppliers may visit BAP, Ranipet before the submission of their techno
commercial bid for a technical discussion.

1.5.2 DOCUMENTS / SERVICE AFTER ORDER

i) The following documents is to be submitted for BHEL's approval.

- Duly filled up data sheet in the enclosed format.
- Dimensional drawing for pipes and fittings.
- Cross-sectional drawing for pipe structure
- GRP joining procedure
ii) The following are to be submitted to BHEL's review and acceptance for the
manufactured GRP items.
- Material test certificate
- Dimensional report for pipes and fittings
- Hydraulic test certificates at shop.
- Performance guarantee certificate.
- GRP Pipe installation and supporting procedure.

1.6 INSPECTION & TESTING

All the stage checks shall be offered to BHEL for inspection. Each pipe shall be tested
hydrostatically at 1.5 times the design pressure for the period of 30 minutes at Vendor’s works.
Necessary test certificates for all pipes to be presented to BHEL for review. BHEL will witness
sample hydro testing. If the sample fails in the hydro test, the entire lot is liable for rejection.

No material shall be despatched without obtaining written clearance from BHEL. During
inspection, the internal inspection reports shall be submitted to BHEL for information.

Product sample test for reputed laboratory shall be provided by bidder.

1.7 PACKING & DISPATCH

a. All pipe and pipe fittings shall be suitably protected, coated, covered or boxed to
prevent damage or deterioration during transit, handling and storage at site, till the
time of erection. Each packing shall have necessary handling marks
b. Each packing shall contain a packing slip indicating the details of item like item
description, quantity, weight etc. Packing slip shall be submitted for BHEL approval
for giving dispatch clearance by BHEL.
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c. Details of handling & Storage instruction shall also be provided in each packing.
d. All items shall be properly packed with adequate cushioning material to prevent
rough handling and inland transport.
e. Special care shall be given to prevent damage to the fragile components.

PART-2: INSTALLATION AND TESTING

2.0 SCOPE

Bidder shall carry out the installation and testing of GRP piping as per the BHEL erection
drawings and manuals/documents.

2.1 SCOPE OF WORK

The vendor's scope of work in installation and testing comprises of the following:
1) The following materials are to be collected as per applicable procedure from BHEL
stores:
i) Vendor supplied GRP pipes & pipe fittings.
ii) BHEL free supplied Piping components like Valves, Bellows, Static Mixers, pipe U-
clamps, Fasteners, Rubber Gasket & other pipe line accessories etc.
2) Safe custody of above drawn materials
3) Laying, joining of GRP pipes and fittings with own joining material as per the enclosed
tentative tender drawing no: 1-WT-240-01282 R00.
4) Erection of piping components along with Fasteners & Gaskets.
5) Hydro-testing & leakage rectification of piping system
6) Handing over of piping system after commissioning and trial operation
7) Reconciliation of drawn material from the store and material accounting for all the
materials used.

GRP PIPING SYSTEM DETAILED WORK

a. Erection of GRP pipes & fittings shall be carried out as per BHEL erection drawing
which will be provided during post order. However preliminary isometric piping and
support arrangement drawings (1-WT-240-01282 SH01 to 10 R00) are enclosed along
with the specification for information. Suppliers are advised to go through the
drawings to understand the scope of work. The drawing gives only tentative work
content and any minor modification shall be carried out to meet the site requirement
by the vendor without any additional commercial implication to BHEL.

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b. Temporary joints of pipes segments to be made as per erection drawings and shall be
offered for stage inspection to BHEL. Final joining of piping shall be done after getting
approval from BHEL.

c. Assembly of valves, bellows, static mixers and other accessories along with gaskets
are to be taken care during erection of pipe segment.

d. All the fasteners and gaskets used for assembly of pipes, valves, bellows etc. will be
issued by BHEL, but proper accounting and returning of surplus items after erection is
bidder’s responsibility.

e. The piping system shall be installed at site as per the erection drawing provided by
BHEL. After the completion of pipe installation at site, entire piping, including
instrument tapings will be cleaned and flushed with water and tested for hydrostatic
testing at 1.5 times the working pressure (as per Drawing) for 30 minutes. All pipe
joints shall be watertight. Joints that are found to leak by observation or during
testing shall be repaired and retested. Protocol for hydro-test shall be obtained from
the customer by the contractor.

2.2 ERECTION, COMMISSIONING AND TESTING OF GRP PIPES AND FITTINGS

a) Details furnished above cannot be considered as exhaustive. Contractor shall make

all efforts to carry out piping works in total as per the specific requirements of the
system and as per the good engineering practice to suit site conditions. All testing
requirements as per the relevant and applicable standards are to be ensured by the
Supplier.

b) Vendors shall submit their price offer in two categories as under.

 Part-1 Item wise price offer (unit rate) for the supply of the GRP pipes and
pipe fittings shall be quoted. Any additional item required at site shall be
supplied by the supplier at the same rate quoted.

 Part-2 Price offer for the erection/installation of the GRP pipes and pipe
fittings, pipeline accessories like valves, bellows, static mixer, etc. and
pressure testing with the following split-up price :

1). Pipe Laying, alignment, Joining & erection with under lay rubber sheet on
the pipe support saddle, fixing of stubs for instruments, vents and drains.
2). Assembly of BHEL supplied Valves, Bellows, Static Mixer, etc with
fasteners and gaskets in the GRP piping system.
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3) Conducting Hydraulic Pressure testing of entire GRP piping as per the

approved procedure.

c) The Intent of this specification is to provide erection, commissioning services for

execution of projects according to most modern and proven techniques and codes.
It is not the intent to specify completely herein, all aspects of the entire system.
Nevertheless, the entire system shall conform in all respects to high standards of
engineering, design and workmanship and shall be capable of performing in
continuous commercial operation. The contract services towards installation of the
Plant shall not relieve the contractor of the responsibility of providing such services,
facilities to complete the project of portion of project awarded to him. The quoted
rate shall deem to be inclusive of all such contingencies.

d) The Contractor shall carry out the work in accordance with instructions/ drawings/
specification/ standard practices supplied / approved by BHEL from time to time.

e) Modification / Rectification / repair / replacement of defective components if any

shall be under bidder’s scope within specified time during execution.

f) Bidder to submit the erection schedule along with stage checks list. For each and every
stage, the bidder shall get clearance from the BHEL Engineer / Customer.

g) All the supplied materials will be issued from BHEL stores and it shall be the
responsibility of the contractor for identification of the consignment and to take
delivery from BHEL stores, transport the same to site & kept in their safe custody for
erection.

h) Necessary site co-ordination and clearance for stage checks, hydraulic test, pre-
commissioning tests, leak check etc., from the customer engineer shall be carried
out by the bidder.

i) All the piping systems, fittings and accessories supplied under this package shall be
designed to operate without replacement and with normal maintenance for a plant
service life of about 25 years and shall withstand the operating parameter
fluctuations and cyclic fluctuation which can be normally expected during this
period.

j) All pipe system shall be properly designed to take care of hydraulic shocks and
pressure surges which may arise in the system during operation.

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k) Suitable slope shall be provided for all pipelines towards drain point. In addition to
the system requirement, all low points in the pipe lines shall be provided with
suitable draining arrangement and all high points shall be provided with air vent
connections where air or gas pockets may occur. Vent for use during hydrostatic test
shall be plugged after the completion of the test. Vent shall not be less than 15 mm
size.

l) Drain shall be provided at low points and at pockets in piping such that complete
drainage of all system is possible. Drain shall not be less than 15 mm for line size up
to 150 mm, not less than 20 mm up to 300 mm and not less than 25 mm for 350 mm
to 600 mm pipes and not less than 50 mm for 600 mm and above pipes.

m)All pipe work shall be designed to provide sufficient flexibility and to prevent
development of undesirable forces or moment at points of connection to
equipment.

n) Extensive use of templates, gauges, plumb lines shall be made for laying, cutting
fitting up of various piping components for fabrication.

o) On completion of both shop and field fabrication, all subassemblies shall be cleaned
for the inside and outside by suitable mechanical means ensuring that they are free
from all loose foreign materials such as scales, sand, oil grease, cutting chips etc.

p) Smooth glassy finish to be maintained for all field joints with the parent color of the
pipes and fittings.

q) All field joints shall be kept clean for detecting leaks during testing. Test pressure
shall be maintained long enough to facilitate complete inspection of system.
Minimum duration of test shall be 6 hrs unless otherwise specified. Pressurizing
equipment shall be isolated immediately after the test pressure is attained.

2.3 EXCLUSIONS

The following are excluded from the scope of supplier and will be arranged by BHEL

a. Storage of supplied items at BHEL store as of received condition

b. All civil works pertaining to GRP piping system
c. Service water at one point near RO-DM Plant
d. Free Power supply at one point near RO-DM Plant for erection.
e. Supply of service / instrument air at one point

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f. Rubber bellows, valves, Instruments, Rubber sheet (Fasteners and Gaskets) etc. for
the piping system
g. Supply and Erection of pipe supports.
The requirement shall be specified by the bidder in their technical offer and the supply shall
be limited to the specified quantities.

2.4 SPECIFICATION, STANDARDS & CODES

All pipe and pipe fittings shall be installed and tested as per the specification, relevant
national / international standards & statutory codes.

2.5 TOOLS AND TACKLES

All the Tools & tackles required for the complete erection of components shall be arranged
by the contractor at his cost. The bidder shall have & own a complete set of special tools
and tackles required erection. The bidder shall also supply any special tools and tackles that
may be required additionally during testing. All tools & tackles shall be reputed make
acceptable to the Purchaser.

2.6 FLUSHING

a. Completed piping systems shall be flushed by bidder with fresh water to clean the
pipe of all dirt, debris, and foreign material. Bidder shall prepare a procedure for
flushing of the system for approval of purchaser/consultant. Flushing shall not be
commenced without approval of flushing procedure.

b. Bidder shall perform all activities like dismantling and reinstalling of all strainers, in
line instruments etc. before and after completion of flushing.

c. Flushing shall be considered as complete only after inspection and approval by

purchaser/consultant.

d. Disposal of muck and flushing media shall be arranged by bidder as directed by

purchaser/consultant, in such a manner that it does not spoil the adjacent
installation. Bidder shall obtain purchaser consultant approval regarding the place
and method to be adopted for disposal of debris.

e. Record of flushing giving following details shall be submitted by bidder to

purchaser/consultant for its approval and record:
a. Date of flushing
b. Identification of line : flushed line number
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2.7 DISPOSAL OF SCRAPS / UNUSED ITEMS

All the pipe scraps & materials are to be removed from the working area and
transported to BHEL scrap area / as per the direction of customer. Un-used balance GRP
pipes & materials are to be handed over at BHEL stores with acknowledgement.

2.8 INSPECTION

All the stage checks shall be offered to BHEL / Customer for inspection.

2.9 HYDROSTATIC TESTING

a.Completed piping system as approved by purchaser/consultant shall be
hydrostatically tested in the presence of purchaser/consultant. The general
requirement for hydrostatic test shall be accordance with design requirement of
this specification and standard codes specified here in.

b. Bidder shall prepare hydrostatic test procedure based on specified codes. The
hydrostatic test shall commence only after approval of procedure by
purchaser/consultant.

c. Site test pressure of GRP pipes and fittings for pressure application should be 1.5 times
the working pressure as per drawing. For non-pressured line the site test pressure
shall be 1.5 bar as per BS-8010-2.5-1989. Necessary test certificate for all pipes to be
presented to BHEL for review BHEL will witness one of such tests. The duration of the
holding time will be 10 minutes for all the cases.

d. All equipment and instrument used for hydrostatic test shall be approved by
purchaser/consultant before start of test.

e. Pressure gauge shall be installed on line to measure test pressure. In case of longer
lines two are more pressure gauge shall be installed as directed by
purchaser/consultant. One gauge shall be installed at the discharge of the
pressuring pump. Pressure gauge used for hydrostatic testing shall be calibrated
with dead weight tester in the presence of engineer-in-charge. Range of pressure
gauge shall generally be 1.5 times the test pressure.

f. Orifice plates and restriction orifices shall not be installed until hydrostatic test is
completed.

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g. All equipment, lines instruments and relief valves shall be disconnected from piping
system by means of blinds during testing. Control valves shall be replaced by spool
pieces during testing, which is in the scope of vendor.

h. High point vent and low point drain required for testing in addition to those
marked in the drawings shall be provided by bidder at his own cost.

i. Vendor shall arrange Gaskets & blind/dummy flanges required for Hydro testing of
GRP Piping System.

2.10 TEST RECORDS

The records in duplicate shall be prepared and submitted by bidder as below:
a. Date of test
b. Identification of pipe tested – line number
c. Test pressure and duration of holding the pressure.
d. Initial test pressure and the final test pressure after the holding time.
e. Test result
f. Signature of bidder
g. Approval signature by purchaser/consultant / customer.

2.11 ADDITIONAL REQUIREMENTS

During execution at site, pipe routing is susceptible to change. The bidder shall carryout
these changes at site without any commercial implications to BHEL.

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2.12 GENERAL REQUIREMENTS TO THE BIDDER

a. Vendor shall post experienced site engineers with skilled/adequate man power for
execution of piping system. Vendor shall prepare a schedule for completion of the
work before the commencement of work.

b. Bidder shall quote for complete work specified in the document. Incomplete
quotations for the part of the work will not be considered even if the quoted
rates/price is lower.

c. Bidder shall contact BHEL and obtain additional details/data if any required to
submit proper quotation.

d. The BHEL reserves the right to omit any one or more items of work at any time of the
contact without assigning any reason what so ever.

e. Adequate lighting facilities such as low volt hand lamps shall be arranged by the
contractor at the site of construction etc. at his cost.

f. All the lifting tackles including wire ropes, slings, shackles and electrically operated
equipment shall be got approved by BHEL Engineer before they are actually put on
use. Test certificates should be submitted before their usage. Test certificate
obtained from the statutory authority should be submitted before their usage.

g. All equipment so used by contractor shall be of proven quality and safe in operation
as approved by BHEL site Engineers from time to time.

h. At periodic / intervals of work, complete and detailed account of the equipment so

erected shall be submitted to the BHEL Engineer.

i. All equipment shall be handled very carefully to prevent any damage and loss. No
bare wire ropes, slings etc.., shall be used for unloading and / or handling for
equipment without the specific written permission of the engineer. The equipment
from the storage yard shall be moved to the actual site of erection / location at the
appropriate time as per the direction of BHEL Engineer so as to avoid damage for
such equipment at site.

j. The work covered under this scope of work is of highly sophisticated nature
requiring best quality / precision workmanship engineering and construction
management. He should also ensure successful and timely commercial operation of

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equipment installed. The contractor must have adequate quantity of precision tools,
construction aids in possession. Contractor must also have adequate trained
qualified and experienced supervisory staff and skilled personnel.

k. All the necessary certificates and licenses required to carry out his scope of work are
to be arranged by the contractor then and there at no extra cost.

l. When the work is temporarily suspended he shall protect all construction materials
equipment and facilities from causing damage to existing property interfering with
the operations of the station when it goes into services. The contractor shall comply
with all applicable provisions of the safety regulations clean – up programme and
other precautionary measures which the BHEL has in effect at the site .

m. It will be the responsibility of the contractor to ensure the safe lifting of the piping
system taking due precautions to avoid any accidents and damage to other piping
system and personnel.

n. All piping shall be adequately supported and protected to prevent damage during
handling and erection.

o. Sometimes it may become necessary for the contractor to handle certain un-
required components in order to install the required materials. The contractor has to
take this contingency also into account. No extra payment is payable for such
contingencies.

p. Due to atmospheric conditions erected support materials are likely to get rusted
more frequently .It is the responsibility of the contractor to preserve the erection
materials drawn from stores for erection till these are commissioned and handed
over to customer. The required paint, thinner all other consumables like painting
brush, emery paper, cotton waste, cloth etc.., have to be arranged by the contractor
at his cost. The contractor should ensure that the materials are not rusted on any
account till they are handed over to customer. The decision of the BHEL Engineer is
final with regard to frequency of application of paint.

q. Final Material accounting shall be provided by vendor for final payment.

2.13 SITE CLEANLINESS AND SAFETY REQUIRMENTS

a. Contractor shall strictly follow all safety regulations / conditions as per general
conditions of contract booklet enclosed with this tender.

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b. Non – conformity of safety rules and safety appliances will be viewed seriously.

c. Contractors shall ensure that the quality is maintained in all the works connected with
this contract at all stages of the requirement of BHEL.

d. Contractor shall ensure that all Inspection, Measuring and Testing equipment that are
used, whether owned by the contractor or used on loan, are calibrated by the
authorized agencies and the valid calibration certificate will be available with them
for verification by BHEL. A list of such instruments possessed by contractor at site
with its calibration status is to be submitted to BHEL Engineer for control.

e. Contractors shall arrange for the inspection of the works at various stages as required
by BHEL. Immediate corrective action shall be taken by the contractor for the non-
conformances if any, observed and pointed out by BHEL.

2.14 OTHER STATUATORY REQUIREMENTS

a. The contractor shall submit a copy of labour license obtained from the licensing
Officer (Form VI) u/r 25 read with u/s 12 of contract labour ( R&A) Act 1970 & rules
and valid WC Insurance copy or ESI Code ( if applicable) and PF code no along with
the first running bill.

b. The contractor shall submit monthly running bills along with the copies of monthly
wages (of the preceding month) u/r 78 (1) (a) (1) of contract labour rules, copies of
monthly return of PF contribution with remittance challans under EPF Act 1952 and
copy of renewed WC insurance policy or copies of monthly return of ESI contribution
with challans under ESI Act 1948 (if applicable) in respect of the workmen engaged
by them.

c. The contractor should ensure compliance of Sec 21 of Contract Labour (R&A) act
1970 regarding responsibility of payment of wages. In case of “Non-compliance of
sec 21 or non-payment of wages” to the workmen before the expiry of wage period
by the contractor, BHEL will reserve its right to pay the workmen under the orders of
appropriate authority at the risk and cost of the contractor.

2.15 TIME OF COMPLETION

a. The time period for completion of GRP Piping System Installation & Testing shall be
within 4 months from Purchase Order delivery date / site readiness date whichever
is later. Site readiness will be informed by BHEL.

Page 18 of 22
 GENERAL SPECIFICATION FOR SPEC.NO.ROS:6204
GRP PIPING SYSTEM REV: 00

b. The entire work shall be completed by the contractor within the time schedule or
within the such extended time as may be allowed under relevant clause.

2.16 ENGAGEMENT OF LABOUR

a. The contractor will be directly responsible for provision of health and sanitary
arrangements more particularly described in contract labour (regulations &
Abolition) Act, safety precautions etc., as may be required for safe and satisfactory
execution of the contract.

b. The contractor shall be responsible for proper accommodation including adequate

medical facilities & transportation to the work spot and back for the personnel
employed by him.

2.17 COMPLIANCES WITH LABOUR LAWS & RULES

The contractor shall comply with all state and central Laws, statutory rules,
regulation etc.., relating to labour in respect of following acts and also as
amended by the Government during the tenure of the contract and having in
force or jurisdiction at site. Dimensions

a. Payment of wages act, 1936

b. Minimum wages act, 1948
c. Workmen’s Compensation act, 1923
d. Industrial dispute act, 1947
e. Employees Provident fund scheme, 1952
f. Payment of Bonus act, 1965
g. Payment of Gratuity act, 1972
h. Contract Labour ( Regulation & Abolition) Act, 1970

Page 19 of 22
 GENERAL SPECIFICATION FOR SPEC.NO.ROS:6204
GRP PIPING SYSTEM REV: 00

Annexure-A

DATA SHEET FOR GRP PIPE AND FITTINGS

Vendor to
S.NO Description BHEL’s Requirement
Specify
AWWA C950, AWWA M-45,
1 Design code ASTM D 2996, ASTM D 3567,
BS 5480, IS12709
2 Interior layer resin Vinylester
3 Interior layer glass C-glass fibre
4 Interior layer resin thickness mm 2.0 (minimum)
5 Interior layer surface ratio (Mat: Resin) 10:90
6 structural layer glass E-glass fibre
7 structural layer ratio (Glass: Resin) 60:40
8 Exterior layer resin Isophthalic resin
9 Exterior surface ratio (Mat: Resin) 30:70
10 Exterior surface UV stabilized resin
11 Winding method Filament wound (Helical)
12 Winding angle 54.7°
Pigment, Dyes, Colouring
13 Additives
Agent
14 Stiffness N/m2 2500 (minimum)
15 Pipe thickness Vendor to provide calculation
16 Design pressure bar 10
17 Hoop tensile modulus Mpa 22000
18 Axial tensile stress Mpa 45
19 Axial tensile modulus Mpa 8000
20 Hoop bending modulus Mpa 22500
21 Coefficient of linear expansion m/m°C 18x10-6 mm/nm/oc
22 Barcol hardness Vendor to specify
23 Hazen-William coefficient (C value) 150
FITTINGS
24 Bend design Swept
25 Flange drilling standard ANSI B16.5#150 ***
26 Flange Thickness ASTM D 5421

Page 20 of 22
 GENERAL SPECIFICATION FOR SPEC.NO.ROS:6204
GRP PIPING SYSTEM REV: 00

Annexure-B

TECHNICAL DEVIATIONS

SEC/CLAUSE Statement of Reason for Cost of

SL.NO Specification
NO deviation/variations deviation withdrawal

Date: Signature & Seal of the Bidder

Page 21 of 22
 GENERAL SPECIFICATION FOR SPEC.NO.ROS:6204
GRP PIPING SYSTEM REV: 00

Annexure-C
List of BHEL supplied components to be assembled in the pipeline
Approx. Approx.
Sl.
Item Description Size Unit Qty# Unit Wt Total Wt
No
(kg) (kg)
Valves
1. Butterfly Valve (Pneumatic) DN50 Set 1 2 2
2. Butterfly Valve (Pneumatic) DN65 Set 3 3 9
3. Butterfly Valve (Manual) DN80 Set 2 5 10
4. Butterfly Valve (Manual) DN100 Set 33 5 165
5. Butterfly Valve (Pneumatic/Manual) DN150 Set 49 8 392
6. Butterfly Valve (Pneumatic/Manual) DN200 Set 106 13 1368
7. Butterfly Valve ( Manual) DN250 Set 6 25 150
8. Butterfly Valve (Pneumatic/Manual) DN 300 Set 35 50 1750
9. Butterfly Valve (Pneumatic/Manual) DN 350 Set 9 60 630
10. Butterfly Valve (Manual) DN400 Set 2 150 300
11. Butterfly Valve (Manual) DN450 Set 11 200 2200
12. Butterfly Valve (Manual) DN600 Set 3 600 1800
13. Wafer Check Valve AR* Set 44 6 264
Approx. Sub-Total Weight (kg) 9040
Bellows
1 DN 450 No 12 6.5 78
2 DN 400 No 6 6 36
3 DN 350 No 6 5.5 33
4 DN 300 No 14 5 70
Rubber expansion bellows
5 DN 250 No 6 4.5 27
6 DN 200 No 15 4 60
7 DN 150 No 14 3 42
8 DN 100 No 4 3 12
Approx. Sub-Total Weight (kg) 358
Other items
1 Fasteners - Lot 1 - 2000
2 Gaskets & rubber sheets - Lot 1 - 150
Approx. Sub-Total Weight (kg) 2150
Note: -
* AR means As Required.
# Qty variation shall be +/- 5% or minimum 1 No; whichever is large.

Page 22 of 22
 }MEL: SAP: RAIVIR 7' Re f: "WW1 i 7: GRP.
''-*(7V-It7M- 'l Water Business Dit 19 ,C + s
Li II P - ualifica ion requirement (PQR) — '771371 I''' , s 85 Rev. : Co
Fittings

The Qualification requirements for GRP Pipes & Fittings are detailed below and Bidders
should meet the same. Offers of bidders who do not meet qualification requirement will not be
considered for evaluation.

1. Bidder should have designed, manufactured, supplied, erected & successfully hydro-
tested the GRP Pipes & Fittings at site either directly or through authorized agency at
least in two different water treatment plants for power plant / industrial / municipal
application.

2. The reference piping systems shall be a combination of pipes, fittings (Flanges, Elbows,
Equal Tee, Unequal Tee etc.) of size not less than DN100 of pressure rating not less than
the PN 6. The referred piping system shall be for frontal piping in a process plant for
filtration system (viz. Media filter system, Micro filtration system, Ultra Filtration System,
Nano filtration system) / Demineralization system.

3. Bidder should submit the details of the reference plants. Laying of GRP Pipes in straight
length (Running meters) will not be considered as a reference plant for meeting the PQR
requirements.

4. The installed pipe & fittings should have been in successful operation for not less than
one year as on date of techno commercial bid opening.

5. The bidder shall submit performance certificates obtained from two different end users.
The performance certificate shall indicate scope of work, type of water treatment plant,
pipe line size range, ratings, commissioning date as minimum.

6. Bidder shall furnish necessary documentary evidence in original /notarized (legible) copy
as a proof of meeting the qualifying criteria for the review by BHEL. Acceptance of
documentary evidence rests with BHEL

General Conditions:

1. Bidders who defaulted, in any of the previous tenders floated by BHEL are not
permitted to respond. Such offers, if found later, will not be considered for evaluation.

2. After receipt of offers, during scrutiny, if any vendor found to have been banned by BHEL,
then their offer will be summarily rejected at any stage.

3. Bidder to make provision in case BHEL decides to visit the reference plant furnished by
the bidder for meeting the PQR requirements.

Prepared
inka by hecke L. by Approved by

,\LT\YEK) (V\ N )
\CL Uk eeNak-C4):A4-4„
 BHEL: BAP: RAMPET Ref'RWT1706 I 7:GRPPQ
Vi-vvitim-' Water Business Dt: 19.04.18

O H Pre-Qualification requirement (PQR) for GRP Pipes &

Fittings

Reference plant-1 Reference plant-2

A. Customer details: -
a. Name
b. Designation
c. Mobile
d. Land line
e. Fax
f. Email id
g. Address

B. Reference Plant Details:-

SI. Reference Plant Reference Plant

Parameters
No. #1 #2

01 Certificate Reference & Date

02 MOC of Pipes & Fittings

a) - Pipe ( Minimum & Maximum Size)

b) - Elbow ( Minimum & Maximum Size)

c) - TEE ( Minimum & Maximum Size)

d) - Flange (Minimum & Maximum Size)

e) - Any other Fittings

03 Applicable Design Standards

04 Design Pressure Rating (min.)

05 Resin Utilized

a) Vinyl Ester

b) Isothalic

c) Combination of Vinyl Ester + lsopthalic

d) Inner Protection Layer

Prepared by Checked by Approved by

..-
' 5,.,v94-) V-V"--\0•AO )
k. * IVIee.0--v•aNtW C-.).Y4,k
 SI' il . BA -. RANIP Rsc f: RIM•T706 I 7:GRP s
-
I Vvv rw Water Business nt: is 04. IS

HO P. ..'a iort requirement (PQR) for G

Fittings
Pi - s 6‘, Rev : 00

SI. Reference Plant Reference Plant

Parameters
No. #1 #2

e) Outer UV Protection Layer

06 Layer content:

a) Interior layer surface ratio (lass: Resin)

b) Structural layer ratio (Mat: Resin)

c) Exterior surface ratio (Mat: Resin)

07 Testing Pressure

08 Testing Standard

09 End use

10 Reference System P&ID , Drawings

11 Applicable site photographs

12 Date of supply

13 Date of commissioning

Prepar \a by Checked b ,EV)1, ovec, by

kid
„------
.\ \_V
NI I )
CS' \a-Q1:1'/ k MeJOILk' -Cu4.44` - it' (N) 'N

Slh 3 3
 PROJECT
2 X 660MW ENNORE SEZ SUPERCRITICAL TPP

CAUTION: THE INFORMATION ON THIS DOCUMENT IS THE

WAY DETRIMENTAL TO THE INTEREST OF THE COMPANY

PROPERTY OF BHARAT HEAVY ELECTRICALS LIMITED. IT
MUST NOT BE USED DIRECTLY OR INDIRECTLY IN ANY
AT ASH DYKE OF NCTPS, CHENNAI
PACKAGE : RO-DM

EPC BHARAT HEAVY ELECTRICALS LIMITED, NEW DELHI

CONTRACTOR
PACKAGE : RO-DM
UNIT : BOILER AUXILARIES PLANT ; RANIPET

TITLE NAME SIGN. DATE

REV DATE ALTD: CHD: APPD:

DRAWN B B SAHU Sd /- 05.02.18
ZONE
CHECKED G RAJENDIRAN Sd /- 05.02.18

APPROVED M NATARAJAN Sd /- 05.02.18

ALL DIMENSIONS ARE IN MILLIMETRES BHEL DRAWING NO. REV

PROJECTION SCALE
N.T.S SH. 01 OF 10
 PROJECT
2 X 660MW ENNORE SEZ SUPERCRITICAL TPP

CAUTION: THE INFORMATION ON THIS DOCUMENT IS THE

WAY DETRIMENTAL TO THE INTEREST OF THE COMPANY

PROPERTY OF BHARAT HEAVY ELECTRICALS LIMITED. IT
MUST NOT BE USED DIRECTLY OR INDIRECTLY IN ANY
AT ASH DYKE OF NCTPS, CHENNAI
PACKAGE : RO-DM

EPC BHARAT HEAVY ELECTRICALS LIMITED, NEW DELHI

CONTRACTOR
PACKAGE : RO-DM
UNIT : BOILER AUXILARIES PLANT ; RANIPET

TITLE NAME SIGN. DATE

REV DATE ALTD: CHD: APPD:

DRAWN B B SAHU Sd /- 05.02.18
ZONE
CHECKED G RAJENDIRAN Sd /- 05.02.18
APPROVED M NATARAJAN Sd /- 05.02.18
ALL DIMENSIONS ARE IN MILLIMETRES BHEL DRAWING NO. REV

PROJECTION SCALE
N.T.S SH. 02 OF 10
 PROJECT
2 X 660MW ENNORE SEZ SUPERCRITICAL TPP

CAUTION: THE INFORMATION ON THIS DOCUMENT IS THE

WAY DETRIMENTAL TO THE INTEREST OF THE COMPANY

PROPERTY OF BHARAT HEAVY ELECTRICALS LIMITED. IT
MUST NOT BE USED DIRECTLY OR INDIRECTLY IN ANY
AT ASH DYKE OF NCTPS, CHENNAI
PACKAGE : RO-DM

EPC BHARAT HEAVY ELECTRICALS LIMITED, NEW DELHI

CONTRACTOR
PACKAGE : RO-DM
UNIT : BOILER AUXILARIES PLANT ; RANIPET

TITLE NAME SIGN. DATE

REV DATE ALTD: CHD: APPD:

DRAWN B B SAHU Sd /- 05.02.18
ZONE
CHECKED G RAJENDIRAN Sd /- 05.02.18

APPROVED M NATARAJAN Sd /- 05.02.18

ALL DIMENSIONS ARE IN MILLIMETRES BHEL DRAWING NO. REV

PROJECTION SCALE
N.T.S SH. 03 OF 10
 PROJECT
2 X 660MW ENNORE SEZ SUPERCRITICAL TPP

CAUTION: THE INFORMATION ON THIS DOCUMENT IS THE

WAY DETRIMENTAL TO THE INTEREST OF THE COMPANY

PROPERTY OF BHARAT HEAVY ELECTRICALS LIMITED. IT
MUST NOT BE USED DIRECTLY OR INDIRECTLY IN ANY
AT ASH DYKE OF NCTPS, CHENNAI
PACKAGE : RO-DM

EPC BHARAT HEAVY ELECTRICALS LIMITED, NEW DELHI

CONTRACTOR
PACKAGE : RO-DM
UNIT : BOILER AUXILARIES PLANT ; RANIPET

TITLE NAME SIGN. DATE

REV DATE ALTD: CHD: APPD:

DRAWN B B SAHU Sd /- 05.02.18
ZONE
CHECKED G RAJENDIRAN Sd /- 05.02.18
APPROVED M NATARAJAN Sd /- 05.02.18

ALL DIMENSIONS ARE IN MILLIMETRES BHEL DRAWING NO. REV

PROJECTION SCALE
N.T.S SH. 04 OF 10
 PROJECT
2 X 660MW ENNORE SEZ SUPERCRITICAL TPP

CAUTION: THE INFORMATION ON THIS DOCUMENT IS THE

WAY DETRIMENTAL TO THE INTEREST OF THE COMPANY

PROPERTY OF BHARAT HEAVY ELECTRICALS LIMITED. IT
MUST NOT BE USED DIRECTLY OR INDIRECTLY IN ANY
AT ASH DYKE OF NCTPS, CHENNAI
PACKAGE : RO-DM

EPC BHARAT HEAVY ELECTRICALS LIMITED, NEW DELHI

CONTRACTOR
PACKAGE : RO-DM
UNIT : BOILER AUXILARIES PLANT ; RANIPET

TITLE NAME SIGN. DATE

REV DATE ALTD: CHD: APPD:

DRAWN B B SAHU Sd /- 05.02.18
ZONE
CHECKED G RAJENDIRAN Sd /- 05.02.18

APPROVED M NATARAJAN Sd /- 05.02.18

ALL DIMENSIONS ARE IN MILLIMETRES BHEL DRAWING NO. REV

PROJECTION SCALE
N.T.S SH. 04 OF 10
 PROJECT
2 X 660MW ENNORE SEZ SUPERCRITICAL TPP

CAUTION: THE INFORMATION ON THIS DOCUMENT IS THE

WAY DETRIMENTAL TO THE INTEREST OF THE COMPANY

PROPERTY OF BHARAT HEAVY ELECTRICALS LIMITED. IT
MUST NOT BE USED DIRECTLY OR INDIRECTLY IN ANY
AT ASH DYKE OF NCTPS, CHENNAI
PACKAGE : RO-DM

EPC BHARAT HEAVY ELECTRICALS LIMITED, NEW DELHI

CONTRACTOR
PACKAGE : RO-DM
UNIT : BOILER AUXILARIES PLANT ; RANIPET

TITLE NAME SIGN. DATE

REV DATE ALTD: CHD: APPD:

DRAWN B B SAHU Sd /- 05.02.18
ZONE
CHECKED G RAJENDIRAN Sd /- 05.02.18
APPROVED M NATARAJAN Sd /- 05.02.18
ALL DIMENSIONS ARE IN MILLIMETRES BHEL DRAWING NO. REV

PROJECTION SCALE
N.T.S SH. 06 OF 10
1-WT-240-01282

PROJECT
2 X 660MW ENNORE SEZ SUPERCRITICAL TPP

CAUTION: THE INFORMATION ON THIS DOCUMENT IS THE

WAY DETRIMENTAL TO THE INTEREST OF THE COMPANY

PROPERTY OF BHARAT HEAVY ELECTRICALS LIMITED. IT
MUST NOT BE USED DIRECTLY OR INDIRECTLY IN ANY
AT ASH DYKE OF NCTPS, CHENNAI
PACKAGE : RO-DM

EPC BHARAT HEAVY ELECTRICALS LIMITED, NEW DELHI

CONTRACTOR
PACKAGE : RO-DM
UNIT : BOILER AUXILARIES PLANT ; RANIPET

TITLE NAME SIGN. DATE

REV DATE
DRAWN B B SAHU Sd /- 05.02.18
ALTD: CHD: APPD:
ZONE CHECKED G RAJENDIRAN Sd /- 05.02.18

APPROVED M NATARAJAN Sd /- 05.02.18

ALL DIMENSIONS ARE IN MILLIMETRES BHEL DRAWING NO. REV

PROJECTION SCALE
N.T.S SH. 07 OF 10
 PROJECT
2 X 660MW ENNORE SEZ SUPERCRITICAL TPP

CAUTION: THE INFORMATION ON THIS DOCUMENT IS THE

WAY DETRIMENTAL TO THE INTEREST OF THE COMPANY

PROPERTY OF BHARAT HEAVY ELECTRICALS LIMITED. IT
MUST NOT BE USED DIRECTLY OR INDIRECTLY IN ANY
AT ASH DYKE OF NCTPS, CHENNAI
PACKAGE : RO-DM

EPC BHARAT HEAVY ELECTRICALS LIMITED, NEW DELHI

CONTRACTOR
PACKAGE : RO-DM
UNIT : BOILER AUXILARIES PLANT ; RANIPET

TITLE NAME SIGN. DATE

REV DATE ALTD: CHD: APPD:

DRAWN B B SAHU Sd /- 05.02.18
ZONE
CHECKED G RAJENDIRAN Sd /- 05.02.18

APPROVED M NATARAJAN Sd /- 05.02.18

ALL DIMENSIONS ARE IN MILLIMETRES BHEL DRAWING NO. REV

PROJECTION SCALE
N.T.S SH. 08 OF 10
 PROJECT
2 X 660MW ENNORE SEZ SUPERCRITICAL TPP

CAUTION: THE INFORMATION ON THIS DOCUMENT IS THE

WAY DETRIMENTAL TO THE INTEREST OF THE COMPANY

PROPERTY OF BHARAT HEAVY ELECTRICALS LIMITED. IT
MUST NOT BE USED DIRECTLY OR INDIRECTLY IN ANY
AT ASH DYKE OF NCTPS, CHENNAI
PACKAGE : RO-DM

EPC BHARAT HEAVY ELECTRICALS LIMITED, NEW DELHI

CONTRACTOR
PACKAGE : RO-DM
UNIT : BOILER AUXILARIES PLANT ; RANIPET

TITLE NAME SIGN. DATE

REV DATE ALTD: CHD: APPD:

DRAWN B B SAHU Sd /- 05.02.18
ZONE 05.02.18
CHECKED G RAJENDIRAN Sd /-

APPROVED M NATARAJAN Sd /-
05.02.18
ALL DIMENSIONS ARE IN MILLIMETRES BHEL DRAWING NO. REV

PROJECTION SCALE
N.T.S SH. 09 OF 10
 PROJECT
2 X 660MW ENNORE SEZ SUPERCRITICAL TPP

CAUTION: THE INFORMATION ON THIS DOCUMENT IS THE

WAY DETRIMENTAL TO THE INTEREST OF THE COMPANY

PROPERTY OF BHARAT HEAVY ELECTRICALS LIMITED. IT
MUST NOT BE USED DIRECTLY OR INDIRECTLY IN ANY
AT ASH DYKE OF NCTPS, CHENNAI
PACKAGE : RO-DM

EPC BHARAT HEAVY ELECTRICALS LIMITED, NEW DELHI

CONTRACTOR
PACKAGE : RO-DM
UNIT : BOILER AUXILARIES PLANT ; RANIPET

TITLE NAME SIGN. DATE

REV DATE ALTD: CHD: APPD:

DRAWN B B SAHU Sd /- 05.02.18
ZONE
CHECKED G RAJENDIRAN Sd /- 05.02.18

APPROVED M NATARAJAN Sd /- 05.02.18

ALL DIMENSIONS ARE IN MILLIMETRES BHEL DRAWING NO. REV

PROJECTION SCALE
N.T.S SH. 10 OF 10
 2-WT-240-00277

FIXED FLANGE
FLANGE DRILLING AS PER ANSI 16.5 B # CL 150 ONLY UPTO DN600
AND AS PER AWWA C207 ABOVE DN600

EQUAL TEE UNEQUAL TEE

PIPE

ID-B
ID-A

L1 L3 L2

CONCENTRIC REDUCER

FLANGED CONC. REDUCER

ECCENTRIC REDUCER FLANGED ECC. REDUCER

BLIND FLANGE
GRP PIPE AND FITTINGS
FLANGE DRILLING AS PER ANSI 16.5 B # CL 150 ONLY UPTO DN600
AND AS PER AWWA C207 ABOVE DN600 DETAILS 2-WT-240-00277