TRAINING MANUALS- DOC No.

: 29040-IC-UFR-0015
INSTRUMENTS
Rev. : R0

Uhde India Limited PREPARATION OF INSTALLATION Page :1

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CONTENTS

Pages

0.0 Cover sheet: 1

1.0 Introduction 2-3
2.0 Preparation Of Installation Tender Document(Part I) 3
3.0 Preparation Of Installation Tender Document(Part II) 3-7
4.0 Preparation Of Installation Tender Document(Part III) 7-8

Annexure: Slides 5 Sheets

Applicable Revision:
Prepared: Checked: Approved:

Date: Date: Date:

First Edition: R0
Prepared: Checked: Approved:

A.K.SARKAR M.B.JOSHI N.C.JAIN

Date:24/07/2000 Date: Date:

File Name: 594534971.doc594534971.doc Server: KUMUS 206

Directory: /conversion/tmp/activity_task_scratch/594534971.doc
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1.0 INTRODUCTION :

Installation tender document is prepared in every project to float the enquiry and enable
the short-listed instrument installation contractors to give a quote. The installation tender
document also defines the exact scope of supply, work method to be adhered to by the
contractor, and the contractor’s responsibilities.

1.1 Contents of the Installation Tender:

This document is divided in 3 parts i.e. Part –I , II and Part III.

1.2 Part –I: Defines the general requirements of the Contractor’s obligations as listed below:

Part-I gives detailed instruction for each activity included in scope of work of contractor
e.g. installation of instruments (Part-I instructs that instrument shall be installed as per
hook-up drawing, they shall be adequately protected from water by covering with plastic
bags, they shall be mounted such that they do not obstruct walkway , etc.) instrument
impulse tubing and piping , etc. It may be noted that these instructions are not likely to
change from project to project and hence we have to make only few changes (e.g.
General project information) while customising Part-I for sending enquiry for erection
tender. Various topics covered under Part-I are as follows:

a. Site management
b. Workmanship and Tidiness
c. Safety requirements
d. Scope of work and responsibility
e. Other responsibilities
f. Structural fabrication , installation and painting
g. Installation of Instruments
h. Panel and Back of panel instruments
i. Control panels , distribution boards and cabinets
j. Junction boxes and distribution air manifolds
k. Cable laying and termination.
l. Cable in trays / ducts and angles
m. Cables in conduits
n. Cable laid beneath false flooring and trenches in control room
o. Cables laid in trenches / underground cables
p. Cable Termination
q. Instrument impulse tubing and piping
r. Pneumatic supply and signal lines
s. Calibration of instruments
t. Hydro testing , leak checking and flushing
u. Loop checking
v. Loop and logic checking between PLC , control room instruments /MCC , HT
switchgear, local panels etc.
w. As built drawings
x. Final handing over of the installation
y. Material Reconciliation
z. Billing Procedure
aa. Progress reports / manpower charts
bb. Technical documents/ Drawings available

1.3 Part-II This part defines the project specific requirements of the scope of supply and
installation requirements and contractor’s responsibilities.

a. Site conditions
b. Scope of work
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c. Scope of supply
d. Quantity variation
e. Inclusions to be considered in unit rates
f. Claims for extra work
g. Material cutting allowance and wastage/scrap.
h. Off loading of work
i. Information required with Bid
j. Special requirements

1.4 Part- III : Defines the schedule of quantities item wise in the following order.

a. Supply items – Items included in contractor’s scope of supply and installation

b. Supply items - Items included in contractor’s scope of supply for which no
separate installation rates are applicable.
c. Free issue items – Items procured separately and issued to the contractor only for
installation purpose.
d. Free issue items for which installation and calibration is in contractor’s scope.
e. Free issue items installed by other contractors where supervision/ checking and
calibration is in the contractor’s scope.
f. Free issue items installed by other contractors where supervision/ checking is in
the contractor’s scope.

For details of content of part I,II,III the relevant spec. no. IC-USP-0100 shall be referred.

2.0 Preparation of Installation tender document(Part-I):

The part – I of the installation tender generally does not undergo any change, except for
the General project information to be filled in relevant to the particular project.

3.0 Preparation of Installation tender document(Part-II):

The Part –II of the installation tender is where the actual project related requirement shall
be filled in as follows:

3.1 Site conditions: For this part environment related data shall be taken from design basis
/ Inst. GES including hazardous area classification.

Project Schedule: In this part data related to the time schedule like start date , duration
of erection , grace period , plant start-up and commissioning duration shall be filled in.
This data shall match with the planning schedule for the project. It would helpful to
understand following terms while preparing clause on project schedule in Instrument
installation tender.

Over Stay Compensation

The contractor quotes his prices based on erection period mentioned in our tender. If the
job delays more than expected then contractor has to spend more money on maintaining
his establishment at site. Vendors would normally quote overstay compensation, which
takes care of expenses on maintaining the establishment at site. Over stay compensation
is chargeable after erection period as mentioned in specification is elapsed.

Grace Period

We want to bind contractor to complete the job in stipulated time so that mechanical
completion is achieved within schedule. However, sometimes instrument contractor
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cannot complete the job in stipulated erection period because fronts are not made
available. In such cases, we will have to pay overstay compensation. We normally specify
grace period in specification during which overstay compensation is not applicable even
after erection period as mentioned in specification has elapsed

3.2 Scope of work: In this part the actual work activity expected to be performed by the
installation and erection contractor shall be indicated.

1 Fabrication: The scope of work for the contractor generally includes

– Fabrication of tray / tray supports, supports for JBs, field instruments, air
manifolds, base frames for main control panel / local panels / marshalling cabinets /
racks in control room
– Fabrication of supports for cables, impulse lines, pneumatic lines
– Fabrication of canopies for JBs, instrument protection boxes
– Fabrication of any other supports as required.

2 Calibration / Checking: Bench calibration of all instruments, providing assistance to

vendor representatives of special instruments such as analysers, Chromatographs etc
shall be included as required.

Functional tests for operation, settings, etc. for solenoid valves, limit switches, float /
displacer type level switches, pneumatic time delay relay etc shall be included as
required.

Where the NIT specifically requires a particular calibration and testing of an instrument ,
the same shall be indicated clearly.

3 Installation: This indicates the specific installation activities to be performed by the

contractor including any special installation requirements if any. It includes the following

– Installation of all fabricated items by the contractor shall be included.

– Installation of all free issue items like ladder trays, GI perforated trays etc.,
– Installation of analyser shelters, panels, consoles, and panel instruments, impulse
tubing, Air headers, conduits, solenoid valves, limit switches, air filter regulators, and
associated tubing on control valves if not already mounted
– Carrying out minor civil works such as chipping, grouting, anchoring, making wall
openings etc.

All installations / supports shall be properly finished with sealing of openings, dressing of
cables on trays, clamping, and termination and painting wherever applicable.

4 Inspection, Testing, Loop checking:

Apart from the standard inspection and testing and loop checking requirements mentioned
in the spec. any site inspection and testing of installation and calibration by third party
should be clearly indicated. For e.g. weighing system installation and calibration
witnessed by representative from weights and measures shall be included if applicable.

5 Painting specification:

Although standard, special attention shall be paid to the type of surface preparation and
the paint finish requirement. Also it is to be ensured that the installation tender includes
the restrictions on sand blasting inside client’s premises as in some plants it may not be
allowed. In such cases the contractor shall get all the items sandblasted outside and then
bring them inside the plant.
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The material specification shall be indicated for consumables shall be such as cable
clamps / GI strips for cables, supply and signal tubing, and fasteners, identification metal
tags, cable lugs, ferrules for tubes.

3.3 Scope of supply:

This section indicates the scope of supply for the project and shall include

– Supply of erection and installation material as per section 1.0 of part III.

– Supply of all consumables, fasteners, and clamping materials, as required.

– Supply of standard calibration instruments with validity certificate during

installation and commissioning as per list attached under section 5.2.1 of spec.

– Supply of all tools and tackles as required

– and supply of unskilled, skilled, and supervisory staff on man-day basis for
commissioning assistance.

3.4 Quantity variation:

Quantity variation for the following items shall be considered by the contractor in the unit
rates quoted.

Variation in unit rates: Indicate the allowable variation of +/- “ “ % ( 30%) of contract
value unit rates to remain firm.

Electric supply availability: Indicate the power supply voltage and availability and tariff
chargeable if applicable. Even if the power is available it is the responsibility of the
contractor to provide power distribution boards with isolation and protection devices.

Water Supply : Indicate availability of water and Tariff chargeable if applicable.

3.5 Inclusion of items to be considered in unit rates:

This clause defines activities which shall be included in unit rates quoted by vendor for a
particular item. Thus for example rates for laying of pneumatic tube shall include charges
for dressing & clamping, leak testing , tagging & flushing of tube and no extra money can
be claimed against these activities. It would be worthwhile to go through list of items
mentioned in tender so that the concept of billing as specified in tender is clear. Following
is the related except from tender document.

Activities involving checking adjustments , trails, solenoid operation , checking of lamps , ,

mimics pushbuttons etc are included in the unit rates for loop checking.

All consumables to be supplied by the contractor are included in unit rates. No separate
unit rate shall be considered. Where consumables are issued as free issue items shall
be highlighted in specification. Contractor shall estimate the consumables when there is
mention of free issue of consumables and build the same in the unit rates.
Unit rates quoted for supply of materials shall include all taxes and levies , packing and
forwarding and transport charges , handling charges of the contractor etc. In case the
contractor is required to supply additional material not listed in Part –III schedule of
quantities, the same shall be supplied by the contractor at actual cost +/- 10 % handling
charges on production of bills.
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For structural steel unit rates includes fabrication, installation, welding, supporting and
painting. etc.

In case of free issue of steel material the unit rate shall include only for installation,
supporting and painting only.

Items like fasteners, bolts, nuts washers’ etc are built into the unit rates. For site
fabricated items such as canopies for Instruments, JBs, local panels, the unit rate for
fabrication and installation shall be quoted on per sq. M based on 16 SWG MS plate and
include painting, and fasteners.

Unit rates for cable laying shall include laying of cable s in trays / ducts / conduits / angles
/ , dressing , clamping , tagging , glanding , termination with lugs , ferruling ,ferruling , tag
plates, built into the unit rates. For cables in conduits, sealing of conduit ends, or
intermediate joints etc including the supply of sealant is built into unit rates.

Unit rates for cable conduit laying, intermediate fittings, pull boxes, making necessary
threads / die taps, termination, sealing including supply of sealing compounds, clamping
and supporting accessories, packing material to avoid galvanic corrosion shall be built into
the unit rates.

Unit rates for air supply / signal tubing laying, including valves and fittings, supports,
fasteners, colour coding, packing material etc dressing, clamping, tagging, termination,
leak testing, and flushing shall be built into unit rates.

Unit rates for Field instruments like pressure and DP transmitters, switches, shall include
3 valve manifolds, seal pots, siphons, gauge savers, and mounting brackets where
applicable.

Unit rates for installation RTD /TCs shall include checking of sensor short ckt. / open ckt. ,
insulation failure prior to installation. No other checking activity related to RTD /TC is
envisaged.

For instrument with capillaries , laying , dressing , clamping , supporting of capillaries

including supply of supports / clamps shall be built in to the unit rates.

Unit rates for installation of analysers shall include associated sampling system, including
the interconnection between the analyser and the sampling system. Mounting of
components of the sampling system on board, completely tubed and wired by analyser
vendor.

Unit rates for panel mounted instruments shall include mounting of clamps , bins , ,
termination , tubing , wiring , ferruling , tagging , dressing of wires , clamping of wires ,
flushing , of tubing if any . For alarm annunciators checking is included in loop
checking .Hence no separate unit rate shall be considered.

Unit rates for installation of following items include fasteners as required.

a. Junction boxes , Air headers , PDBs, Local panels , MAIN CONTROL PANELS , Auto /
manual station s, Pressure , DP and temperature gauges , , gauges with capillaries ,
Remote mounted transmitters , converters , turbine meters , radio active instruments ,
rear of panel instruments , relays , connectors, analysers , chromatographs , sampling
system s, etc.

For items not listed in the tender and for which unit rates are not available , the unit rate of
similar item shall be considered for billing or as per mutual agreement.

3.6 Claims for Extra work:

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Where a contractor is required to re-do a part of already completed work , charges for the
extra claim for the extra work shall be considered . Prior approval for the same is
required.

Re- Calibration of any instrument

Re- installation and shifting of all fabricated items like cable trays , ducts , stanchions ,
etc.

Relaying of cables by removing from existing locations

Relocating / relaying of impulse tubing / supply / signal lines

For all the above extra re- work the unit rates applicable shall be same as normal rates.

Activities on which no extra claim is considered :

– Small paint touch-ups

– Disconnection , removal and re-termination of inline instruments when flushing or

hydro testing

– Small repair work of pneumatic tubing , impulse tubing , ( lime dressing , re-doing
a loop and termination not involving replacement of tubing) arising due to occasional
damage at site.

– Disconnection and re-connection of terminations during continuity checks/ loop

checks

– Temporary removal of panel instruments for purposes of checking.

– Re-work needed due to contractor’s mistakes, deviation from procedures , or

negligence .

The extra work when completed by the contractor shall be duly signed by Uil site engineer
and client’s staff for billing purpose.

3.7 Material cutting allowance / wastage : for angles , channels , cables of all type , multi
tube bundles , impulse tubes / pipes , air supply / signal tubing , piping etc shall be as
mentioned under 9.0 - 9.3 of the specification.

3.8 Off loading of work:

The contractor shall be prepared and capable of meeting exigencies in case of crash
schedule for erection work due to site conditions In case of inability of the contractor
under such circumstances to mobilise manpower and additional equipments , the contract
may be terminated and the compensation to be paid to the contractor for severance of
contract to be mutually decided.

Alternatively if the contractor wishes to terminate the contract , one-month prior notice will
be required to arrange an alternative.

4.0 Preparation Of Installation Tendor Document(Part III)

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Part –III – Schedule of quantities: This part already lists the description items to be
covered in installation tender. However actual project specific requirements shall be
incorporated by suitably modifying this part of the specification.

Schedule of quantities is the summary of various bill of quantities estimated for the
various erection materials as mentioned in the training module for estimation of bill of
quantities.

4.1 List down in this part the bill of quantities under the relevant categories mentioned under
part –III. In the following manner.

4.2 Supply items

4.2a Items included in contractor’s scope of supply and installation

Examples of such items are Plates, 2” pipe for stanchions etc.

4.2b Items included in contractor’s scope of supply but for which no separate installation rate is
required:

Examples of such items are Anchor fasteners , cable glands, etc.

4.3 Free issue Items

4.3.1 Erection hardware for which only Fabrication & installation is in contractor’s
scope.

Examples of such items are cables, impulse tube, etc.

4.3.2 Free issue instruments for which only installation of instruments is in contractor ‘s
scope.

Examples of such instruments are Annubar, Load cells etc.

4.3.3 Free issue instruments for which installation and calibration is in contractor’s scope shall
be listed in this part.

Examples of such instrument are DP transmitters, Displacer level transmitters, etc.

4.3.4 Free issue instruments installed by other contractors where supervision/ checking and
calibration is in the contractor’s scope.

Examples of such instrument are control valves.

4.3.5 Free issue instruments installed by other contractors where supervision/ checking is in the
contractor’s scope.

Examples of such instrument are orifice plate, magnetic flow tube, ON-OFF valves, etc.
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