Instrumentation Design Basis

The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED.
They are merely loaned and on the borrower's express agreement that they will not be reproduced,
MATERIAL REQUISITION (TOP SHEET)
ITEM DESCRIPTION: Analyser Systems
GROUP ITEM CODE 15FU DESTINATION : HPCL Visakh
ITEM CATEGORY II DELIVERY PERIOD :
DOCUMENT NUMBER
(Always quote the Document Number given below as reference)
A406 079 YA MR 2603 B 22/08/2013 16 51

copied, exhibited or used, except in limited way permitted by a written consent given by the lender to the borrower for the indended use. EIL-1641-515 Rev.1 A4-210x297
JOB NO UNIT/ MAIN DOC. SR.NO. REV DIVN. DEPT.

COST CODE DATE
ORIGINATOR
Notes:
1. This page is a record of all Revisions of this Requisition
2. The nature of the Revision is briefly stated in the "Details" column below, the Requisition in its entirety shall be considered for
contractual pupose.
3.Vendor shall note the MR category and shall submit his offer in line with the requirements included in attached
'Instructions to Bidders'
REV DATE BY CHK APPD DETAILS

A 17/04/2013 AS JJ SB Issued for Bids
B 22/08/2013 AS SB SB Revised and issued for Bids
This is a system generated approved document and does not require signature.
Project : HPCL-TGTU
ENGINEERS INDIA LIMITED
Client : HPCL Sheet 1 Of 4
NEW DELHI
Page 198 of 373
S.NO TAG NO . DESCRIPTION QUANTITY
/ ITEM CODE
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned and on the borrower's express agreement that they will not be reproduced,
1 Design ,engineering,manufacture,procurement of materials and

bought out components, assembly at shop,inspection,testing at
manufacturer's works, packing, delivery, documentation as per the
enclosed EIL standard specifications, instructions to vendors, job
specification, data sheets etc
1.01 GROUP-001 TCD Type Hydrogen Analysers 3 Nos

2 Unloading,handling,transportation to store and from store to work

site,storage at site,assembly at site,installation,testing,pre-
commissioning,painting,insulation,commissioning,performance
gurantee run,handing over to cli
ioning spares for the following,as per the enclosed EIL standard
speciations,instructions to vendors,job specification,data sheets etc.
5 Supply of two years operation and Maintenance Spares,as per clause
B16 of special instructions to vendor.
7 Post warranty maintenance contract as per MR requirement.
Vendors shall quote prices against these items in their price schedule
Vendor to note that the numbers given in square '[]' and curly '{}' brackets are not for their use and
meant for store purpose only.Items shall be tagged as per equipment Tag No. only.
Project : HPCL-TGTU REQUISITION No. REV

A406-079-YA-MR-2603 B
NEW DELHI Client : HPCL
Page 199 of 373 Sheet 2 Of 4
LIST OF ATTACHMENTS
S. No. DOCUMENT TITLE DOCUMENT NO. REV DATE SHEETS
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned and on the borrower's express agreement that they will not be reproduced,
1 Vendor Data Requirement A406-079-YA-VD-2603 1 22/08/2013 2
2 Special Instruction to Vendor A406-079-YA-SI-2603 1 22/08/2013 7
3 Technical Questionarrie A406-079-YA-TM-2603 B 22/08/2013 1
4 Data Sheet Index A406-079-YA-ID-2603 0 17/04/2013 1
5 Scope of Work A406-079-YA-SOW-2603 0 17/04/2013 1
6 Spec. for quality management sys.req. 6-78-0001 0 04/06/2009 9

from bidders
7 ITP for process stream analysers 6-81-2035 2 22/03/2012 6
8 Standard specification forProcess Stream 6-52-0035 4 30/03/2012 22

Analyzers
9 Spec. for documentation requirements 6-78-0003 0 04/06/2009 12
from supplier
10 Sample Schematics A406-079-YA-SK-2603 0 17/04/2013 1
11 Saftey Measures for electrical Installation 7-51-0332 0 17/04/2013 2
12 Utility Consumption A406-079-YA-OD-2613 0 17/04/2013 1
13 Calibration Gas Requirement A406-079-YA-OD-2614 0 17/04/2013 2
14 Format for Proven Track Record A406-079-YA-PTR-2603 0 17/04/2013 1
15 Compliance Format A406-079-YA-CF-2603 0 17/04/2013 1
16 Responsibility Defination A406-079-YA-RC-2603 0 17/04/2013 3
17 Deviation List Format A406-079-YA-OD-2615 0 17/04/2013 1
18 Logistic Support Format A406-079-YA-LSF-2603 0 17/04/2013 3
19 Standard Specification for HSE at 6-82-0001 0 17/04/2013 55

construction
In case of any subsequent revision of MR or PR,only revised sheets of the attachments listed above shall be issued
alongwith the revision.
GENERAL NOTES:
Project : HPCL-TGTU REQUISITION No. REV

A406-079-YA-MR-2603 B
NEW DELHI Client : HPCL
Page 200 of 373 Sheet 3 Of 4
Engineers India Limited Vendor Drawing/ Document Submission Schedule
Client/ Project:HPCL/ HPCL-TGTU Vendor's Name : Contact Person (Name/ Tel/ Fax/ email) : Status Date:
Item Description:Analyser PR No.: Review Status Code:

Systems 1. No Comments
Date of LOI:
2. Proceed with manufacture/ fabrication as per commented document.
PO No.: Revised document required.
3. Document does not conform to basic requirements as marked.
Page 201 of 373

Date of PO: Resubmit for Review. R: Retained for Reference V: Void
EIL Originating Department :Instrumentation Contact Person(EIL):
Anticipated (Ant) Date of submission by vendor

Schedule
Drg/ Doc. Nomenclature Vendor Drg/ Doc No. Category Date of 1st Actual (Act) Date of submission by vendor Form
S.No. as per EIL Vendor Data Review(R)/ Submission Date of Return (Rew) by EIL Electronic Remarks
Requirement Records(I) (Rev. 0) (E)/ Print (P)
Title Review Status (Code)
Rev. 0 Rev. 1 Rev. 2 Rev. 3
Ant
Act
Rew
Code
Ant
Act
Rew
Code
Ant
Act
Rew
Code
Ant
Act
Rew
Code
Ant
Act
Rew
Code
Form No. EIL-1641-1923 Rev.1
Data Sheet Index
TAG NO DATA SHEET NO Analyser Type Rev Date
1. 79‐AT‐3301
65‐AT‐4301 A406‐079‐YA‐DS‐6242 TCD A 17.04.13
65‐AT‐5301
VENDOR DRAWING NO-

REQUISITION NO. A406-079-YA-MR-2603 17.04.13 AS SB SB
CLIENT : HPCL-Vizag DATE BY CHK APP
ENGINEERS INDIA LTD. PROJECT- TGTU DATA SHEET NO. REV.
NEW DELHI A406-079-YA-ID-2602 A
This drawing and the design it covers are the property of ENGINEERS INDIA LIMITED. They are merely loaned and on the borrower’s express agreement that they will not be
reproduced, copied, exhibited, nor used except in the limited way and private use permitted by any written consent given by lender to the borrower.
Page 202 of 373
TCD Analyser for H2
This document, drawing, and the design/ details given in this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower’s express agreement that they will not be reproduced, copied, exhibited
1. Tag No. Refer Table-1 below.
Quantity 3 Nos.
2. Service TAIL GAS FROM QUENCH COLUMN
3. Line no. for Process Tapping Refer Table-1 below.
4. Location To be mounted in a self-standing cabinet in the
field.
Haz. Loc 5. Electrical Area Classification IEC Zone 1 Gr. IIB + H2 (Note 6)
6. Type TCD
7. Process Connection 2” Flanged ANSI 150#, RF, facing 125 AARH,

(By Purchaser). Further connection with
Probe/
matching flange with sample probe is by
Sample Cell
vendor.
8. Facing and Finish RF, 125 AARH
9. Flange Material ASTM A 105
10. Probe Length / Diameter mm * (Note 5)
11. Items Required The sampling system shall include the all
necessary equipments and components for
or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.EIL-1641-507. A4-210 x 297.
sample probe, line isolation valve, sample pre-

conditioning/ pressure/ temperature regulation,
sample transfer line, fast loop (if required),
sample conditioning system, sample bypass &
return lines, calibration port, vent/ drain header,
pre fabricated electrically traced sample take off
and lines etc.
12. Location of Sample handling Primary sampling system: Near sample take off
System point (if required)
Secondary sampling handling system: Near
Analyser Cabinet
Sample
13. Probe (Note 7)
Handling
Probe material - SS316
System
Probe rating shall be same as line rating.
(SHS)
Line Isolation Valve material :- Carbon Steel
14. Type of protection All the electrical components shall be flame
proof / purged to IEC zone 1Gr-IIB + H2 T3 and
weather proof to IP55
15. Interconnection tubing &
fittings between sample take
off points, sample conditioner Required, to be supplied by vendor
and the sample handling/
conditioning system
16. Interconnection tubing &
fittings between sample
Required, to be supplied by vendor
handling / conditioning
system and Analyser
A 17.04.13 AS SB SB MR: A406-079-YA-MR-2603 LEGEND :
REV DATE BY CHK APPD VENDOR: * - By Vendor

^ - Data Revised
PLANT : TGTU SPECIFICATION REV

NEW DELHI UNIT : 079
A406-079-YA-DS-6242 A
CLIENT : M/s HPCL
Page 1 of 4
Page 203 of 373
TCD Analyser for H2
17. Sample Module Vendor’s scope shall include supply of all the
components, interconnecting tubings/ piping,
tube fittings / pipe fittings including connectors.
Sample shall be returned to sample take off
line.The tubing from sample take off to Analyser
shall be in vendors scope (Refer attached
sketch).
18. Size of tubing ¼” (OD)
(Vendor to furnish calculation for sample
transport time. Tubing shall be selected to
minimise transportation time and also to
prevent clogging)
19. Material of tubing & all wetted
SS 316 as a minimum
parts of Sampling System
20. Tube fittings Tube fittings shall be double compression type
(Swagelok / Parker make) and material shall be
same as that of tubes.
21. Tubing length to be
considered from Process tap 25 meters (approx)
to Analyser
22. Electric Tracing of Sample Required

lines
23. Control Unit Type Microprocessor Based
24. Analyser Type Thermal Conductivity Type.
25. Location of Analyser To be mounted in the analyser cabinet in field
26. Protection of the analyser Flame proof / Purged to the area classification
and weather proof to IP-55
27. Memory Type Non Volatile type or RAM with battery back up.
28. Self Diagnostics facility Required.
29. Configuration changes Through in-built keypad or external handheld
configurator (Note 4)
30. Output -1No 4-20 mA DC isolated linear for H2
concentration
Analyser
31. Local Display Unit LCD alpha numeric
32. Measurement range 0-5 Mol% of Hydrogen
33. Accuracy < +/- 1 % of scale.
34. Response time *
35. Repeatability and response As per standard specification process stream
time analyser 6-52-0035 clause no.2.4.5
36. Automatic Zeroing Facility Required
37. Automatic calibration Facility Required (Note-3)
38. Power Supply 110 V AC ±10%, 50 Hz±3% AC UPS
39. Power Consumption *
40. Utilities requirement *
Process Conditions
Service 41.
Conditions 42. Fluid | State TAIL GAS FROM QUENCH COLUMN | Vapor
43. Operating Pressure Kg/cm2g 0.12
44. Design Pressure Kg/cm2g 1.05

^ - Data Revised

A406-079-YA-DS-6242 A
CLIENT : M/s HPCL
Page 2 of 4
Page 204 of 373
TCD Analyser for H2
45. Operating Temperature °C 40
46. Design Temperature 150
47. Vapour MW 26.85
48. Vapour Viscosity cP 0.02
49. H2S : 2.02%
H2O : 5.59%
Gas Composition Mol% N2 : 87.75%
CO2 : 0.36%
H2 : 3.03%
50. Statutory Certificates Required
Certification
51. Others -
52. Model No. *
Others
53. Manufacturer Mote 8
Notes:
1. Vendor to note that all utilities like power, instrument air etc. shall be provided by
Purchaser at one point in field near each cabinet. Further distribution with all
accessories such as power supply pack, regulators etc. shall be in vendor’s scope of
supply. For further details of scope, tube sizing, flanges, valves, sample vent
scheme refer to the analyser sample schematic A406-079-YA-SK-2602 Sht 2
enclosed in MR.
2. Vendor to note that the distances from the sample take-off point to the analyser in
the analyser cabinet are tentative and shall be finalised during detail engineering.
3. It shall be possible to include the auto calibration cycle either by single manual push
button operation from analyser cabinet or automatically at prescribed time. Vendor
should provide all required components and accessories to achieve the same.
Vendor to specify frequency and duration of auto calibration
4. In case external configurator is required, vendor shall supply the same.
5. Vendor to calculate probe length considering 50% insertion in the line and nozzle
projection as per sketch A406-079-YA-SK-2602.
6. All the Electrical/ Electronic components including sampling handling system,

electronic enclosure, control unit shall be Explosion proof to IEC Zone 1, Gas Gr. IIB
+ H2, T3.
7. Analyser sample shall be returned to sample take off line only. No separate analyser
return line is envisaged. Vendor shall consider suitable sample take off Probe having
the facility to return the sample to the sample take off line.
8. Manufacturer shall be Western Research (Ametek) or equivalent.

^ - Data Revised

A406-079-YA-DS-6242 A
CLIENT : M/s HPCL
Page 3 of 4
Page 205 of 373
TCD Analyser for H2
9. Table-1
Sl No. Analyser Tag No. Sample Line No.

1. 79-AT-3301 12"-P-79-3301-A9A-IT
2. 65-AT-4301 12"-P-65-4301-A9A-IT
3. 65-AT-5301 12"-P-65-5301-A9A-IT
Vendor shall consider 3 Nos. of analysers for 3 different SRU trains as per the table
above which shall be mounted in 3 separate cabinets along with all required
accessories with separate sample probe, sample tubes etc for each analyser.

^ - Data Revised

A406-079-YA-DS-6242 A
CLIENT : M/s HPCL
Page 4 of 4
Page 206 of 373
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned and on the borrower's express agreement that they will
not be reproduced, copied, exhibited or used, except in limited way permitted by a written consent given by the lender to the borrower for the indended use. EIL-1651-726 Rev.0 A4-
SPECIAL INSTRUCTION TO VENDORS
Part A:
BIDDING INSTRUCTIONS
A1.The Bidder must follow the following guidelines while submitting their offer. Offers not complying with these guidelines
may be rejected without any intimation to the Bidder:
a) The Material Requisition (MR) specifications (i.e. data sheets, standard specifications, sketches and other attachments to
this MR shall be fully complied with. No deviations of any type are acceptable in general.
b) Bidder shall submit the price against Group specified in this MR in the separate price schedule sheet. No information /
description, technical or non-technical, other than what is required as per price fromat shall be filled or submitted.
Prices indicated in pricing schedule shall include prices for all accessories , special tools and tackles, consumable spares
and commissioning spares, testing, documentation & applicable statutory certification requirements corresponding to the
items.Alternate quote / prices shall not be furnished.
A2. The Bidder is responsible for the selection of proper analyser and design of the sample conditioning system to analyse
the component of interest within the stated performance requirements and to meet the specifications in totality. If at any
stage, till the completion of the order, the offered instruments & accessories are found unsuitable for the specified operating
and design conditions, the Bidder shall replace the same with a suitable model no. meeting the specifications without any
schedule/cost implication. Bidder shall provide all hardware and software, as necessary, to meet the functional requirements
specified in MR.
A3. Bidder shall note that the offer will be evaluated on the basis of the following Documents only. Bidder shall submit the
same along with the offer.
a) Filled up Compliance Statement (A406-079-YA-CF-2602)
b) Proven Track Record Format (A406-079-YA-PTR-2602)
c) Logistic Support Certificate (A406-079-YA-LSF-2602)
d) Responsibly Definition format (A406-079-YA-RC-2602)
e) Utility Consumption (A406-079-YA-OD-2612)
f) Scope of work (A406-079-YA-SOW-2602). It shall be signed and stamped by bidder.
g) Deviation List (if any) (A406-079-YA-OD-2613)
h) Undertaking and details for service provider in india for 7 years ( Refer clause B21 below).
A4. Acceptance Criteria

i)All items as offered shall be field proven and should have been operating satisfactorily individually for a period of minimum 6
months in hydrocarbon industry like refinery, petrochemical, gas processing plant etc in the last 5 years.Items with prototype
designs or items not meeting provenness criteria specified above shall not be offered. Analyser and probe shall have PTR in
TGTU of Suphur Recovery Unit for a period of minimum 6 months after commissioning.
ii)The offered analysers shall continue to be supported by the bidder for a minimum period of 10 years. The quoted systems
shall not be withdrawn by analyser manufacturer from Indian market as a matter of corporate policy. Bidder and analyser
manufacturer shall continue to support the Owner in providing back-up engineering, maintenance support and spare part
support for a period of 10 years from the date of placement of order. Bidder shall furnish the Certificate from analyser
manufacturer for providing necessary support services in favour of the Owner (M/s HPCL) committing themselves to provide
logistic support to purchaser in the format (A406-079-YA-LSF-2602) attached with MR.
iii) Bidder shall submit the proven track record for the offered items in the proven track record format attached with this MR
along with offer. Incomplete, ambiguous and incorrect entries in the proven track record format may lead to rejection of the
offer without any intimation to the bidder.
iv) Analyzer manufacturer shall stand guarantee for the performance of the complete analyzer as per specified performance
specifications given in MR.
v) In case bidder who is not analyser manufacturer , the following shall apply :
a) Basic engineering including design of sample handling system and sample disposal system shall be by Analyser vendor
(OEM).
1 22/08/2013 AS SB SB REQ. NO. : A406-079-YA-MR-2603

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0 17/04/2013 AS JJ SB ORDER NO. : Page 1 Of 7
REV DATE BY CHKD APPVD VENDOR :
PLANT : HPCL-TGTU SPECIFICATION REV

UNIT : 079
NEW DELHI A406-079-YA-SI-2603 1
CLIENT HPCL
Page 207 of 373
b) Make & model of critical components for the SHS to be indicated by Analyser vendor (OEM).
vi) Responsibility Definition format attached with the MR shall be completely and correctly filled by bidder and shall be
furnished along with the offer. Bidder shall indicate clearly the responsibilities of each of the agencies in Responsibility
Definition format in line with definition of various agencies given in the MR. The responsibility assigned in the format shall be
from the agency or location, which meets the proveness criteria given in the MR.
Offers will be evaluated as received on the basis of criteria set forth in Clauses A3 & A4 above. The Bidder shall note that
there may / may not be any subsequent technical correspondence.
A5. MUST COMPLY REQUIREMENTS

a) Bidder must indicate their contact person, email ID, fax number, telephone number and postal address.
b) Offer must be complete in all respect complying fully to the MR requirements without exception. No price change
whatsoever shall be allowed to the Bidder after submission of bid even if it results from any technical clarification.
c) Any price change subsequent to the submission of the offer because of any technical query or any other reason
attributable to the Bidder may lead to rejection of the offer.
d) Technical queries if necessary shall be forwarded either in email or by fax. Bidder shall forward their replies either by email
or by fax, addressed directly to purchase department from where the enquiry is issued indicating the enquiry number in each
of such correspondence. Bidder shall also forward a hardcopy of the email duly signed.
e) Any query raised on the email or fax must be replied within the specified period. Replies received beyond the specified
period may lead to ignoring any subsequent correspondence from the bidder.
A6. The Bidder shall submit the required drawings/documents as per the Vendor Data Requirements enclosed with the MR.
A7. The Bidder shall submit the 'Technical Questionnaire' in this MR duly filled in along with the offer. Answers to the
contents of this Technical Questionnaire shall be unambiguous i.e. 'yes', 'no' or the required data/information. An offer without
the filled-in Technical Questionnaire or with vague, non-committal replies or referenced reply to some catalogue etc., without
specific page and paragraph no. shall be considered incomplete and is liable for rejection.
A8. Offered models shall be accompanied by detailed technical catalogues in English language of Offered Analyser and
accessories. An offer without catalogues shall be considered incomplete and is liable for rejection.
PART - B
(SPECIFIC JOB REQUIREMENTS)
--------------------------------------------------------
B1. The Analysers covered in this MR are of TCD type for Hydrogen measurement as per the following details required for
Tail Gas Treating Unit of Visakh SRU Revamp Project Licensed by EIL for HPCL Visakh .
Group-001:TCD Analysers Qty 3 No's
Bidder to note that the evaluation shall be carried out on bottom line basis (lump sum basis) for all the tags in a group
including commissioning & consumable spares and all other requirements of MR. Ordering shall be carried out Group Wise
i.e. all analysers for one group shall be ordered together on one bidder.
B2. This Special Instructions to Vendor together with analyser data sheets, Standard Specification for Process Stream
Analysers and all other documents attached with the MR defines the minimum requirements of TCD type analysers designed
for reliable and effective analysis of componenent of interest (Hydrogen) as given in the MR.
B3. In the event of any conflict between special instructions to vendor, data sheets, Standard specification, statutory
regulations, related standards, codes etc. the following order of priority shall govern.
(i) Statutory regulations.
(ii) Data sheets & Special instructions to vendor.
(iii) Standard Specifications.

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Page 208 of 373
(iv) Codes & Standards.
B4 For each Tag No.the TCD type analyser system along with sample handling system, sample cell, source/detector module,
filter/beam choppers etc. as applicable shall be installed in a free standing closed analyser cabinet. The analyser cabinet for
each analyser shall be provided with a vortex cooler or air conditioning unit suitable for the specified hazardous area
classification, in case, the offered analyser is not suitable for the site conditions indicated in the MR. The requirement of
vortex cooler or air conditioning unit shall be clearly indicated by bidder in his offer.The analysers, electrical/electronic
components in the primary sample handling system / sample conditioning system etc. shall be suitable for hazardous Area
classification as per data sheet. The cabinet shall be provided with a sunshade. The dimensions of cabinets shall be limited
to 2100mm H X 800mm W. Cabinet shall be suitable for side and bottom cable entry.
The vortex cooler (if required) shall be provided with compressed air system and air dryer of suitable size and capacity. No
instrument air shall be provided by purchaser for vortex cooler. Bidder shall use 415V AC power supply provided by
Purchaser at one point near the cabinet for Air conditioning (if required).
B5.Hazardous Area Certification

All the individual electrical/electronic components of the offered analyser, analyser Sample Conditioning Systems (SCS)
and individual electrical / electronic components etc. shall be flame proof certified by statutory authorities for use in
hazardous Area classification as mentioned in each data sheet. The bidder shall be responsible for obtaining all statutory
approvals as applicable for all instruments . In general, the following certification shall be provided by the bidder:
The requirement of statutory approvals for usage of equipment/instruments/ systems in electrically hazardous areas shall be
as follows:
a) The bidder shall be responsible for obtaining all statutory approvals, as applicable for all instruments and control systems.
b) Equipment/instrument/systems located in electrically hazardous areas shall be certified for use by statutory authorities for
their use in the area of their installation. In general, the following certification shall be provided by the bidder:
- For all intrinsically safe/ flameproof/ protected by other methods, equipment/ instrument/systems, which are manufactured
abroad (outside India) and certified by any approving authority like Baseefa, FM, UL, PTB,LCIE etc., certification by the
Indian authorities - Petroleum Explosives Safety Organisation (PESO) /Chief Controller of Explosives (CCE), Nagpur, India is
mandatory.
- For all flameproof equipment manufactured locally (within India), the testing shall be carried out by any of the approved
testing houses - PESO/Central Mining Research Institute (CMRI) / ERTL etc. The item shall in addition bear the valid
certification from PESO / CCE and also the manufacturer shall hold a valid Bureau of Indian Standards (BIS) license.
- For all intrinsically safe equipment manufactured locally (within India), the testing shall be carried out by any of the approved
testing houses - Central Mining Research Institute (CMRI) / ERTL etc. The item shall in addition bear the valid certification
from PESO/ CCE.
B6. Analyser Requirements:

(i) Analyser and its related equipments directly connected to process line shall be capable of withstanding line pressure and
temperature conditions specified in data sheets.
(ii) Design of Analyser and sample handling system shall be such that components or any sub-assembly that requires
removal shall be possible without any need to dis-assemble any other component. Such components shall include items like
filters, pressure regulators, flow indicator, detector, electronic modules etc.
(iii) Analyser shall be microprocessor based and shall be capable of being configured from analyser front panel locally using
built-in keyboard. In case any other external configurator/ or special software is required for configuration of analyser, same
shall be supplied by bidder.
(iv) The configuration related data of the analyser including set range shall be stored in a non-volatile memory such that this
data remains unaffected by power off condition. In case bidder's standard product stores configuration data in battery backed
RAM, analyser shall have facility to provide battery drain alarm as diagnostic maintenance message.
(v) Analyser shall run diagnostic sub routines on continuous basis and shall be able to provide diagnostic alarms related to
analyser detector and electronics as and when any failure /malfunctioning is detected.
(vi) Analyser shall have an integral output meter with digital read out in engineering units.
B7. Sample Handling System:

(i) The sample handling system shall be in line with sample schematic A406-079-YA-SK-2602 attached with this MR.

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Page 209 of 373
(ii) The probe design shall ensure following:

a) The probe diameter shall be such that it can be easily inserted or removed through the line isolation valve when in fully
open condition.
b) The length of the probe shall be selected considering its insertion 30% to 50% of the pipe. For the purpose of calculating
probe length, consider nozzle lengths as 200 mm.
(iii) Bidder to note that SOVs shall be suitable for operating on 110VAC power supply. Solenoid valves, wherever used, shall
be flameproof type suitable for specified area classification.
B8. The analysers shall be supplied in pre-assembled, pre-tubed and pre-wired condition complete with sample handling
system duly installed in respective free standing cabinet with sunshade in ready to commission condition except that the
primary sample conditioning unit (if applicable) i.e conditioning at sample tap-off point and sample tubing between sample
take off point and analyser shall be supplied separately. Site activities shall be kept as minimum.
B9. Bidder to furnish flow schematic / hookup diagram during detailed engineering for the offered analyser indicating the
complete analyser system from the sample take-off point to the sample return including sample conditioning system (SCS),
free-standing rack, sample transportation line etc. Complete details of sample conditioning systems shall also be furnished
during detailed engineering. Bidder shall furnish legend for the flow scheme.
B10. Bidder shall be completely responsible for the selection of proper material & design to ensure proper functioning of the
analyser based on sample process conditions described in data sheets and specifications. However, bidder must ensure that
requirements and material of construction as specified in this MR are complied as a minimum. Material of construction of all
components wetted by sample shall be SS316 as a minimum.
B11. Bidder shall furnish bill of material for analysers during detail engineering. Bidder shall be fully responsible for providing
all necessary items / accessories to meet the functional and operational requirements as specified in this MR. Any additional
hardware or software found necessary at a later date to meet MR requirements, shall be supplied by bidder without any time
and price implications.
B12. Utilities:
Bidder shall furnish exact utility requirements for the offered analysers along with the offer. Following utilities shall be
provided by purchaser(if required) at one point near each Analyser Panel in field. Further distribution of utilities required for
the operation of analysers supplied by the bidder shall be carried out by bidder
a) Instrument Air:
Pressure: Minimum 4 kg/cm2g Normal 5 kg/cm2g, Design 9 kg/cm2g
Temperature: Normal Ambinet, Design 65 DegC
Instrument air tapping Connection: 1 " 150# Flanged
b) LP Nitrogen:
Pressure: Minimum 4 kg/cm2g / Normal 8/6 kg/cm2g / Design 10.5 kg/cm2g
Temperature: Normal Ambinet / Design 65 deg C
Nitrogen: 1 " 150# Flanged
Vendor shall not consider above utilities for zero gas.
c) Power supplies: Purchaser shall provide 110 V AC ± 10%, 50 Hz ± 3% UPS power supply feeder at one point near each
analyser cabinet. Further distribution to analyser and its accessories operating at 110 VAC and derivation to the required
power levels is in bidders scope. Bidder shall provide power distribution junction box and all wiring within each analyser
cabinet shall be done by bidder. Purchaser's feeder shall be terminated in the power distribution box supplied by the bidder.
The power distribution box shall be explosion proof to the specified hazardous area classification. Purchaser shall also
provide 415 VAC power supply at one point near each analyser cabinet for air conditioning (if required), tracing & lighting
purpose.
Bidder to indicate the exact utility requirement for each of the offered analyzer along with the offer as per Document No.
A406-079-YA-OD-2612.
B13. General Requirements (Cables, Junction Boxes, Cable Glands, Tubes, Tube Fittings etc.,):
(i) Bidder shall supply all the interconnecting cables, cable glands, tubes/ tube fittings etc. between the tap-off and the
sample handling system, between sample handling system and analyser to achieve proper functioning of analysers. Cables
between all electronic modules and sample cell, source/detector modules,beam choppers etc. shall be in bidder's scope.

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(ii) All interconnecting cables shall be PVC insulated armoured with flame retardant PVC inner & outer sheath.
(iii) All cable glands shall be weather proof to specified hazardous area classification. Cable entries and cable gland sizes
shall be in 1/2" NPTF for signal cables.
(iv) Tube fittings shall be double compression type ( Swagelok / Parker / Equivalent make) and shall be of minimum SS 316
or better.
(v) All the cables shall be properly terminated in junction / terminal boxes. Flying leads are not acceptable.
(vi) All electrical components like junction boxes, cable glands etc shall be weather proof to IP 55 suitable for specified
hazardous area classification
(vii) Junction boxes(if required) shall be of die cast aluminium alloy (LM-6) body and shall have terminals suitable for
accepting minimum 2.5sq mm copper conductor for signal, alarm and control cables. 20% spare terminals shall be supplied
in each junction box.
(viii) Diemsnions of Purchasers Power cables will be given during detailed engineering for Vendor to select the cable entry
and glands.
B14. Bidder shall supply any special instrument or tools needed for testing, calibration and maintenance of offered analysers
such as spanner set (for tubes smaller than 6mm or 1/4") non-magnetic tools, bubble rotameter etc. List of same shall be
furnished by bidder in his offer and price shall be included in price furnished for Analyser covered under each group. In case
no special tools are required same shall be categorically mentioned in the offer by bidder.
B15. Calibration / Testing:

Analyser shall be supplied as precalibrated from bidder works.
B16. Bidder shall furnish separate list along with unit price for two years operational and maintenance spare for offered
analysers and its accessories as per bidder's recommendation. The list shall include spare parts like electronic module, flow
meter, solenoid valve, pressure regulator, local indicator, set of O ring, set of fuses, electrode/ sensor etc.
B17. Bidder shall supply startup and commissioning spares for the offered analysers as per bidder's recommendation and
price for the same shall be included for in price furnished for each Group. The list of commissioning spares must include 5%
or minimum one of each type of following items as a applicable:
i)Set of O rings
ii)Set of fuses
iii)Tubing and tube fittings (sizes smaller than 6mm or 1/4")
Additional spares as required, during start-up and commissioining even though not listed above shall be supplied by the
bidder without any price and delivery implications.
B18. Bidder shall supply calibration gas cylinders (zero gas & span gas cylinders) and Carrier Gas cylinders required for
calibration of sensors for each analyser which shall be necessary for warranty period plus 6 months of normal operation
considering a frequency of one calibration at one week interval as per Doc. No. A406-079-YA-OD-2611. Calibration period
shall be considered as 30 minutes for calculation purpose. Any other consumables required as per Bidder's recommendation
during startup,commissioning and warranty period plus 6 months of normal operation for each of the offered analysers shall
be supplied by bidder and price shall be included in price furnished for analyser covered under each Group. Any additional
consumables required for the specified period shall be supplied by bidder without any implications.
B19. Inspection shall be carried out by the third party inspection agency appointed by the bidder for all items supplied by the
bidder at manufacturing works. As a minimum, Inspection Test plan for Process Stream Analyzer (6-81-2035 Rev.0) and
Standard Specification for Process Stream Analyzer (6-52-35 Rev.2) shall be adhered to. All indigenous items supplied
/integrated by the bidder at his works shall be subject to third party inspection at bidders works appointed by
owner/EIL.However for non indigenous items,inspection shall be carried out by third party inspection agency
at bidders works to be appointed by bidder .Price for the same shall be included in base price of Group-001.
B20. Bidder shall submit Vendor drawings / documents through EIL's Electronic Document Management System (EDMS).
B21. Service provider in INDIA :

Following shall be applicable for both OEMs and analyser system integrator :
a) Orignal eqipment manufacturer has to give an undertaking with offer that they shall support the system for 7 years through
an indian service provider. In case of change in the service provider during this 7 years, they shall inform the same to M/s
HPCL well in advance and offer necessary technical support free of cost till the new service provider is trained.
b) Service provider in india is a must. Address and organisation chart to be provided along with the details of experience of
the service personnel.

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B22. Post Warranty Maintenance Contract (PWMC) :
B22.0 Bidder to quote separately for PWMC (Post Warranty Maintenance Contract) for 3 Years. This will be considered for
evaluation. Purchaser at its discreting may place the order before the expiray of the warranty period.
B22.1 Bidder shall quote for PWMC for the offered system for a period of 3 years from the date of completion of warranty
period. Bidder shall ensure the calibration/ proper functioning of the analyzers.
B22.2 Following are the requirements wrt the PWMC:
a) Periodical checking the proper functioning of analysers. Attending failure immediately by repair or replacement of the failed
component. Provide system maintenance and repair of system or workmanship defects during the PWMC free of
charge (parts and labor).
b) In case of failure on part of Bidder/Vendor, to attend to the complaints that are raised by HPCL or to replace any
component/equipment for ensuring desired performance from the analyser within the PWMC period, HPCL reserves the right
to cancel the PWMC and withhold any payments payable to the party irrespective of the value of the items which need to be
replaced /rectified.
c) Service or maintenance personnel shall be able to receive 24-hour help-desk technical support provided by the system
manufacturer.
d) The offer for PWMC shall be compulsory and the HPCL reserves the right to accept or reject the bid based on the non
compliance to meet PWMC requirement.
e) The proposal shall include supply of maintenance spares, tools and tackle as required; travel, boarding & lodging of
service engineer. The bid shall be made year wise up to 3 years and the price validity shall be available for the entire period
of contract.
f) In the event of any malfunction of the analysers, experienced service engineer shall be made available at site within 48
hours on the receipt of such information from HPCL.
g) Bidder/Vendor may utilize the spare modules available with HPCL if necessary. However if Bidder/Vendor desires,
additional spares other than what is available as spares may be stored at HPCL premises to meet the schedule of
rectification of fault during emergency/maintenance.
h) In case any hardware /software used from HPCL stock, it shall be replaced by Bidder/Vendor within 7 days with no cost to
HPCL. Bidder/Vendor shall maintain a record of all faults during post warranty period.
B22.3 The services under Post Warranty Maintenance Agreement, including supply of spare parts and services shall broadly
comprise of:
a) Preventive Maintenance:
This involves complete periodic overhaul of the analysers, inspection of the sample handling, environmental operating
condition checks, calibration checks and detailed reporting,
This visit is in addition to visit required for periodic maintenance.
b)Periodic Maintenance
This involves site visits, minimum two (2) times in a year (total days expected 6 in a year), schedule of visits to be discussed
and finalised jointly between Bidder/Vendor and HPCL after placement of order/delivery. It shall include inspection of general
healthiness of the system, study and advice on daily maintenance, inspection of analysers if any problem is reported, and
running of test programs, on-line servicing and solving reported problems. Checks shall be conducted on-line analysers.
c) Emergency Service
In the event of any malfunction of the analysers during this period, service Engineer must report at site within 48 hours of
report of failure, with necessary spares. The system must be brought back within maximum 24 hours after reporting at site.
B22.4 Bidder/Vendor to note that while carrying out the PWMC activities, HPCL engineers shall oversee/associate with the
Bidder/Vendor's service engineer. Also on-job, training to HPCL's engineers if HPCL required shall be covered under this
scope.
B22.4.1 PWMC shall include all items being supplied by Bidder/Vendor, including any bought out items but not limited to the
following:
a) Labor and materials, at no additional cost, to repair any analyser.
b) Labor and materials, at no additional cost, to provide tests, and adjustment to analysers.
B23. SITE CONDITIONS:

The Analysers covered in the MR shall be suitable for unprotected installation in Hot, Humid and Corrosive environment

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having following ambient condition.
The site environmental conditions at Visakh are as follows:

Ambient Temperature (Max./ Min.) : 45 Deg C/ 15 Deg C
Relative Humidity : 95% @ 45 deg C (Max).
Maximum recorded rainfall: 100mm in 1 hour & 293 mm in 24 hours

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VENDOR DATA REQUIRMENT
With Final
Description AFTER PURCHASE ORDER
Proposal Documentation
(Prints) / As Built
Prints Date Needed
1. *Vendor drawings / documents schedule 6 6W
2. *Sub Vendor List 6 6W 6W\S
3. *Sample transportation time calculation 6 6W 6W\S
4. *Details of sample probe & sampling system general 6 6W 6W\S
5. *Sample tubing hookups including sample handling system 6 6W 6W\S
6. *Analyser cabinets general arrangemet and layout drawing 6 6W 6W\S
7. Wiring diagrams 6 6W 6W\S
8. *Power supply distribution 6 6W 6W\S
9. Filled in data sheet for analyser 6
10. Utility requirements & consumption details 6 6 6W
11. Power consumption details for each analyser and its 6 6 6W 6W\S
accessories
12. Analyser cabinet grounding details 6 6W 6W\S
13. Certificate from statutory body 6W\S
14. Bill of material 6 6W 6W\S
15. *Testing and inspection procedures 6 6W 6W\S
16. Spaecial tols and tackles required for maintenance 6
17. Catalogues in english 6 6W\S
18. Installation,operation and maintenance manual including 6W\S
calibration procedures
19. *Calibration gas cylinder requirements 6 6W 6W\S
20. Logistic support certificate 6
21. Proven track record in format attached 6
22. Responsibility chart in format attached 6
23. Soft copy of final document in CD 6W\S
24. Deviation list (if any) in format attached 6
25. compliance statement 6

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VENDOR DATA REQUIRMENT
NOTES :
1. Fold all drawings to 216mm X 279mm and roll transparencies.
2. Vendor to provide all printed matter to ENGINEERS INDIA LIMITED (EIL).

ATTENTION -
Vendor Print Control

EIL
LEGEND: 1, Bhikaji Cama Place, New Delhi-66
Categories preceeded with * will be approved for fabrication by Engineers India Limited.
The remaining drawings are needed for information only.
A/C = As compiled A/R = As required W/S = With shipment W = Weeks
IMPORTANT
While submittimg drawings and documents for review as indicated in vendor data requirement,
vendor must ensure the following :
1. A blank space measuring 75 mm W x 38 mm H shall be provided on all vendor drawings

(on the front side) for marking review codes etc. by ENGINEERS INDIA LIMITED.
2. The review of the drawings shall be done as applicable, under the following review codes :
a) Review Code 1 : No Comments.
b) Review Code 2 : Proceed with manufacture / fabrication as per commented drawing.
Revised drawing required.
c) Review Code 3 : Document does not conform to the basic requirements as marked.
Resubmit for review.
3. Review of the vendor drawings by EIL would be only to check compatibility with basic design and
concepts and would in no way absolve the manufacturer / fabricator of his responsibility to meet the
applicable codes, specifications and statutory rules and regulations.
4. For drawings / documents indicated as FOR INFORMATION in the vendor data requirement,
vendor must clearly mark FOR INFORMATION ONLY on the submitted drawings / documents.

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CLIENT HPCL
Page 215 of 373
FORMAT FOR COMPLIANCE
DOCUMENT No.
A406-079-YA-CF-2603 Rev A
Page 1 of 1
COMPLIANCE STATEMENT
(TO BE SIGNED BY VENDOR’S CORPORATE LEVEL SIGNATORY ON COMPANY LETTERHEAD)
I, ON BEHALF OF M/s _______________________________ CONFIRM THAT THE

PROPOSAL OF THE ANALYSERS (HYDROGEN) FOR HPCL VIZAG TGTU AGAINST
MATERIAL REQUISITION NO. A406-079-YA-MR-2603 MEETS ALL THE SPECIFICATIONS
GIVEN IN MR.
(SIGNATURE WITH SEAL)
Format No. 8-00-0001-F1 Rev. 0 Copyrights EIL – All rights reserved

Page 216 of 373
TECHNICAL QUESTIONNAIRE
This questionnaire shall be duly filled in and submitted along with unpriced sets of offers to avoid further
queries and to ensure proper evaluation of your offer in time. If this is not complied with, your offer is liable to be rejected.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------
not be reproduced, copied, exhibited or used, except in limited way permitted by a written consent given by the lender to the borrower for the indended use. EIL-1651-TEQ
ANSWER 'YES' 'NO' OR 'NOT APPLICABLE'
DESCRIPTION BIDDER'S RESPONSE

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1. Have you any deviations to the following:

i) General Specifications (clausewise)
ii) Special requirements (clausewise)
iii) Instrument specifications indicated in the data sheets.
iv) The scope of supply as indicated in the material requisition. If `yes' have you included
the list of deviations? (If no deviations are furnished, it will be assumed that all
the specifications and requirements of the subject requisition are complied with and
no deviations whatever will be accepted after the placement of order.)
-------------------------------------------------------------------------------------------------------------------------------------------------------------
2. Have you quoted for the spare parts including consumable items required for the startup
and 2 years normal operation/maintenance of the Instruments?
-------------------------------------------------------------------------------------------------------------------------------------------------------------
3. Have you quoted for the mounting accessories, special calibration kits and equipments
(complete with technical details) required if any, for the erection, commissioning and
maintenance of the instruments?
-------------------------------------------------------------------------------------------------------------------------------------------------------------
4. A) Have you enclosed the relevant technical catalogue/Literature in ENGLISH language including
model decoding details, drawings etc. necessary for the evaluation of your offer?
(NOTE: In case of line mounted instruments, viz. control valves, positive displacement meters,
Pressure relief valves etc., for all the lines quoted, relevant dimensional details required for
the installation must be furnished along with the offer.)
B) Have you confirmed that the documents required as per vendor data Requirements will be
supplied after the placement of order.
C) If so, have you indicated the extra price applicable, if any?
-------------------------------------------------------------------------------------------------------------------------------------------------------------
5. Have you furnished sizing, noise level calculations and certified capacity curves for the
instruments, wherever applicable?
-------------------------------------------------------------------------------------------------------------------------------------------------------------
6. Have you furnished, separately the `Shop inspection charges, if any, for inspection at
your works by EIL/Third party? (The details of the tests to be carried out on the instruments
during shop inspection are to be furnished)
-------------------------------------------------------------------------------------------------------------------------------------------------------------
7. Have you furnished the certificates from statutory bodies vis. BASEEFA, FM, CSA etc. for the
Explosion proof construction / intrinsically safe design of the instruments, wherever specified?
-------------------------------------------------------------------------------------------------------------------------------------------------------------
8. Have you furnished the certificates from statutory authority i.e., CCOE certificate for all electrical
equipments for intrinsically safe/ explosion proof design wherever specified?
-------------------------------------------------------------------------------------------------------------------------------------------------------------
9. Have you confirmed that IBR certification in Form III(C) or equivalent certification from statutory
bodies viz. Lloyds, Bureau veritas, TUV etc. will be furnished wherever specified?
-------------------------------------------------------------------------------------------------------------------------------------------------------------
10. Have you indicated separately the installation and commissioning charges, in case the same
are included in your scope of work?
-------------------------------------------------------------------------------------------------------------------------------------------------------------
11. Have you furnished the estimated power / utility consumptions and special cable requirements,
if any, for the instruments quoted?
-------------------------------------------------------------------------------------------------------------------------------------------------------------
12. Have you furnished the customer reference list in India/Abroad.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------
- NOTE : If the answer is 'NO' , then furnish reasons thereof.
[ ] Deviation [ ] No Deviation Vendor Seal And Signature
B 22/08/2013 AS SB SB REQ. NO. : A406-079-YA-MR-2603

A 17/04/2013 AS JJ SB ORDER NO. : Page 1 Of 1

UNIT : 079
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CLIENT HPCL
Page 217 of 373
Page 218 of 373
A406-079-YA-SK-2603
17.04.13
SPECIFICATION
CALIBRATION GAS CYLINDER
A406-079-YA-OD-2614 Rev. A
REQUIREMENTS
Page 1 of 2

REQUIREMENTS
A 17.04.2013 ISSUED FOR BIDS AS SB SB

Rev. Prepared Checked Approved
Date Purpose
No by by by
Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Page 219 of 373
SPECIFICATION
A406-079-YA-OD-2614 Rev. A
REQUIREMENTS
Page 2 of 2
Sl. No. TAG NO. ANALYSER TYPE ZERO GAS SPAN GAS CARRIER GAS
CYLINDER WITH CYLINDER WITH CYLINDER WITH
REGULATOR, REGULATOR. REGULATOR.
PRESSURE PRESSURE PRESSURE
GAUGE, RELIEF GAUGE, RELIEF GAUGE, RELIEF
VALVE VALVE VALVE
(IF
APPLICABLE)
1) 79-AT-3301 TCD * * *
2) 65-AT-4301 TCD * * *
3) 65-AT-5301 TCD * * *
1) Vendor shall supply calibration sample cylinders for zero and span calibration for each analyser.
Quantity of total cylinders for each analyser shall be calculated by vendor with following basis:-
a) Calibration gases are required for startup, field-testing, commissioning, final acceptance and for
warranty period plus 6 months of normal operation.
b) These calibration gas cylinders shall be supplied in two sets. One set of these cylinders shall be
connected to the analyser and another set of cylinders shall be kept in store.
c) Calibration gas accuracy shall be adequate to demonstrate the repeatability of the analysers.
d) Calibration / Zero gas quantity shall be calculated based on a frequency of one calibration at one
week interval. Calibration period shall be considered as 30 minutes for calculation purpose.
e) Calibration gas cylinders material of construction shall be suitable for maintaining stability of the
calibration gas mixture for the specified time.
2) Vendor shall also supply carrier gas cylinders (as applicable). Quantity of total no. of cylinders for
each analyser shall be calculated by vendor with following basis:-
a) Carrier gases are required for startup, field-testing, commissioning, final acceptance and for
warranty period plus 6 months of normal operation.
b) Carrier gas cylinders shall be supplied in dual manifold arrangement. The cylinder shall be
arranged so that one cylinder may be replaced while the analyser remains in operation on other
cylinder. The cylinder shall be provided with automatic switching mechanism for switching from
one cylinder online to standby cylinder.
c) One set of spare cylinders for carrier gas shall be kept in stores.
d) Carrier gas cylinder material of construction shall be suitable for maintaining stability of the
Carrier gas mixture for the specified time.
3) Vendor to note that the delivery of calibration / Span gas cylinders can be staggered in such way
that the composition and stability of gas do not deteriorate.
* - Vendor shall workout total number of zero, span gas & carrier cylinders required for each
analyser and furnish calculation of same during detail engineering.

Page 220 of 373
SAFETY MEASURES FOR STANDARD No.
alf-ar_Jek ENGINEERS
kVieg INDIA LIMITED ELECTRICAL INSTALLATIONS 7-51-0332 Rev. 2
r222.. ofnok: Unde, tnkir70)
DURING CONSTRUCTION Page 1 of 2
ELECTRICAL POWER IS THE MAINSTAY OF ANY CONSTRUCTION ACTIVITY. AT THE SAME TIME IT REQUIRES
UTMOST CARE IN IT'S UTILISATION TO AVOID ACCIDENTS DUE TO ELECTRICAL SHOCK, FIRE INCIDENTS OR
ELECTRIC SHORT CIRCUITS. EXPOSURE OF ELECTRICAL INSTALLATION TO ADVERSE ENVIRONMENTAL
CONDITIONS INCREASE THE RISK OF SUCH ACCIDENTS. HENCE IT IS NECESSARY TO TAKE EXTRA
PRECAUTIONS FOR SUCH INSTALLATIONS TO ENSURE SAFETY OF PERSONNEL AND EQUIPMENT. THIS
STANDARD ADDRESSES THE SAFETY MEASURES REQUIRED TO BE ADOPTED FOR THE ELECTRICAL
INSTALLATIONS BY ALL CONTRACTORS DURING CONSTRUCTION PHASE.
ALL ELECTRICAL CONNECTIONS/WORK FOR ELECTRICAL INSTALLATIONS SHALL BE CARRIED OUT AS PER
PROVISIONS OF THE LATEST REVISION OF THE FOLLOWING CODES AND STANDARDS IN ADDITION TO THE
REQUIREMENTS OF STATUTORY AUTHORITIES AND IE RULES:
OISD—STD-173 : FIRE PREVENTION AND PROTECTION SYSTEM FOR ELECTRICAL INSTALLATIONS.
SP-30 (BIS) : NATIONAL ELECTRIC CODE.
THE INSTALLATION SHALL HAVE APPROVAL FROM CONCERNED STATUTORY AUTHORITIES.
ALL ELECTRICAL CONNECTIONS SHALL BE DONE BY AN ELECTRICIAN WITH VALID LICENCE AND TO THE
SATISFACTION OF ENGINEER—IN—CHARGE.
ONE COMPETENT LICENCED ELECTRICIAN SHALL BE MADE AVAILABLE BY CONTRACTOR AT SITE ROUND
THE CLOCK TO ATTEND TO THE NORMAL/EMERGENCY JOBS.
ALL SWITCH BOARDS/WELDING MACHINES SHALL BE KEPT IN WELL VENTILATED & COVERED SHED.
THE SHED SHALL BE ELEVATED TO AVOID WATER LOGGING. NO FLAMMABLE MATERIALS SHALL BE
USED FOR CONSTRUCTING THE SHED. ALSO FLAMMABLE MATERIALS SHALL NOT BE STORED IN AND
AROUND ELECTRICAL EQUIPMENT/SWITCHBOARD. ADEQUATE CLEARANCES AND OPERATIONAL SPACE
SHALL BE PROVIDED AROUND THE EQUIPMENT.
FIRE EXTINGUISHERS AND INSULATING MATS SHALL BE PROVIDED IN ALL POWER DISTRIBUTION CENTERS.
TEMPORARY ELECTRICAL EQUIPMENT SHALL NOT BE EMPLOYED IN HAZARDOUS AREAS WITHOUT OBTAINING
SAFETY PERMIT.
PROPER HOUSE KEEPING SHALL BE DONE AROUND THE ELECTRICAL INSTALLATIONS.
ALL TEMPORARY INSTALLATIONS SHALL BE TESTED BEFORE ENERGISING, TO ENSURE PROPER

EARTHING, BONDING, SUITABILITY OF PROTECTION SYSTEM, ADEQUACY OF FEEDERS/CABLES ETC.
ALL WELDERS SHALL USE HAND GLOVES IRRESPECTIVE OF HOLDER VOLTAGE.

MULTILINGUAL (ENGLISH, HINDI AND LOCAL LANGUAGE) CAUTION BOARDS, SHOCK TREATMENT CHARTS
AND INSTRUCTION PLATE CONTAINING LOCATION OF ISOLATION POINT FOR INCOMING SUPPLY, NAME
& TELEPHONE NO. OF CONTACT PERSON IN EMERGENCY SHALL BE PROVIDED IN SUBSTATIONS AND
NEAR ALL DISTRIBUTION BOARDS/LOCAL PANELS.
OPERATION OF EARTH LEAKAGE DEVICE SHALL BE CHECKED REGULARLY BY TEMPORARILY CONNECTING

SERIES TEST LAMP (2 BULBS OF EQUAL RATING CONNECTED IN SERIES) BETWEEN PHASE AND EARTH.
12. THE FOLLOWING DESIGN FEATURES SHALL BE ENSURED FOR ALL ELECTRICAL INSTALLATIONS DURING
CONSTRUCTION PHASE.
12.1 EACH INSTALLATION SHALL HAVE A MAIN SWITCH WITH A PROTECTIVE DEVICE, INSTALLED IN AN
ENCLOSURE ADJACENT TO THE METERING POINT. THE OPERATING HEIGHT OF THE MAIN SWITCH
SHALL NOT EXCEED 1.5 M. THE MAIN SWITCH SHALL BE CONNECTED TO THE POINT OF SUPPLY
BY MEANS OF ARMOURED CABLE.
12.2 THE OUTGOING FEEDERS SHALL BE DOUBLE OR TRIPLE POLE SWITCHES WITH FUSES/MCBs. LOADS
IN A THREE PHASE CIRCUIT SHALL BE BALANCED AS FAR AS POSSIBLE AND LOAD ON NEUTRAL
SHOULD NOT EXCEED 20% OF LOAD IN THE PHASE.
2 02.03.12 REAFFIRMED & ISSUED );t46#14C UAP/JMS DM

1 26.09.06 REVISED & ISSUED AS STANDARAD BP RKS/UAP JMS VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Page 221 of 373
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
SAFETY MEASURES FOR STANDARD No.
Of=a-ael ENGINEERS
INDIA LIMITED ELECTRICAL INSTALLATIONS 7-51-0332 Rev. 2
015leg, n di o Undertoking;
DURING CONSTRUCTION Page 2 of 2
12.3 THE INSTALLATION SHALL BE ADEQUATELY PROTECTED AGAINST OVERLOAD, SHORT CIRCUIT AND EARTH
LEAKAGE BY THE USE OF SUITABLE PROTECTIVE DEVICES. FUSES WHEREVER USED SHALL BE HRC TYPE.
USE OF REWIRABLE FUSES SHALL BE STRICTLY PROHIBITED. THE EARTH LEAKAGE DEVICE SHALL HAVE
AN OPERATING CURRENT NOT EXCEEDING 30 mA.
12.4 ALL CONNECTIONS TO THE HANDTOOLS/WELDING RECEPTACLES SHALL BE TAKEN THROUGH PROPER
SWITCHES, SOCKETS AND PLUGS.
12.5 ALL SINGLE PHASE SOCKETS SHALL BE MINIMUM 3 PIN TYPE ONLY. ALL UNUSED SOCKETS SHALL BE
PROVIDED WITH SOCKET CAPS.
12.6 ONLY 3 CORE (P+N+E) OVERALL SHEATHED FLEXIBLE CABLES WITH MINIMUM CONDUCTOR SIZE OF
2
1.5 MM COPPER SHALL BE USED FOR ALL HAND TOOLS.
12.7 ONLY METALLIC DISTRIBUTION BOXES WITH DOUBLE EARTHING SHALL BE USED AT SITE. NO WOODEN
BOXES SHALL BE USED.
12.8 ALL POWER CABLES SHALL BE TERMINATED WITH COMPRESSION TYPE CABLE GLANDS.
LUGS SHALL BE USED FOR MULTISTRAND WIRES/CABLES.
12.9 CABLES SHALL BE FREE FROM ANY INSULATION DAMAGE.
12.10 CABLES SHALL BE LAID IN UNDERGROUND AT A MINIMUM DEPTH OF 750 MM, FOR LV & CONTROLS
AND 900MM FOR HV CABLES COVERED WITH SAND, BRICK AND SOIL FOR ENSURING MECHANICAL
PROTECTION. CABLES SHALL NOT BE LAID IN WATER LOGGED AREA AS FAR AS PRACTICABLE
CABLE ROUTE MARKERS SHALL BE PROVIDED AT EVERY 25 M OF BURIED TRENCH ROUTE. WHEN
LAID ABOVE GROUND, CABLES SHALL BE PROPERLY CLEATED OR SUPPORTED ON RIGID POLES OF
ATLEAST 2.1 M HIGH. MINIMUM HEAD CLEARANCE OF 6 METERS SHALL BE PROVIDED AT ROAD CROSSING.
12.11 UNDER GROUND CABLES SHALL NOT BE ALLOWED TO CROSS THE ROADS WITHOUT PIPE SLEEVE
12.12 ALL CABLE JOINTS SHALL BE DONE WITH PROPER JOINTING KIT. NO TAPED/TEMPORARY JOINTS SHALL
BE USED.
12.13 AN INDEPENDENT EARTHING FACILITY SHOULD PREFERABLY BE ESTABLISHED WITHIN THE TEMPORARY
INSTALLATION PREMISES. ALL APPLIANCES AND EQUIPMENT SHALL BE ADEQUATELY EARTHED. IN CASE
ARMOURED CABLES ARE USED, THE ARMOUR SHALL BE BONDED TO THE EARTHING SYSTEM.
12.14 ALL CABLES AND WIRE ROPE USED FOR EARTH CONNECTIONS SHALL BE TERMINATED THROUGH TINNED
COPPER LUGS.
12.15 IN CASE OF LOCAL EARTHING, EARTH ELECTRODES SHALL BE BURIED NEAR THE SUPPLY POINT AND
EARTH CONTINUITY WIRE SHALL BE CONNECTED TO LOCAL EARTH PLATE FOR FURTHER DISTRIBUTION
TO VARIOUS APPLIANCES. ALL INSULATED WIRES FOR EARTH CONNECTION SHALL HAVE INSULATION OF
GREEN COLOUR.
12.16 SEPARATE CORE SHALL BE PROVIDED FOR NEUTRAL. EARTH/STRUCTURES SHALL NOT BE USED AS A
NEUTRAL IN ANY CASE.
12.17 ON/OFF POSITION OF ALL SWITCHES SHALL BE CLEARLY DESIGNATED/PAINTED FOR EASY ISOLATION
IN EMERGENCY.
13. ALL INSULATIONS SHALL BE INSPECTED BY ENGINEER—IN—CHARGE ATLEAST ONCE IN A MONTH.
X--S('S/ 9Th .1
2 02.03.12 REAFFIRMED & ISSUED BP *- •-• C UAP/J MS DM
1 26.09.06 REVISED & ISSUED AS STANDARD BP RKS/UAP J MS VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
No. by by
Page 222 of 373 Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
Deviation List Document No.
For A406-079-YA-OD-2613
ANALYSERS (HYDROGEN) Rev. No. A
Page 1 of 1
Sl. Document No. Clause No. Deviation Technical Reason for Deviation
No.
Page 223 of 373
Vendor Seal & Signature
Template No. 5-0000-0001-T3 Rev. 1 Copyrights EIL – All rights reserved

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This document, drawing, and the design/ details given in this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower’s express
agreement that they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended
use.EIL-1641-507. A4-210 x 297.
No.
Date
Page 236 of 373

17.04.13
LIMITED
NEW DELHI
ENGINEERS INDIA
Revisions
ISSUED FOR BIDS
PLANT: TGTU
CLIENT : HPCL
UTILITY CONSUMPTION
AS
By
SB
Page 1 of 3
CHK
A406-079-YA-OD-2603
Specification No.
SB
APPR
A
Rev.
use.EIL-1641-507. A4-210 x 297.
3.
2.
1.
3.
2.
1.
S.No.
S.No.
Page 237 of 373

LIMITED
NEW DELHI
ENGINEERS INDIA
ITEM
ITEM
65‐AT‐5301
65‐AT‐4301
79‐AT‐3301
65‐AT‐5301
65‐AT‐4301
79‐AT‐3301
PLANT: TGTU
CLIENT : HPCL
TABLE I (A)
LP NITROGEN (IF REQUIRED)
MAXIMUM
MAXIMUM
INSTRUMENT AIR REQUIREMENT (IF REQUIRED)
Page 2 of 3
A406-079-YA-OD-2603
Specification No.
A
Rev.
use.EIL-1641-507. A4-210 x 297.
3.
2.
1.
S.No.
Page 238 of 373

3.
2.
1.
S.No.
LIMITED
NEW DELHI
ENGINEERS INDIA
ITEM
65‐AT‐5301
65‐AT‐4301
79‐AT‐3301
ITEM
PLANT: TGTU
CLIENT : HPCL
65‐AT‐5301
65‐AT‐4301
79‐AT‐3301
TABLE I (C)
TABLE I (B)
MAXIMUM
MAXIMUM
110 VAC UPS FOR ANALYSER CABINET IN FIELD
415VAC FOR LIGHTING OF CABINETS / HVAC / TRACING
Page 3 of 3
A406-079-YA-OD-2603
Specification No.
A
Rev.
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DOCUMENT No.
Logistic Support
H2 Analyser A406-079-YA-LSF-2603
Page 1 of 3
Logistics Support

Date Purpose
No by by by
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 248 of 373
DOCUMENT No.
Logistic Support
Page 2 of 3
Logistic Support Certificate
1. Vendor must furnish Certificate for providing necessary support services in favour of the
Owner (M/s HPCL-Vizag) committing themselves to provide logistic support and performance
guarantee to purchaser in the format furnished along with this portion of MR.
2. The Certificate must be signed with seal by the official signatory on the company’s letter
head.
Page 249 of 373
DOCUMENT No.
Logistic Support
Page 3 of 3
Certificate for logistics support
(To be signed by Vendor's corporate level signatory on company's letterhead)
I, on behalf of M/s confirm that the Analysers Model No.

__________________for _______________________ measurement quoted by
M/s for HPCL TGTU Project at Vizag shall continue to be
supported by us. The quoted item shall not be withdrawn from Indian market as a matter of our
corporate policy.
I further confirm that in case of placement of order by HPCL on M/s , we shall
continue to support M/s HPCL in providing back-up engineering, maintenance support and
spare part to HPCL for a period of 10 years from the date of placement of order.
SIGNATURE WITH SEAL

AUTHORIZED, SENIOR MANAGEMENT LEVEL
Page 250 of 373
PROVEN TRACK RECORD FORMAT
NAME OF THE VENDOR :
SL. NO. DESCRIPTION AS OFFERED ANALYSER ANALYSER ANALYSER ANALYSER AS

Page 251 of 373
FOR THIS AS AS AS INSTALLED @

PROJECT INSTALLED @ INSTALLED @ INSTALLED @ SITE 4
SITE 1 SITE 2 SITE 3
1
NAME OF PLANT
2 NAME, ADDRESS, FAX NO., e-MAIL & TELEPHONE
NO. OF CONTACT PERSON IN THE PLANT.
3 NAME, ADDRESS, FAX NO., e-MAIL OF
CONSULTANT
4
MONTH & YEAR OF ANALYSER SUPPLY
5
MONTH & YEAR OF ANALYSER COMMISSIONING
6
ANY MAJOR BREAKDOWNS TILL DATE
7
IF YES, CAUSE OF BREAK-DOWN
8
8.1 Analyser Details:
MODEL NOS.
8.2 ANALYSER AREA CLASSIFICATION
8.3 ANALYSER DETAILS

Operating Pressure and temperature
8.4 SCOPE OF VENDOR’S RESPONSIBILITY:
a) Design
b) Supply
c) Testing and integration
d) Warranty
e) SAT
REQUISITION NO : A406-079-YA-MR-2603 PROJECT: HPCL, TGTU
Specification: A406-079-YA-PTR-2603
PROVEN TRACK RECORD FORMAT
NAME OF THE VENDOR :
SL. NO. DESCRIPTION AS OFFERED ANALYSER ANALYSER ANALYSER ANALYSER AS

Page 252 of 373
FOR THIS AS AS AS INSTALLED @

PROJECT INSTALLED @ INSTALLED @ INSTALLED @ SITE 4
SITE 1 SITE 2 SITE 3
8.5 ACTIVITIES CARRIED OUT BY VENDOR (INDICATE

LOCATION)
a) Manufacture of analyser
b) Design of Sample Handling system
c) Engineering
d) Manufacturing of sample Handling system
e) Calibration of Analyser
f) Integration of Analyser with Sample
Handling System
8.6 SALIENT FEATURES OF OFFERED ANALYSER

OVER EARLIER INSTALLED ANALYSERS
VENDOR’S STAMP AND SIGNATURE
REQUISITION NO : A406-079-YA-MR-2603 PROJECT: HPCL, TGTU
Specification: A406-079-YA-PTR-2603
STANDARD SPECIFICATION STANDARD SPECIFICATION No.
1510-zre?#a ENGINEERS FOR PROCESS STREAM 6-52-0035 Rev. 4
sitri Offleg VW INDIA LIMITED ANALYSER
‘A Go. of Mdia Undeavong,
Page 1 of 22
r k(*) i h * Frm
q t c
STANDARD SPECIFICATION FOR

PROCESS STREAM ANALYSER
40;&--fi CAr■-•)
4 30.03.12 Revised and Reissued as Standard Specification CS RG RP/JMS DM
3 27.09.06 Revised and Reissued as Standard Specification RP TGM PM VC
2 01.11.96 Revised and Reissued as Standard Specification RK BRS RB AS
1 09.06.89 Issued as Standard Specification PVS TSN AKV AK

Standards Standards
Rev. Prepared Committee Bureau
Checked
No by by
Approved by
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
Page 253 of 373

sartei ENGINEERS
STANDARD SPECIFICATION
FOR PROCESS STREAM
STANDARD SPECIFICATION No.
/gar Meg INDIA LIMITED 6-52-0035 Rev. 4

ANALYSER Page 2 of 22
Abbreviations:
AARH Arithmetic Average Roughness Height
CRCA Cold Rolled Cold Annealed
DC Direct Current
DCS Distributed Control System
HART Highway Addressable Remote Transducer
HVAC Heating Ventilation and Air conditioning
LCD Liquid Crystal Display
LED Light Emitting Diodes
MAWP Maximum Allowable Working Pressure
MOC Material of Construction
NPT National Pipe Thread
PTFE Poly Tetra Fluoro Ethylene
RAM Random Access Memory
SPDT Single Pole Double Throw
SS Stainless Steel
Instrumentation Standards Committee
Convener: Ms. R. Priyamvada

Members: Mr. P.K.Sahay
Mr. S. Bhowal
Mr. M.Nandi
Ms.R. Shanthi Devi
Mr. M.P. Jain (Proj.)
Page 254 of 373

012-43€5,4a ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
Igzir fair& NW INDIA LIMITED FOR PROCESS STREAM 6-52-0035 Rev. 4

CONTENTS
1.0 GENERAL 4
2.0 DESIGN AND CONSTRUCTION 9
3.0 NAMEPLATE 21
4.0 INSPECTION AND TESTING 22
5.0 SHIPPING 22
6.0 REJECTION 22
Page 255 of 373

StilfteTS ENGINEERS
LII toRes ley INDIA LIMITED FOR PROCESS STREAM 6-52-0035 Rev. 4
1.0 GENERAL
1.1 Scope
1.1.1 This specification, together with the data sheets, covers the requirements for the complete
design, materials, fabrication, nameplate marking, inspection, testing and shipment of
process stream analysers and accessories. This standard specification shall be applicable for
all types of process stream analysers irrespective of whether separate specifications are
included or not included in this specification.
1.1.2 The related standards referred to herein and mentioned below shall be of the latest editions
prior to the date of the purchaser's enquiry:
ASME American Society of Mechanical Engineers.
1.20.1 Pipe Threads, General Purpose (Inch).
16.5 Pipe Flanges and Flanged Fittings.
16.20 Metallic Gaskets for Pipe Flanges- Ring Joint, Spiral
wound and Jacketed.
B 31.3 Process Piping
API American Petroleum Institute
RP 551 Process Measurement Instrumentation
RP 552 Transmission Systems
RP 554 Process Control Systems
RP 555 Process Analyzers
ASTM American Society for Testing and Materials
G93 Standard Practice for cleaning methods and cleanliness
levels for material and equipment used in oxygen-enriched
environments.
EN European Standards.
EN 10204 Inspection Documents for Metallic Products.
IS/IEC Indian Standards/ International Electro Technical Commission.
IS/IEC 60079 Electrical Apparatus for Explosives Gas Atmosphere.
IS/IEC 60529 Degree of Protection Provided by Enclosures. (IP Code)
IEC 61000-4 Electromagnetic Compatibility for Industrial Process
Measurement and Control Equipment.
IEC-61285 Industrial Process Control - Safety of Analyzer Houses
NFPA 496 National Fire Protection Associations
1.1.3 In the event of any conflict between this standard specification, job specification/data
sheets, statutory regulations, related standards, codes etc., the following order of priority
shall govern.
Statutory Regulations
Job Specification / Data Sheets
Standard Specification
Codes and Standards
1.1.4 In addition to meeting the purchaser's specification in totality, vendor's extent of
responsibility shall include the following:
a) Purchaser's data sheet indicates the type of analyser and the minimum sample
conditioning system requirements. Vendor shall be responsible for the selection of
proper analyser and design of the sample conditioning system to analyse the
component/components of interest within the stated performance requirements.
Format No. 8-00.0001-F1 Rev. 0 Copyright EIL — All rights reserved
Page 256 of 373

ENGINEERS
laOreg INDIA LIMITED FOR PROCESS STREAM 6-52-0035 Rev. 4
IA Gov/ al India undeplal■ngd
Carry out complete application engineering of the process gas analyser so as to

achieve the desired analysis within stated performance requirements.
Provide all hardware and software, as necessary, to meet the functional

requirements specified in the purchaser's specifications.
Provide complete data to purchaser for successfully proving serial communication

with purchaser's host system i.e. DCS when specified in the job specification.
Purchaser's data sheets indicate the minimum requirements of material of

construction for the analyser and its sample conditioning system. Alternate superior
material of construction shall also be acceptable provided vendor assumes complete
responsibility of the selected material for any part of the analyser system so as to be
compatible with the process stream and its operating conditions and surrounding
atmosphere as specified in purchaser's data sheet.
1.2 Bids
1.2.1 Vendor's quotation shall be strictly as per the bidding instruction to vendor attached with
the material requisition.
1.2.2 Whenever a detailed technical offer is required, vendor's quotation shall include the
following:
Compliance to the specifications.
Whenever the requirement of detailed specification sheet for Process Stream

analyser is specifically indicated, a detailed specification sheet for each analyser,
which shall provide information regarding type, materials of construction,
performance specification and accessories of analyser The material specification
and units of measurement for various parts in vendor's specification sheets shall be
to the same standards as those indicated in purchaser's data sheets.
A detailed drawing showing various components of sample conditioning system and

their piping/tubing hook-up arrangement including sample return, vent, utilities
connection and requirement of heat tracing (i.e electrical or steam tracing), as
necessary.
Sample transportation time calculations for the specified distance between sample
point and analyser indicating sample flow rate and the recommended size of the
sampling tube.
e) Calibration gas cylinder calculations considering six months of continuous

operation with once a week calibration. The calculation sheet shall indicate the rate
of gas consumption and specification of gases including composition, concentration,
accuracy and shelf life of calibration blend.
References gas cylinder calculations considering six months of continuous

operation. The calculation sheet shall indicate the rate of gas consumption and
specifications of the reference gas.
Proven references for each offered model of analyser inline with clause 1.2.3 of this
specification.
A copy of approval for intrinsically safe/flameproof enclosure, whenever specified,

from local statutory authority, as applicable, such as Petroleum and Explosives
Page 257 of 373

IWO ENGINEERS
FOR PROCESS STREAM
4Rn- tOtPreg INDIA LIMITED 6-52-0035 Rev. 4
iA GoN InON UnOofte.o91
ANALYSER Pane 6 of 22
Safety Organisation (PESO)/Chief Controller of Explosives (CCE), Nagpur or

Director general of Mines Safety (DGMS) in India, along with:
Test certificate from recognised house like Central Institute of Mining &
Fuel Research (CIMFR)/ Electronics Regional Testing Laboratory (ERTL)
etc. for flameproof enclosure and/or intrinsic Safety, as specified in the
datasheet, as per relevant Indian Standard for all Indian manufactured
equipments.
Certificate of conformity from agencies like Laboratorie Central Des

Industries Electriques (LCIE), British Approval Service for Electrical
Equipment in Flammable Atmospheres (Baseefa), Factory
Mutual (FM), Physikalisch-Technische Bundesanstalt (PTB), Canadian
Standards Association (CSA), Underwriters Laboratories (UL) etc. for
compliance to ATEX directives or other equivalent standards for all
equipments manufactured outside India
Utility requirements and their consumption i.e. instrument air, cooling water, steam
etc. along with their process conditions like flow, pressure and temperature.
.i) Power consumption for each analyser and its accessories for 110 V / 240 V AC
UPS, & 415 V / 240 V AC non-UPS.
k) HVAC requirements i.e. heat load, humidity particulate/chemical filtration etc
1) Deviations on technical requirements shall not be entertained. In case vendor has

any valid technical reason, they must include a list of deviations tag number wise,
summing up all the deviations from the purchaser's data sheets and other technical
specifications along with the technical reasons for each of these deviations.
m) Catalogues giving detailed technical specifications, model decoding details and

other related information for each type of analyser and accessories covered in the
bid.
1.2.3 All items, as offered, shall be field proven and should have completed trouble free
satisfactory operations individually for a period of minimum 4000 hours on the bid due date
in the similar application with the process conditions similar to those as specified in the
purchaser's data sheets. Items with prototype design or items not meeting provenness criteria
specified above shall not be offered.
1.2.4 Whenever specified, vendor must furnish certified values of failure rates, probability of
failure on demand and test interval for the safety integrity level analysis
1.2.5 All documentation submitted by the vendor including their quotation, catalogues, drawings,
installation, operation and maintenance manuals, etc shall be in English language only.
1.2.6 Vendor shall also quote for the following: -
a) Complete calibration kit consisting of calibration gas cylinders with material of

Construction SS or Al (for carrier (continuous) gas cylinders, CS is also acceptable),
pressure regulators, gauges, cylinder gas piping manifolds and driers, (as required)
etc. as a minimum, for each analyser. In case of dual range analyser, separate
calibration standards shall be provided for each range. For the purpose of
calculating requirement of zero and span calibration samples/gases, consider
calibration time of 30 minutes every week for each analyser for a period of six (6)
months of continuous operation.
Page 258 of 373

ra ENGINEERS
0Na-el A STANDARD SPECIFICATION
FOR PROCESS STREAM
STANDARD SPECIFICATION No.
6-52-0035 Rev. 4
11g7IntOleg. W INDIA LIMITED
Complete reference gas kit consisting of Reference gas cylinders, pressure

regulators, gauges, cylinder gas piping manifold and drier etc as a minimum
separately for each analyser as applicable. The reference gas cylinders shall be
supplied for a period of six (6) months of continuous operation.
Consumable spares for the duration of six months with list of items as per vendor
recommendations for each analyser system, unless otherwise specified in job
specification.
d) Start up and commissioning spare parts for each analyser/analyser system as per
vendor recommendations. However this list of spare parts must include 5% or
minimum one of each type of following spare parts:
Solenoid valve
Pressure regulator
Filters
Temperature controller
IR/UV Source (lamp)
Peristaltic pump
Set of fuses
Set of o-rings
Tubing and tube fittings (sizes smaller than 6 mm or 1/4").
Additional spare parts, if required, during start-up and commissioning, even though
not listed in the list of start-up and commissioning spares, shall be supplied by the
vendor without any implication.
e) Any special instrument or tool needed for testing, calibration and maintenance of
the analyser such as spanner set (for tubes smaller than 6 mm or 1/4"), non-magnetic
tools, bubble rotameter etc.
0 Training at vendor works and at site as specified in job specifications.
g) Two years operational and maintenance spares for each analyser and its accessories
as per vendor recommendations, which shall include spare parts like electronic
modules, temperature controller, power supply module, flow meter, solenoid valve,
pressure regulator, local indicator, tubes, fan assembly, sample cell, detector
assembly, UV/IR source/lamps, set of o-rings, set of fuses etc.
1.3 Drawing and Data
1.3.1 Detailed drawing, data, catalogues and manuals required from the vendor are indicated by
the purchaser in the vendor data requirement sheets attached with the enquiry. The required
number of prints and soft copies shall be despatched to the address mentioned, adhering to
the time limits indicated.
1.3.2 Final documentation consisting of design data, installation, operation and maintenance
manual etc., submitted by the vendor after placement of purchase order shall include the
following, as a minimum:
Specification sheet for each analyser and its accessories.
Certified drawings for each analyser and its accessories, tag number wise, which
shall provide the following information:
i) Overall dimensions in millimetres.
Page 259 of 373

WI-at ENGINEERS
sig7 Wag VIP INDIA LIMITED FOR PROCESS STREAM 6-52-0035 Rev. 4
IA Goo of Ind. uncitoloka»
Sampling system details identifying each component with make and model
number, process connection, utility connection, calibration sample/gas
connection, heat tracing requirements, sample vent and fast loop details etc.
The flow, pressure and temperature at interface and other appropriate
location must be shown in the sampling system drawing.
Detailed interconnection drawing of each analyser identifying each

component with terminal number, cable type, cable size and cable entry
details. The interface details shall be clearly identified in the drawing.
Grounding details.
Power supply distribution details.
Programming/configuration data for each analyser, as applicable.
Serial interface specification including its configurational data (addresses) for host
communication.
e) Power consumptions and utility requirements.
1) Calibration curves and calibration data for each analyser.
Zero and span calibration gas specification including composition, shelf life time
and accuracy.
Copy of type test certificates.
i) Copy of the test certificates of all the tests indicated in clause 4.0 of this
specification.
I) Installation procedure for each analyser and their accessories.
k) Calibration and maintenance procedures including replacement of its parts/internals

wherever applicable.
1.4 Definitions
1.4.1 The following definitions shall apply for analysers and their accessories:
Transportation time
Transportation time is the time interval between a step change in the process fluid
composition in the process line and the initial analyser response (excluding analyser
response time).
Response Time
The time interval between the initial response of the analyser and the time required
for the analyser output to reach a value of 90% of the final output value for a step
change in sample quality.
Time Constant
The analyser response to reach a value of 63% of the final output value for a step
change in sample quality is called the analyser time constant.
Repeatability
Repeatability of a measurement is the band of values within which an analyser
repeats its measurement when the same sample is applied to it. The short termed
repeatability is generally determined by multiple readings of a sample during
Page 260 of 373

ItitPzre? ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
INDIA LIMITED FOR PROCESS STREAM 6-52-0035 Rev. 4
S'i1619:eq, iA CAA ol incha
calibration and is usually true random error over short period of time if external
influences like pressure and temperature etc remain constant.
It is also defined as the difference between two successive analyser results that
would be exceeded in the long run in only one (1) case in twenty (20) when a single
analyser system is operated on a flowing sample of uniform quality.
Sensitivity
The sensitivity of an analyser is a measure of an analyser's ability to detect a least
change in concentration of a measured component that is not masked by the
background noise.
Accuracy
Accuracy of a measurement is the measure of how close the measured value is to
the true value of the sample. For all type of analysers, accuracy is primarily a
function of the accuracy of the standards used for calibration.
Analyser Rack
An open analyser mounting structure with/without canopy used for mounting
analysers, sample handling system and their accessories individually or together in
combination.
Analyser Cabinet
Small housing in which analysers are installed individually or grouped together.
Maintenance is performed from outside the cabinet with door (s) open.
2.0 DESIGN AND CONSTRUCTION
2.1 Analyser Requirements
2.1.1 The type of analyser and its measuring principle is specified in the purchaser's data sheet.
Accessories and equipments as required to make online analysis complete are also specified
in the data sheet. In general, the scope shall include the following:
Sample probe and sampling system (primary or secondary), as applicable.
Analyser complete with all hardware and software consisting of detector, transmitter
and associated equipments.
Fast loop and Sample return system, as applicable
Calibration and maintenance equipment.
e) Gas cylinders for zero and span calibration.
Unless otherwise specified the scope shall also include supply of all interconnecting tubing,
piping, fittings, heat tracing equipment etc., excluding sample return piping from analyser
battery limit to sample return header.
In-situ analysers when specified may not include items 2.1.1(a) and (c)
2.1.2 Analysers and its related equipments directly connected to process line and In-situ analysers
shall be capable of withstanding line pressure and temperature conditions specified in the
purchaser's data sheet.
2.1.3 The analyser design and design of sample handling system shall be such that components or
any sub-assembly that requires removal shall be possible without any need to disassemble
Page 261 of 373

ar&lei ENGINEERS
127 thare-
A INDIA LIMITED FOR PROCESS STREAM 6-52-0035 Rev. 4
IA GOA ot inch uneenaking)
ANALYSER Pane 10 of 22
any other component. Such components shall include items like stream selector valves,
filters, pressure regulators, flow-indicator, detector, electronic modules etc.
2.1.4 Analyser shall be microprocessor based with state-of-the-art technology and shall be capable
of being configured from analyser front panel locally using built-in keyboard. When
specified, it shall also be possible to configure the analyser from remote through a separate
terminal.
2.1.5 The configuration related data of the analyser including set range shall be stored in a non-
volatile memory such that this data remains unaffected by power fluctuations or power off
condition. In case vendor's standard product stores configuration data in battery backed
RAM, analyser shall have facility to provide battery drain alarm as diagnostic maintenance
message.
2.1.6 The span of the analyser shall be field adjustable from the analyser front without opening the
analyser enclosure. In case, separate device is required to make such a change, the same
shall be included, by vendor in their scope of supply.
2.1.7 Analyser shall run diagnostic subroutines on continuous basis and shall be able to provide
diagnostic alarms related to analyser optics, detector and electronics, as and when any
failure/malfunction is detected.
2.1.8 Analyser shall have an integral output meter with digital readout in engineering units.
2.1.9 All interconnecting wiring shall be colour coded/numbered and terminal blocks be clearly
identified.
2.1.10 The analyser shall be capable of providing the following outputs:
Isolated 4-20 mA DC current output for each analysed component. Smart or field
bus output shall be provided when specifically indicated in the purchaser's data
sheet.
RS 485 / TCP/IP serial output with MODBUS (RTU) protocol, whenever serial
output is specifically indicated in the purchaser's data sheet. The serial output signal
shall contain analyser data of component of interest and diagnostic alarms, as a
minimum.
c) SPDT contact outputs for various following diagnostic alarms, whenever specified,
shall be provided:
High or low set point alarm as measurement

Analyser failure
Low sample flow
Temperature control failure
v) Purge failure
Any other alarm contact, either specifically indicated in purchaser's data sheet or
available as standard with the analyser, shall also be provided.
Unless specified otherwise, all contacts shall be normally closed type (contact open
in alarm) and shall be rated for 110V AC, 0.5 Amperes.
Whenever serial interface/ HART option is specified in the purchaser data sheet, the
above alarms shall be made available through serial/ HART output as a minimum.
Page 262 of 373

OWE? ENONEERS
FOR PROCESS STREAM 6-52-0035 Rev. 4
INDIA LIMITED
5e-izilooreg, A Go4 Indo undertammg■
2.1.11 The design of electronic components of analyser system shall be in compliance with the
electromagnetic compatibility requirements as per IEC 61000-4 and shall be immune to RR
and EMI radiation.
2.1.12 Material of Construction
2.1.12.1 Unless otherwise specified, the material of construction of all components wetted by the
sample shall be SS316, as a minimum. Vendor must ensure the compatibility of material of
each component with the process fluid.
2.1.12.2 Material of all soft parts like diaphragms and o-rings shall be of PTFE. Other vendor
standard materials can also be acceptable provided these are compatible with the specified
process condition.
2.1.12.3 The material of construction of all non-wetted parts shall be as per manufacturer's standard.
However non-metallic materials for casings, enclosures and instrument covers shall be
avoided.
2.1.13 Power Supply
2.1.13.1 Unless indicated otherwise, the analyser including the sample handling system shall operate
at 110y / 240 AC, 50Hz power supply.
2.1.13.2 The analyser performance shall be within the specified limits when the supply voltage varies
by + 10% of specified value and supply frequency varies by ±3 Hz of specified value.
2.1.13.3 Electrical tracing when specified, shall operate at 240V, 50 Hz supply. 240V, 50Hz power
supply shall also be used for analyser cabinet/panel lighting and air conditioning unit, when
specified.
The maintenance temperature (It is minimum temperature that is required to be maintained

in the line to avoid congeal or condensation inside the tube/line) shall be as follows:
The maintenance temperature shall be 10°C higher than the highest expected pour
point for congealing service or the operating temperature, whichever is minimum.
The maintenance temperature shall be minimum 5°C higher than the highest
expected condensation temperature for the condensing service or the operating
temperature, whichever is minimum.
2.1.14 End Connection
2.1.14.1 Unless otherwise mentioned, end connection details shall be as below:
Threaded end connections shall be to NPT as per ASME B 1.20.1.

Flanged end connections shall be as per ASME B 16.5.
Grooves of ring type joint flanges shall be octagonal as per ASME B16.20.
Flanged face finish shall be as per ANSI B 16.5. The face finish shall be as
follows:
125 AARH : 125 to 250 microinch AARH
63 AARH : 32 to 63 microinch AARH
2.1.14.2 Gaskets, bolts and nuts shall be suitable for the service conditions indicated.
2.1.14.3 End connection of sizes 6 mm or below shall be suitably protected against damage.
Page 263 of 373

SitiaZle;Mth ENGINEERS
ligaiajlegler INDIA LIMITED FOR PROCESS STREAM 6-52-0035 Rev. 4
coxwi.eo
, unanrmgi ANALYSER Page 12 of 22
2.1.14.4 All end connections shall be clearly identified by attaching labels or stainless steel plate of
suitable size.
2.1.15 Enclosure Type
2.1.15.1 Analyser enclosures and related accessories shall be suitable for the electrical area
classification indicated in purchaser's data sheets. Unless otherwise specified, the enclosures
shall comply to the following standards:
Weatherproof housing IP-65 to IS/IEC-60529
Flameproof housing Flameproof/Ex (d) as per IS/IEC-60079
Purged Enclosure NFPA 496
Flameproof and purged equipment shall also be made weatherproof.
2.1.15.2 In addition to meeting weatherproof requirements specified in clause 2.1.15.1 of this

specification, intrinsically safe analysers shall meet the requirements specified in IS/IEC
60079 and shall be certified for the area classification specified in the purchaser's data sheet.
2.1.15.3 Analyser where air/nitrogen purge is provided, purge shall be as per NFPA 496 Type X.
Analyser power shall cut off in case of purge failure. Purge failure alarm shall be provided
for purchaser use.
2.1.15.4 Separate cable entries shall be available in the analyser/enclosure for power and signal cable.
Unless otherwise specified, following shall apply:
Cable entry and terminal size for power cable shall be informed during detail
engineering. Explosion proof 3 way junction box with cable glands shall be
supplied, if required.
Cable entry for Serial cable/signal cables (Signal output) shall be 1/2" NPT (F).
c) Cable entry for multi-pair signal cables (Multiple outputs) shall be I' " NPT (F).
2.1.15.5 All enclosure entries including sample, utilities, cables etc. shall be clearly identified by
attaching label or stainless steel plate of suitable size.
2.2 Sample Handling System
2.2.1 The sample handling system shall consist of primary sample conditioning near sample take
off point, sample transportation line, secondary sample conditioning near the analyser,
sample return, sample/analyser vent and sample drain/recovering system, as applicable.
The primary sample-conditioning unit shall be a fabricated assembly and shall be mounted
on a stainless steel plate suitable for surface mounting.
Secondary sample conditioning shall also be a fabricated assembly and shall be either
mounted on a stainless steel plate or within an enclosed cabinet/box with a viewing window.
In case the temperature is required to be maintained at primary and secondary sample
conditioning, both these conditioning units shall be installed in the heated box/cabinet.
2.2.2 Process Stream sampling shall be continuous and analyser shall be located as near as
possible to the sample take-off point. Where the analyser is located away from the sample
take-off point, vendor shall design the sample fast loop (bypass loop) as part of sampling
system. Design shall ensure that the sample drawn is true representative of the process
stream to be analysed. Typically, locations for sample take-off & sample return connections
are suction side of Pumps or Compressors or Control Valve and discharge side respectively.
Page 264 of 373

1510-zrei irr41 ENGINEERS
INDIA LIMITED FOR PROCESS STREAM 6 - 52 - 0035 Rev. 4
IMeg, undenakogp
(A Co. ol Inda
2.2.3 In general, sampling systems shall be designed and constructed in accordance with API-RP-
555. The design of sample handling system shall consider the following factors, as a
minimum:
The pressure-temperature conditions required for the analyser.
Interfering components in the process sample.
Normal and abnormal sample compositions.
Sample return pressure-temperature conditions.
e) Fouling sample conditions e.g. polymer formation or presence of solids etc.
Transportation time requirements.
g) Utilities available and their process conditions.
2.2.4 Unless otherwise specified, material of all components wetted by sample shall be suitable for
the process fluid and sample process conditions specified in the purchaser's data sheet. The
material of construction for all wetted parts shall be, 316 SS, as a minimum. For applications
where SS cannot be used due to process stream & conditions, other materials such as Monel,
Hastelloy or Incoloy can be considered. For materials, other than specified in this clause, if
used, must have provenness and approval of the principal/ OEM as well as from Purchaser.
2.2.5 Sampling system shall include all elements as necessitated by the process conditions
indicated in the purchaser's data sheets, to make the sample suitable for the analysis. This
shall include but not limited to filters (coarse and fine), pressure regulators, relief valves,
flow indicators, flow controllers, temperature indicators, scrubbers, heaters, coolers, dryers,
sample pumps, aspirators etc.
Each sampling system element shall be capable of being removed without disassembling the
entire system.
2.2.6 Sample probe shall be provided by the vendor to obtain representative sample from the line.
The sample probe shall be inserted in the pipe through a ball valve, which shall be part of
vendor's scope of supply. Minimum Body wall thickness for ball valves shall not be less
than specified ASME B 16.34.The probe design shall ensure the following:
On-line removal and insertion of the probe with non-fly-off design. Whenever
specifically indicated in the purchaser data sheet, the on-line probe removal facility
shall also include depressurising / pressure relieving mechanism.
Unless otherwise specified, end connection for installation in the line shall be 11/4"
flanged with type and rating as specified in purchaser's data sheet. The line isolation
valve shall also be of the same size and rating as probe end connection.
The probe diameter shall be such that it can be easily inserted or removed through
the line isolation valve when in fully open condition.
The length of the probe shall be selected considering its insertion upto the middle of
the pipe. For the purpose of calculating probe length, consider nozzle length as 200
mm.
2.2.7 Sampling system shall include a sample block valve on all process sample line.
The block valve shall be provided meeting the following requirements:
Page 265 of 373

NIP-rfie? ENGINEERS
51g-a id9M, INDIA LIMITED
The block valve shall be located immediately after the sample probe.
Where purchaser's data sheet does not indicate the requirement of sample probe,
the block valve shall be provided in the sample line as a part of primary sample
conditioning unit.
The size of the sample block valve shall be as per the sample line size while the
rating shall be as specified in the purchaser's data sheet.
For Each system it shall be decided whether piping or tubing shall be used for
sample transport lines. Tubing shall be used unless:
- The required sample volumes to be circulated cannot be accommodated

- Lag times become too long due to sample volumes.
Piping materials shall be as per piping class specified in the data sheet.
e) The design pressure of components and tubing shall be in accordance with ASME B
31.3. Relief Valves shall be installed to protect those components installed in a
system which have a limited pressure rating. The relief valve shall be connected to a
vent or a drainage system, as required.
0 Variable Area Flow Meters, in Sample Conditioning System shall have a metal
metering tube.
2.2.8 The size of the sample tubing shall be decided by the vendor considering:
The distance between sample take off and analyser specified in purchaser's data
sheet.
The specified sample transportation time.
Where no transportation time is specified in the purchaser's data sheets, vendor

shall consider the sample transportation time as 60 seconds.
c) Pressure at the sample take-off point.
2.2.9 Where sample is required to be transported in hot condition, sample shall be drawn using
pre-fabricated heated tubes. The heated medium shall be electric power unless otherwise
specified in purchaser's data sheet.
Heating shall be controlled such that the sample temperature is maintained typically around
+20°C above the sample dew point.
2.2.10 When fast loop is specified or recommended by vendor, vendor shall provide flow meter for
sample bypass flow. Sample return line to process shall be provided with isolation valve and
check valve. Vendor shall ensure that return pressure of the sample shall be higher than the
pressure of the process return point specified in purchaser's data sheet.
Samples should be returned back to process stream as specified in data sheet. For those
applications where other arrangements are required, the samples should be directed to:
Flare system: - As the flare system operates at a varying pressure, the maximum
operating pressure shall be considered for design of the sampling system.
Recovery system: - HC liquid, which cannot be returned directly to the process,

shall be discharged either to the HC recovery system or drained to Closed Blow
down as per the philosophy specified in the data sheet. While designing the same, it
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL - All rights reserved
Page 266 of 373

lareeT ENGINEERS
271 Miag INDIA LIMITED
shall be ensured that the total quantity of liquid disposed is limited to the minimum
necessary for adequate sampling. Suitable arrangement with dual pump
configuration shall be considered for the recovery system to prevent overflow from
the system.
2.2.11 Sampling system shall include provision for connecting calibration sample/gases in auto or
in manual configuration as specified in purchaser's data sheet.
Whenever auto-calibration requirement is specified in the purchaser's data sheet, it shall be
possible to initiate auto calibration cycle at preset time interval defined by user either
manually via the analyser keyboard or remotely through an external contact.
The sample handling system shall be designed to include all hardware and/or software to
meet this requirement. The analysed component concentration output shall remain at the last
good measured value during auto calibration cycle
2.2.12 In case of multi stream analyser, the sample handling system shall utilize double block and
bleed configuration to prevent cross-contamination of samples. All stream selection valves
shall have bubble tight shut off. The block valves shall be fail-close type while bleed valve
shall be fail-open type.
2.2.13 Filters shall always be provided in dual configuration. It shall be possible to replace the filter
without upsetting the operation of the analyser.
2.2.14 The sampling system shall be designed to consider plugging of sample lines under following
conditions, if applicable:
Failure of heat tracing

Failure of sample pump
Failure of instrument air, particularly when sample dilution technique is adopted for
sample.
Upset or start-up conditions, if excessive solids/solid particles are expected under
these operating conditions.
2.2.15 Unless specified otherwise, sample lines used for carrying samples, for more than one
analyser, shall be-provided with sample pumps in dual configuration. It shall be possible to
remove or insert the pump without upsetting the sampling system. In case common sample
handling system is asked for in the purchaser data sheet for more than one analyser, isolation
for maintenance each analyser shall be provided.
2.2.16 A suitable restriction orifice shall be provided in each sample line to limit the sample flow
exceeding thrice the normal flow in the event of tube rupture or opening of tube down the
line.
2.2.17 Analyser rack and cabinet
The analyser shall be supplied in pre-assembled, pre-tubed and pre-wired condition

complete with sample handling system. The primary sample-conditioning unit i.e.
conditioning at sample tap-off point, shall be supplied separately.
When open rack mounted installation is specified in purchaser's data sheet, the
analyser and sample handling system shall be supplied installed in an open rack
with canopy to protect the analyser from direct sunlight and rain. The open rack
shall be fabricated using channels/pipes of suitable size. The material of
construction shall be stainless steel. The canopy shall also be fabricated out of SS
plate of 1.2 mm thick.
Page 267 of 373

a&lei
pw ,
ENCJNEERS
Itg-fa INDIA LIMITED FOR PROCESS STREAM 6-52-0035 Rev. 4
IA GOO of Md.% L. odertafmol
c) Whenever closed cubical mounted installation is specifically indicated in the

purchaser's data sheets, analyser and sample handling system shall be supplied pre-
installed in freestanding closed analyser cabinet. The analyser cabinet shall be
suitable for outdoor installation and shall be provided with a key lock.
Cabinet shall be fabricated out of 2.0mm SS sheet reinforced with angles of suitable
sizes. Fittings and hinges shall be of stainless steel. Anchor bolts required for
installation of cabinet shall also be supplied by vendor.
A power isolation switch with suitable circuit breaker or fuse shall be provided for
the incoming power supply.
All items including analyser installed within the cabinet shall be suitable for the
maximum possible temperature likely to be attained within the cabinet (i.e. at
maximum ambient temperature with all items fully powered-on within the cabinet)
and area classification specified in the purchaser's data sheet.
Heating/cooling of analyser cabinet shall be provided either when purchaser's data

sheet specifies the requirement of heating and/or cooling or recommended by the
analyser manufacturer or found necessary by the manufacturer to meet following
requirements:
i) The temperature induced measurement error exceeds ± 1% of full scale in

the worst temperature conditions.
The maximum allowable ambient temperature condition of any component

within the cabinet exceeds its limits.
Whenever cooling is specified or found necessary, Sub - systems or system

components which are installed outdoor shall be suitable to continuously
operate at ambient temperature and humidity specified under ambient
conditions. The heat generation effect of current carrying for the electronic
modules shall also be considered. For this purpose the system shall be rated for
minimum 5 degC more than the maximum ambient temperature specified. In
case the system is not suitable for the above conditions, necessary cooling
arrangement shall be provided.
Vendor may select one of the following cooling methodologies, unless specifically
indicated otherwise:
Cabinet mounted air conditioner certified for the specified area

classification.
Vortex cooler with compressed air system and air dryer of suitable size and
capacity. No separate instrument air shall be provided by purchaser for
vortex cooler.
d) The maximum height of rack/cabinet shall be limited to 2100 mm. Cabinet shall be
suitable for side and bottom cable entry.
e) Power supply cable entry and terminal size shall be as defined during detail
engineering by purchaser.
2.3 Infra-Red/ Ultra-Violet (IR/UV) Analysers
2.3.1 IR/UV analyser shall preferably be non-dispersive type.
Page 268 of 373

filtZleTtft, ENGINEERS
1ga ial5rag INDIA LIMITED FOR PROCESS STREAM 6-52-0035 Rev. 4
2.3.2 Analyser cell length shall be selected as per specified analyser component range. In case of
dual range analysers, the selected cell length shall be suitable for both the ranges.
2.3.3 The analyser cell material and window material shall be suitable for the specified process
condition. Unless otherwise specified or required otherwise by pressure-temperature
conditions, the o-ring material shall be Teflon.
2.3.4 The analyser design shall be such that it is insensitive to source fluctuations or degradation
or partial cloudiness of cell window.
2.3.5 Special filters shall be offered to minimise the interference of background components,
which are of least interest in process stream.
2.3.6 Unless otherwise specified, analyser shall meet the following performance requirements:
Repeatability ± 1% of full scale
Zero drift ± 1% full scale per 24 hours.
Response Time 5 seconds for 90% of final reading.
2.4 Thermal Conductivity Analyser
2.4.1 Thermal conductivity analyser shall be suitable for measuring hydrogen/hydrocarbon in

binary gas mixture or in a multi component gas mixture.
2.4.2 Analyser shall have precise temperature controller which shall be able to maintain
temperature within ± 0.1°C to ensure stable detector operation.
2.4.3 Analyser cell shall have flowing reference gas or sealed in (non-flowing) reference as per
manufacturer's standard product.
2.4.4 The analyser sensor cell material shall be suitable for the specified process conditions, unless
otherwise specified or required by temperature condition, o-ring material shall be PTFE.
2.4.5 Performance specification
Unless otherwise specified, Analyser shall meet the following performance specifications:
Accuracy ± 1% of FSR
Repeatability ± I% of FSR in 24 hours
Response time Maximum 20 seconds for 90% response
2.5 Moisture Analyser/ Dew Point
2.5.1 The requirements of moisture analyser for corrosive as well as non-corrosive applications
are specified in this clause. Vendor shall offer the type of analyser as specified in the
purchaser's data sheet.
Whenever, the type of analyser is not indicated in the purchaser's data sheet, vendor shall
select the type of moisture analyser as per the specified process conditions.
2.5.2 Moisture analyzer for non-corrosive application.
2.5.2.1 The probe shall be in-line mounted (i.e. shall be located at the point of measurement) in
general and shall not be damaged by severe shock and line abrasion conditions.
Page 269 of 373

ENGINEERS
INDIA LIMITED FOR PROCESS STREAM 6-52-0035 Rev. 4
seig709eg if( GoN inthe Underiawng
2.5.2.2 The pressure and temperature rating of the probe shall be suitable for the process condition
specified in the data sheet.
2.5.2.3 When mounted remote, the probe shall be installed in a sample cell. The end connections of
sample cell shall be flanged with ANSI rating as specified in the purchaser's data sheets.
2.5.2.4 Unless otherwise specified or found necessary by vendor, no sample handling system shall
be required. However, whenever the sample handling system is specified, the design shall
ensure the integrity of sample i.e. moisture contents integrity shall be maintained.
2.5.2.5 The probe shall have Aluminium oxide moisture sensor. Alternate type moisture probe shall
also be acceptable, if this meets the performance requirements specified in the purchaser's
data sheet.
2.5.2.6 Each probe shall be supplied as pre-calibrated and shall be supplied with its own calibration
curve. The calibration shall be valid for a period of minimum six (6) months from the date
of supply, as a minimum.
2.5.2.7 Performance specification
The moisture probe shall meet the following requirements as a minimum:
Accuracy: ±2°C within a range of 60°C to 65°C (Dew point)
± 3°C within a range of —66°C to —110°C
Repeatability: ± 0.5°C in range of 60°C to 65°C
± 1.0°C in range of-60°C to —I10°C
Life time: One year
Time Constant: 5 seconds for 63% of steady state value.
2.5.3 Moisture analyser for corrosive application.
2.5.3.1 The moisture probe shall be hygroscopically sensitised quartz crystal or equivalent suitable
for the specified process samples containing unsaturated hydrocarbon, chlorides, oils etc.
2.5.3.2 Sample shall be conditioned in a sample handling system which shall include filters,
condensate trap, dryer, pressure regulator (with or without heating as required) etc., however
the design shall ensure that moisture integrity is maintained by the sample handling system.
2.5.3.3 The system shall incorporate a dried reference gas cycle after each sample gas measurement
in order to strip volatile contaminants from the detector during reference gas cycle.
2.5.3.4 In order to ensure accuracy and reliability of the moisture analyser, the system shall
incorporate a moisture generator, consisting of temperature controlled water reservoir and a
permeation tube. The moisture generator shall generate a known moisture sample against
which calibration of the analyser can be verified.
2.5.3.5 Performance Specification
The moisture probe shall meet the following performance requirements, as a minimum:
Accuracy: ± 5% of reading
Repeatability: ± 1% of reading
Page 270 of 373

02-Zre? a ENGINEERS
faMeg NW INDIA LIMITED FOR PROCESS STREAM 6-52-0035 Rev. 4
Response time: max. 60 seconds for 90% of steady state value
2.5.4 Analyser Monitor/Controller
2.5.4.1 The analyser monitor/controller shall be microprocessor based and shall be programmable
type.
2.5.4.2 The monitor/controller shall be remote mounted type with built-in display with keyboard for
data display. The cable between analyser and monitor/controller shall be supplied by the
vendor.
2.5.4.3 The monitor/controller shall be able to provide sequential display for various parameters and
shall be selectable from the display keyboard.
2.6 Oxygen Analyser
2.6.1 The type of oxygen analyser shall be offered as specified in the purchaser's data sheet.
Where purchaser's data sheet does not specify the type of oxygen analyser, vendor shall
select the type meeting all functional and performance requirements indicated in purchaser's
data sheets.
2.6.2 The analyser design shall ensure that the analysis is not affected by other sample constituents
present in the sample.
2.6.3 Paramagnetic Type Oxygen Analyser.
2.6.3.1 Unless otherwise specified, the principle of operation for paramagnetic type of oxygen
analyser shall be magnetodynamic type or thermomagnetic type.
2.6.3.2 The analyser shall either have integral or split transducer unit containing the measuring cell
and control unit containing the analyser electronics. The control unit facia shall have with
LCD/LED display.
2.6.3.3 Whenever the control unit is remote mounted, cable between control unit and measuring cell
shall be supplied by vendor.
2.6.3.4 Whenever paramagnetic type analyser is specified for pressurised or variable pressure
application, the offered analyser shall have required pressure compensation to ensure that the
measurement is not affected by changes in sample pressure and sample vent pressure.
The analyser design shall be such that the measurement shall not be affected by changes in
ambient temperature and sample flow rate.
2.6.3.5 Paramagnetic analyser shall meet the following performance characteristics as a minimum:
Accuracy +1% of full scale.
Repeatability 10.5% of full scale.
Response time Less than 15 seconds for 90% response.
2.6.4 Electrochemical (Electrolytic) Type Oxygen Analyser.
2.6.4.1 The electrochemical type of oxygen analyser shall have either aqueous or non-aqueous
measuring cell and shall meet the following requirement;
Page 271 of 373

ORTreq a ENGINEERS
iaReg Wir INDIA LIMITED FOR PROCESS STREAM 6-52.0035 Rev. 4
The analyser shall be self or auto-calibrating type. The calibration cycle shall be
initiated either after a pre-defined time or whenever analyser senses excessive
drop/drift in the output.
Analyser shall provide a suitable alarm for excessive drift. This information may be
available as part of HART output signal.
2.6.4.2 In case, in those analysers where cell need to be replaced after the depletion of electrolyte,
the analyser shall, in addition, meet the following requirements;
The electro-chemical cell shall be easily replaceable.
The analyser shall provide a warning for maintenance i.e. expiration of sensor well
in advance (Typically 2 weeks). In addition analyser shall also provide an alarm in
case output drops below the minimum reliable calibration level.
c) One spare cell shall be supplied as part of consumable spare.
2.6.4.3 The analyser shall have integral electronics with built in LCD/LED display.
2.6.4.4 Electrochemical analyser shall meet the following performance characteristics as a

minimum:
Accuracy +1% of full scale.
Repeatability ±1% of full scale.
2.6.5 Zirconia Type Oxygen Analyser
2.6.5.1 The Zirconia type oxygen analyser shall be either in-situ type or extractive type as specified
in the purchaser's data sheet.
2.6.5.2 In case of in-situ type of analyser, vendor shall ensure that the analyser as offered is suitable
for the pressure-temperature specified in the data sheet and the measurement shall not be
effected by changes in sample pressure and flow rate. In case of variable pressure
application, vendor shall ensure that offered analyser has the provision for pressure
compensation and/or pressure balancing arrangement.
2.6.5.3 Zirconia type of oxygen analyser shall be provided with auto-calibration facility to take care
of zero-drift of cell.
2.6.5.4 The zirconia analyser shall consist of the following sub-assemblies;
2.6.5.4.1 Sensor Assembly
The sensor assembly shall consist of the measuring cell, heater assembly,
temperature sensor and connections for reference and calibration gases.
The measuring cell shall be a zirconia sensor specific for oxygen measurement.
c) The sensor shall be suitable for operating sample temperature up to 700°C.
Page 272 of 373

Ofazre? ENGINEERS
FOR PROCESS STREAM
Ifg7Elfireg INDIA LIMITED 6-52-0035 Rev. 4
IA GOA al Ind. Undeflakinw
2.6.5.4.2 Control Electronics
The control electronics shall have capability to execute all required controls,
indications, temperature control for normal operation and output signals as specified
in purchaser's data sheet.
Sensor temperature shall be maintained through temperature controller.

Temperature sensor shall preferably be ISA type K thermocouple.
Temperature controller shall cut-off power to heater in case of thermocouple burns

out.
Control electronics shall preferably be remote mounted type. Cable between control
electronics and sensor assembly shall be supplied by vendor.
2.6.5.4.3 Reference Gas Control
Reference gas shall be flow and pressure controlled. Flow shall be controlled by rotameter
with needle valve while pressure shall be controlled by self-actuated pressure control valve
provided with pressure gauge.
2.6.5.5 Zirconia type oxygen analyzer shall meet the following performance characteristics as a
minimum:
Accuracy ± 2% of measured value.
Repeatability ± 1.0% of full scale.
2.7 Calibration Gas and Reference Gas Cylinders
2.7.1 Each analyser shall be supplied with following gases with stainless steel or Aluminium
cylinders;
Reference gas dual cylinder with manifold where required. The reference gas
system shall be dedicated one for each analysers, where required along with
automatic switchover to standby cylinder when the first cylinder is exhausted.
Certified calibration gases. In case of dual range of measurement, separate

calibration gas for each range shall be provided.
2.7.2 Each of the gas cylinders shall be provided with two stage pressure regulator. Manifold shall
be provided for reference gas with dual cylinder configuration.
2.7.3 All gas cylinders shall be located near the analyser and shall be supplied with gas cylinder
rack with free standing support.
2.7.4 In case the calibration gas deteriorates or depletes with time, vendor may either supply
calibration gas cylinders with deferred delivery or supply alternate devices for preparing
calibration blend.
3.0 NAMEPLATE
3.1 Each analyser and its accessory shall have a stainless steel nameplate firmly attached to it at
a visible place, furnishing the following information as applicable:
a) Tag number as per purchaser's data sheets.

Page 273 of 373

arei ASA ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
lea 1a g elii° INDIA LIMITED FOR PROCESS STREAM

ANALYSER
6-52-0035 Rev. 4
Page 22 of 22
Manufacturer's serial number and model number.
Manufacturer's name/trade mark.
Component being analysed and its range.
Area classification in which the equipment can be used.
1) Power supply requirements.
g) Analyser Outputs
4.0 INSPECTION AND TESTING
Purchaser reserves the right to inspect and witness testing of all the items at vendor's works
as per Inspection Test Plan and approved quality documents for Process Stream Analysers.
All these tests shall be completed by the vendor and test reports shall be submitted to
Purchaser for scrutiny.
5.0 SHIPPING
5.1 All threaded and flanged openings shall be suitably covered to prevent entry of foreign
material.
5.2 Each major part shall be sealed in thick plastic bag. Suitable moisture absorbent shall be
provided for electronic components.
6.0 REJECTION
6.1 Vendor shall prepare their offer strictly as per clause 1.2 of this specification and shall attach
only those documents, which are specifically indicated in the material requisition.
6.2 Any offer not conforming to the above requirements, shall be summarily rejected.
Page 274 of 373

DOCUMENT No.
Responsibility Definition
A406-079-YA-RC-2603 Rev A
Page 1 of 3

Date Purpose
No by by by
Page 275 of 373
DOCUMENT No.
A406-079-YA-RC-2602 Rev A
Page 2 of 3
1. Vendor must indicate clearly the responsibilities of each of the agencies in the format
attached (Responsibility Chart) along with the definition of various agencies as described
below:
a) Vendor - The agency who manufactures the analyser / any other item at his manufacturing
works and who has quoted for the complete analyzer system.
b) Sub vendor – Agency who manufactures components and accessories and supply same
to vendor.
2. The responsibility assigned in the format shall be from the agency or location, which meets
provenness criteria specified elsewhere in MR.
Page 276 of 373
DOCUMENT No.
A406-079-YA-RC-2602 Rev A
Page 3 of 3
Responsibility Chart (Format)
RESPONSIBILITY
S. NO. DESCRIPTION LOCATION
VENDOR SUBVENDOR
1 SOURCE OF SUPPLY
a) TCD TYPE ANALYSER

¾ PROBE
¾ SAMPLING HANDLING SYSTEM
¾ ANALYSER
(i) DESIGN OF SAMPLE HANDLING

2 SYSTEM
(ii) DESIGN OF ANALYSER SYSTEM
SUPPLY AND DESIGN OF ANALYSER
3
CABINETS
ANALYSER CALIBRATION INCLUDING

4
TESTING AND FAT
INTEGRATION AND INSTALLATION OF

5
ANALYSERS WITH IN THE CABINETS
6 WARRANTY
7 OVERALL SINGLE POINT RESPONSIBILITY
8 SITE INSTALLATION
Page 277 of 373
STANDARD SPECIFICATION NO.
01151zIeLe ENGINEERS INSPECTION AND TEST PLAN
sgar EtRag NW INDIA LIMITED FOR 6-81-2035 Rev. 2
(A Gov' of WM Un<enamngi PROCESS STREAM ANALYSERS Page 1 of 6
m sti mai6 vc)ticni

ffiternr Item
INSPECTION AND TEST PLAN
FOR
PROCESS STREAM ANALYSERS
> 211"./-
2
1
22.03.12
09.05.08
Revised and Reissued
Revised and Reissued RB SKD

IT KC
SKP
DM
VC
0 03.03.02 Issued for implementation RG AKC AKB GRR
Standards Committee Standards Bureau
Rev. Prepared Checked Convenor Chairman
No. Date Purpose by by
Approved by
Page 278 of 373

ENGINEERS
INDIA LIMITED FOR 6-81-2035 Rev. 2
(A Gaol al India undertaking) PROCESS STREAM ANALYSERS Page 2 of 6
Abbreviations
AS Alloy Steel MRT Mechanical Run Test
BASEEFA : British Approval Service for Electrical Equipment in Flammable MPT/MT Magnetic Particle Testing
Atmospheres MTC Material Test Certificates
BIS Bureau of Indian Standards MOC Material of Construction
CCE or CCOE Chief Controller of Explosives NPSH Net Positive Suction Head
CELL Certification Engineers International Limited NDT Non Destructive Testing
CIMFR Central Institute of Mining & Fuel Research NEMA National Electrical Manufacturers Association
CE Carbon Equivalent PO Purchase Order
DFT Dry Film Thickness PESO Petroleum Explosive Safety Organization
DT Destructive Testing PQR Procedure Qualification Record
DP or DPT Dye Penetrate Testing PR Purchase Requisition
ERTL Electronics Regional Test Laboratory PMI Positive Material Identification
FCRI Fluid Control Research Institute PTB Physikalisch-Technische Bundesanstalt
FM Factory Mutual QC Quality Control
FLP Flame Proof RT Radiography Testing
HART Highway Addressable Remote Transducer SS Stainless Steel
HV High Voltage TC Test Certificate
ITP Inspection and Test Plan TPI or TPIA Third Party Inspection Agency
IP Ingress Protection UT : Ultrasonic Testing
IC Inspection Certification UL Under writer Laboratories
IR Insulation Resistance VDR Vendor Data Requirement
IEC International Electro technical Commission WPS : Welding Procedure Specification
JEC : Japanese Electro technical Committee WPQ Welders Performance Qualification
LPT Liquid Penetrate Testing XLPE Cross Linked Poly Ethylene
Inspection Standards Committee
Convenor : Mr. A.K. Chaudhary
Members:
Mr. S.C. Gupta Mr. RK Singh Mr. MP Jain (Projects)
Mr. G. Suresh Mr. Rajeev Kumar Mr. G. Poornachandra Rao
Format No. 8-00-0001-F7 Rev. 0

Copyright EIL — All rights reserved
Page 279 of 373

Ig-ia ages w
lalf4aelOa ENGINEERS
INDIA LIMITED
IA Gan ol India Underlying)
FOR
6-81-2035 Rev. 2
Page 3 of 6
1.0 SCOPE
This Inspection and Test Plan covers the minimum inspection and testing requirements for Process Stream Analysers.
2.0 REFERENCE DOCUMENTS
PO/PR / Standards referred there in /Job specifications / Approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS
SCOPE OF INSPECTION
SL QUMANTU
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
1.0 Procedures -- -- -- -- -- --
2.0 Material Inspection
Incoming material for Material Identification, Chemical &
sampling system including Mechanical Properties, Make, Model no,
sample probes, flanges, Calibration & Functional Check.
sample filters, pressure
Material Test
reducers, safety relief
2.1 Certificates / Test H H R
valves, moisture separators,
100% Lab Certificates (Note 1)
flow regulators, pressure
gauges, isolation valve etc.
and Piping & tubing.
3.0 In process Inspection

Visual, Dimensional verification, functional 100% Supplier's Test .. H -
Assembly of SHS Records
3.1
4.0 Final Inspection

Page 280 of 373

INSPECTION AND TEST PLAN STANDARD SPECIFICATION NO.
0:51M-zieTiet ENGINEERS
lig-91e5lagt, INDIA LIMITED FOR 6-81-2035 Rev. 2
IA Govt Al ma. Undeptilongl PROCESS STREAM ANALYSERS Page 4 of 6
SCOPE OF INSPECTION
SL QUANTUM
SUPPLIER
Visual and Dimensional verification

Check calibration status of all testing
equipment
Bill of material check for each analyzer
system including sample handling system.
Calibration test
Repeatability test
Power supply variation check.
Leak test for complete analyzer system
including sample handling system.
Check for retractable Probe mechanism (if 100% by Supplier's Test
specified) Supplier and on Records and
Random basis Inspection -- H H/W
Check for various system functions and
4.1 Final Inspection diagnostics. by EIL/TPIA Witness report
Check for analog, digital, serial outputs as
specified
Following checks shall be carried out on
shelter (if specified):
Visual & Dimensional check
Air conditioning & ventilation
Alarms for fire & LEL detection
Wiring check
e) Leakage test on tubing & piping
0 Painting & Grounding check

Copyright EIL - All rights reserved
Page 281 of 373

INSPECTION AND TEST PLAN STANDARD SPECIFICATION NO.
larEag gfat ENGINEERS
Igar EN-esle, INDIA LIMITED FOR 6-81-2035 Rev. 2
elem. al
Page 5 of 6
SCOPE OF INSPECTION
SL QUANTUM
SUPPLIER
Certificate from testing agency like
BASEEFA, FM, ATEX, PTB, CIMFR etc.
for analyzers, electrical heat traced tubes and
other components for use in specified
hazardous area..
BIS approval for analyzers and other
components manufactured indigenously for Statutory
use in specified hazardous area. Approval
Submission of certificates / Prototype for
4.2 Statutory approval certificates
tes for analyzers Certificates / H R
Documents each model
from CCOE/PESO for use in specified Type Test
hazardous area. Certificates
Degree of protection certificate (IP) for
instrument housing.
Certificate for electromagnetic compatibility
and radio frequency protection as per IEC
61000-4.
5.0 Painting
Special cleaning and packing for oxygen and
chlorine services Packing list /
5.1 Painting and Packing 100% Supplier's - H
Pre treatment, primer and final paint, shade,
thickness. Records
6.0 Documentation and IC

Review of Internal Test Reports, MTC Supplier's Test
IC issuance. Prototype for Records /
6.1 Documentation and IC - H H
each model Inspection
Certificate

Copyright EIL —All rights reserved
Page 282 of 373

area ENGINEERS
$igziT tiff5:1e-Ce INDIA LJMITED
FOR
6-81-2035 Rev. 2
Page 6 of 6
Legends: H- Hold (Do not proceed without approval), Random 10% , R-Review, RW-Random witness, W- Witness (Give due notice, work may
proceed after scheduled date).
NOTES (As applicable)
All NACE, Hydrogen service, AS, SS flanges to be inspected by TPIA appointed by the Main Supplier. CS flanges upto size 24" — 300 ANSI will be accepted
on review of Supplier Test Certificates. Supplier test certificate to be reviewed by TPIA.
Wherever W/R or H/W is indicated, Inspection Engineer shall decide the option to be exercised for the particular stage and supplier
Supplier's in house procedures may be accepted in case TPI/EIL is satisfied with adequacy of procedures to comply with Purchase Order/Specifications
requirements. In case of non availability of suitable procedures, fresh procedures may be qualified under TPI/EIL witness. .
In case of conflict between purchase specification, contract documents and ITP, more stringent conditions shall be applicable.
This document describes generally the requirements pertaining to all types of the item. Requirements specific to PO and the item are only applicable.
Acceptance Norms for all the activities shall be as per PO/PR/ Standards referred there in/ Job specifications /Approved documents

Page 283 of 373

SPECIFICATION
SCOPE OF WORK A406-079-YA-SOW-2603 Rev. A
Page 1 of 3
SCOPE OF WORK

Date Purpose
No by by by

Page 284 of 373
SPECIFICATION
Page 2 of 3
SCOPE
Sr.No DESCRIPTION
VENDOR PURCHASER
1 Design, engineering, procurement of bought out items,
manufacture, calibration, integration, inspection, factory
testing and supply of 3 Nos. of TCD Type Analyser
Tag Nos. 79-AT-3301,65-AT-4301 & 65-AT-5301 as
per MR including:
(a) Analyser complete with all hardware, software and X -
necessary accessories.
(b) Analyser cabinet / racks with sunshade for each X -
analyser complete with sample probes, sample cell,
sample handling & conditioning system and associated
accessories including tubing, wiring etc.
(c) Complete installation material including:
(i) Material required for probe and sampling handling X
system.
(ii) Pre-fabricated electrically traced tubes, bare tubes, X -
pipe, tube fittings between sample take off and analyser
cabine, fast loop.
(iii) Cables, cable glands and accessories for X -
interconnection of equipments supplied by vendor
including all interconnection cable between Analyser
and control unit.
(iv) Power cable (110VAC & 415 VAC) between each X
Analyser cabinet in field and satellite rack room.
(v) Signal cable (4-20 ma) between Analyser cabinet in X
field and Purchasers DCS.
(vi) Power distribution boxes as necessary for power X -
distribution, junction boxes for termination of the
signals.
(vii) Pipes/ tube and pipe/ tube fittings necessary for X -
utility distribution for vendor supplied equipment
(viii) Any other items not specifically listed but X -
necessary for the installation of complete Analyser.
(d) Any other item necessary but not specifically listed for X -
installation of complete Analyser.
2 Packing, forwarding, transportation of all analyser and X -
analyser cabinets.
3 Installation of analysers, Analyser cabinet/rack and
Analyser hook ups with analyser cabinet /racks and
associated accessories including calibration gas
cylinders, tubing, piping, cabling, junction boxes,
power supply, distribution boxes etc.
(a) Installation of sample probe, sample handling & X
conditioning system for all analysers.
(b) Installation of all Analyser cabinet /rack, junction X -
boxes, power distribution boxes, vents etc. as specified
and complete with IR analyser and their accessories.
(c) Installation of all loose supplied items if any for X -
analysers.

Page 285 of 373
SPECIFICATION
Page 3 of 3
(d) Laying of all cables, tubes/ pre heated tubes in GI trays X -

and their support for analysers from tap off to each
analyser cabinet /rack.
(g) Laying of cables (supplied by Purchaser) between X
Analyser cabinet/rack in field and SRR
(h) Utility distribution to vendor supplied items X -
(i) Providing all utilities as specified in MR at each - X
Analyser cabinet in field.
(j) Termination and interconnection of all cables and tubes X -
for all vendor supplied items
(k) Power supply distribution for 415 V AC and 110V AC X -
UPS as necessary for vendor supplied items.
(l) Installation of all junction boxes, power supply X -
distribution boxes including those required for 110V
UPS ,415V AC.
(m) Any other activity necessary but not specifically listed X -
for installation of complete IR Analyser System.
4 Providing all utilities as specified in MR at one point - X
near each Analyser cabinet in field.
5 Utility distribution to vendor supplied items X -
6 Documentation including as-built documentation, X -
warranty of analysers.
7 Supply of special tools and test equipments required for X -
testing, maintenance and calibration of analysers.
8 Supply of zero and span gas cylinders along with X
accessories as per Doc. No. A406-079-YA-OD-2601 for
each analyser.
9 Third party inspection of all vendor supplied X
equipments as per SIV.
10 Supply of consumables and commissioning spares as X -
per MR requirements for analysers.
11 Any other item or/ and activity not listed/ indicated X -
specifically but necessary for successful operation of
Analyser.

Page 286 of 373
STANDARD
ENGINEERS SPECIFICATION No.
'Meg,
°g7
INDIA LIMITED HEALTH, SAFETY & ENVIRONMENT 6-82-0001 Rev. 5
In Gant ol India Unavtaking)
MANAGEMENT AT CONSTN SITES Page 1 of 87
I v1+iIuI Tic ITT
Tku Lig
qv,'
31-449. rairakii
HEALTH, SAFETY & ENVIRONMENT
(HSE) MANAGEMENT
AT CONSTRUCTION SITES
5 19/12/2012 REVISED & UPDATED Piatt

SM SM RKD DM
4 13/02/2008 REVISED & UPDATED
AS RK SCB VC
3 17/07/2007 REVISED & UPDATED
AS MPJ VNP VC
2 11/08/2005 REVISED & UPDATED MPJ MPJ VNP VJN
1 29/05/2003 REVISED & UPDATED AS MPJ HOD(C) SKG
ISSUED AS STANDARD
0 19/07/2002 AB MPJ HOD(C) GRR
SPECIFICATION
Standards Standards
Prepared Checked Committee Bureau
Rev Date Purpose Convenor Chairman
by by
Approved by

Page 287 of 373
STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
HEALTH, SAFETY & ENVIRONMENT 6-82-0001 Rev. 5
Abbreviations
AERB : Atomic Energy Regulatory Board

ANSI : American National Standards Institute
BARC : Bhabha Atomic Research Centre
BS : British Standard
EIL : Engineers India Limited
ELCB : Earth Leakage Circuit Breaker
EPC : Engineering, Procurement and Construction
EPCC : Engineering, Procurement, Construction and Commissioning
ESI : Employee State Insurance
GCC : General Conditions of Contract
GM : General Manager
GTAW : Gas Tungsten Arc Welding
HOD : Head of Department
HSE : Health, Safety & Environment
HV : High Voltage
IS : Indian Standard
IE : Indian Electricity
JSA : Job Safety Analysis
LOTO : Lock Out & Tag Out
LPG : Liquefied Petroleum Gas
LSTK : Lump Sum Turn Key
MV : Medium Voltage
PPE : Personal Protective Equipment
RCM : Resident Construction Manager or Site-in-Charge, as applicable
ROW : Right of Way
SCC : Special Conditions of Contract
SLI : Safe Load Indicator
TBM : Tool Box Talks
Construction Standards Committee
Convenor : Sh. RK Das, ED(Construction)
Members : Sh. SK Kaul, GM (C&P)

Sh. M.P. Jain, GM (CRA & HSE)
Sh Rakesh Nanda, DGM (Piping)
Sh. S Mukherjee, DGM (Construction)
Sh. B Chakraborty, AGM (Construction)
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

Page 288 of 373
CONTENTS
CLAUSE TITLE PAGE NO.

1.0 Scope 5
2.0 References 5
3.0 Requirement of Health, Safety and Environment (HSE) Management System 5
to be complied by Bidders
3.1 Management Responsibility 5
3.1.1 HSE Policy & Objective 5
3.1.2 Management System 5
3.1.3 Indemnification 6
3.1.4 Deployment & Qualification of Safety Personnel 6
3.1.5 Implementation, Inspection & Monitoring 7
3.1.6 Behavior Based Safety 8
3.1.7 Awareness and Motivation 9
3.1.8 Fire prevention & First-Aid 9
3.1.9 Documentation 9
3.1.10 Audit 10
3.1.11 Meetings 10
3.1.12 Intoxicating drinks & drugs and smoking 11
3.1.13 Penalty 11
3.1.14 Accident/Incident investigation 14
3.2 House Keeping 14
3.3 HSE Measures 15
3.3.1 Construction Hazards 15
3.3.2 Accessibility 16
3.3.3 Personal Protective Equipments (PPEs) 16
3.3.4 Working at height 17

3.3.5 Scaffoldings & Barricading 18
3.3.6 Electrical installations 18
3.3.7 Welding/Gas cutting 21
3.3.8 Ergonomics and tools & tackles 21
3.3.9 Occupational Health 22
3.3.10 Hazardous substances 23
3.3.11 Slips, trips & falls 23
3.3.12 Radiation exposure 23
3.3.13 Explosives/Blasting operations 23
3.3.14 Demolition/Dismantling 24
3.3.15 Road Safety 24
3.3.16 Welfare measures 24
3.3.17 Environment Protection 25
3.3.18 Rules & Regulations 26
Contd to page 4 …

Page 289 of 373
CONTENTS (contd. from page 3)
3.3.19 Weather Protection 26

3.3.20 Communication 26
3.3.21 Confined Space Entry 27
3.3.22 Heavy Lifts 27
3.3.23 Key performance indicators 27
3.3.24 Unsuitable Land Conditions 28
3.3.25 Under Water Inspection 28
3.3.26 Excavation 28
3.4 Tool Box talks (TBT) 29
3.5 Training & Induction Programme 30
3.6 Additional safety requirements for working Inside a running plant 31
3.7 Self Assessment and Enhancement 32
3.8 HSE Promotion 32
3.9 LOTO for isolation of energy source 32
4.0 Details of HSE Management System by Contractor 33
4.1 On Award of Contract 33
4.2 During Job Execution 33
4.3 During short listing of the sub-contractors 34
5.0 Records 34
Appendices
1. Standards/Codes on HSE Appendix-A
2. Details of First AID Box Appendix-B
3. Types of Fire Extinguishers & their Appln. Appendix-C
4. Indicative List of statutory Acts & Rules Appendix-D
5. Construction Hazards and their mitigation Appendix-E
6. Training subjects / topics Appendix-F
7. Construction Power Board ( typ) Appendix-G
8. List of HSE procedures Appendix-H
Attachments (Reporting Formats)
I. Safety Walk through Report HSE-1 Rev.0
II. Accident/Incident Report HSE-2 Rev.0
III. Suppl. Accident/Incident Investigation Report HSE-3 Rev.0
IV. Near Miss Incident Report/Dangerous occurence HSE-4 Rev.0
V. Monthly HSE Report HSE-5 Rev.0
VI. Permit for Working at height HSE-6 Rev.0
VII. Permit for Working in Confined Space HSE-7 Rev.0
VIII. Permit for Radiation work HSE-8 Rev.0
IX. Permit for Demolishing/ Dismantling HSE-9 Rev.0
X. Daily Safety Checklist HSE-10 Rev.0
XI. Housekeeping assessment & compliance HSE-11 Rev.0
XII. Inspection of temporary electrical booth / installation HSE-12 Rev.0
XIII. Inspection for scaffolding HSE-13 Rev.0
XIV. Permit for erection / modification & dismantling of HSE-14 Rev.0
scaffolding
XV. Permit for heavy lift/critical erection HSE-15 Rev.0
XVI. Permit Energy Isolation & De-Isolation HSE-16 Rev 0
XVII. Permit for Excavation HSE-17 Rev 0

Page 290 of 373
1.0 SCOPE
This specification establishes the Health, Safety and Environment (HSE) management
requirement to be complied by Contractors/ Vendors including their sub-contractors/ sub
vendors during construction.
This specification is not intended to replace the necessary professional judgment needed to
design & implement an effective HSE system for construction activities and the contractor is
expected to fulfill HSE requirements in this specification as a minimum. It is expected that
contractor shall implement best HSE practices beyond whatever are mentioned in this
specification.
Requirements stipulated in this specification shall supplement the requirements of HSE

Management given in relevant Act(s)/legislations, General Conditions of Contract (GCC),
Special Conditions of Contract (SCC) and Job (Technical) Specifications. Where different
documents stipulate different requirements, the most stringent shall apply.
2.0 REFERENCES
The document should be read in conjunction with following:
- General Conditions of Contract (GCC)

- Special Conditions of Contract (SCC)
- Building and other construction workers Act,
- Indian Factories Act
- Job (Technical) specifications
- Relevant International / National Codes (refer Appendix-A for standards/codes on HSE)
- Relevant State & National Statutory requirements.
- Operating Manuals Recommendation of Manufacturer of various construction
Machineries
3.0 REQUIREMENTS OF HEALTH, SAFETY & ENVIRONMENT (HSE) MANAGEMENT

SYSTEM TO BE COMPLIED BY BIDDERS
3.1 Management Responsibility
3.1.1 HSE Policy & Objectives
The Contractor should have a documented HSE policy duly & objectives to demonstrate
commitment of their organization to ensure health, safety and environment aspects in their line
of operations.
HSE Policy of the contractor shall be made available to Owner / EIL at the place of execution of
specific contract works, as a valid document.
3.1.2 Management System
The HSE management system of the Contractor shall cover the HSE requirements &
commitments to fulfill them, including but not limited to what are specified under clause 1.0
and 2.0 above. The Contractor shall obtain the approval of its site specific HSE Plan from EIL /
Owner prior to commencement of any site works. Corporate as well as Site management of the
Contractor shall ensure compliance of their HSE Plan at work sites in its entirety & in true
spirit.

Page 291 of 373
3.1.3 Indemnification
Contractor shall indemnify & hold harmless, Owner/EIL & their representatives, free from any
and all liabilities arising out of non-fulfillment of HSE requirements or its consequences.
3.1.4 Deployment & Qualifications of Safety Personnel
The Contractor shall designate/deploy various categories of HSE personnel at site as indicated
below in sufficient number. In no case, deployment of safety Supervisor / Safety Steward shall
substitute deployment of Safety Officer / Safety Engr what is indicated in relevant statute of
BOCW Act i.e deployment of safety officer/Safety Engineer is compulsory at project site. The
Safety supervisors, Safety stewards etc. would facilitate the HSE tasks at grass root level for
construction sites and shall assist Safety Officer / Engineers.
a) Safety Steward
For every 250 workmen, one safety steward shall be deployed.
As a minimum, he shall preferably possess High School leaving Certificate (of Class
XII with Physics & Chemistry etc.) and trained in fire-fighting as well as in
safety/occupational health related subjects, with minimum two year of practical
experience in construction work environment and preferably have adequate knowledge
of the language spoken by majority of the workers at the construction site.
b) Safety Supervisor
For every 500workmen, one safety Supervisor shall be deployed.
As a minimum, he shall possess a recognized Degree in Science (with Physics &

Chemistry) or a diploma in Engg. or Tech. with minimum Two years of practical
experience in construction work environment and should possess requisite skills to deal
with construction safety & fire related day-to-day issues.
c) Safety Officer / Safety Engineer
One for every 1000 workers or part thereof shall be deployed.
Safety officer/Engineer Should Possess following Qualification & Experience :
(i) Recognized degree in any branch of Engg. or Tech. or Architecture with

practical experience of working in a building or other construction work in
supervisory capacity for a period of not less than two years, or possessing
recognized diploma in any branch of Engg. or Tech with practical experience
of building or other construction work in supervisory capacity for a period of
not less than five years.
(ii) Recognized degree or diploma in Industrial safety with one paper in

Construction Safety
(iii) Preferably have adequate knowledge of the language spoken by majority of

the workers at the construction site.
Alternately
(i) Person possessing Graduation Degree in Science with Physics & Chemistry
and degree or diploma in Industrial Safety (from any Indian institutes
recognized by AICTE or State Council of Tech. Education of any Indian

Page 292 of 373
State) with practical experience of working in a building, plant or other

construction works (as Safety Officer, in line with Indian Factories Act, 1958)
for a period of not less than five years, may be considered as Safety Officer, in
case Owner/Client of the project agrees for /approves the same.
d) HSE In-Charge
In case there is more than one Safety Officer at any project construction site, one of
them, who is senior most by experience (in HSE discipline), may be designated as HSE
In-Charge. Duties & responsibilities of such person shall be commensurate with that of
relevant statute and primarily to coordinate with top management of Client and
contractors.
In case the statutory requirements i.e. State or Central Acts and / or Rules as applicable like the
Building and Other Construction Workers’ Regulation of Employment and Conditions of
Service- Act,1996 or State Rules (wherever notified), the Factories Act, 1948 or Rules
(wherever notified), etc. are more stringent than above clarifications, the same shall be
followed.
Contractors shall ensure physical availability of safety personnel at the place of specific work
location, where Hot Work Permit is required / granted. No work shall be started at any of the
project sites until above safety personnel & concerned Site Engineer of Contractor are
physically deployed at site. The Contractor shall submit a HSE organogram clearly indicating
the lines of responsibility and reporting system and elaborate the responsibilities of safety
personnel in their HSE Plan.
The Contractor shall verify & authenticate credentials of such safety personnel and furnish Bio-
Data/ Resume/ Curriculum Vitae of the safety personnel as above for EIL/Owner’s approval, at
least 1 month before the mobilization. The Contractor, whenever required, shall arrange
submission of original testimonials/certificates of their Safety personnel, to EIL/Owner (for
verification/scrutiny, etc.)
Imposition / Realization of penalty shall not absolve the Contractor from his/her responsibility
of deploying competent safety officer at site.
Adequate planning and deployment of safety personnel shall be ensured by the Contractor so
that field activities do not get affected because of non-deployment of competent & qualified
safety people in appropriate numbers.
3.1.5 Implementation, Inspection / Monitoring
 The Contractor shall be fully responsible for planning, reporting, implementing and
monitoring all HSE requirements and compliance of all laws & statutory requirements.
 The Contractor shall also ensure that the HSE requirements are clearly understood &
implemented conscientiously by their site personnel at all levels at site.
 The Contractor shall ensure physical presence of their field engineers / supervisors, during
the continuation of their contract works / site activities including all material transportation
activities. Physical absence of experienced field engineers / supervisors of Contractor at
critical work spot during the course of work, may invite severe penalization as per the
discretion of EIC, including halting / stoppage of work.
 Contractor shall furnish their annual Inspection Plan, with regard to project issues /subjects,
frequency and performers to EIL/Owner.
 The Contractor shall regularly review inspection report internally and implement all
practical steps / actions for improving the status continuously.
 The Contractor shall ensure important safety checks right from beginning of works at every
work site locations and to this effect format No: HSE-10 “Daily Safety Check List” shall
be prepared by field engineer & duly checked by safety personnel for conformance.
Page 293 of 373
 The Contractor shall carry out inspection to identify various unsafe conditions of work
sites/machinery/equipments as well as unsafe acts on the part of
workmen/supervisor/engineer while carrying out different project related works.
 Adequate records for all inspections shall be maintained by the Contractor and the same
shall be furnished to EIL/Owner, whenever sought.
 The Contractor shall not carry-out work by engaging single worker anywhere without any
supervisor anytime during day or night.
 To demonstrate involvement/commitment of site management of Contractor, at least one
Safety Walk through in a month shall be carried out by Contractor’s head of site (along
with his area manager/field engineers) and a report shall be furnished to EIL/Owner as per
format No: HSE-1” Safety walk through report” followed by compliance for unsatisfactory
remarks.
 As a general practice lifting tools/tackles, machinery, accessories etc. shall be inspected,
tested and examined by competent people (approved by concerned State authorities) before
being used at site and also at periodical interval (e.g. during replacement,extension,
modification, elongation/reduction of machine/parts, etc.) as per relevant statutes. Hydra,
cranes, lifting machinery, mobile equipments / machinery / vehicles, etc. shall be inspected
regularly by only competent / experienced personnel at site and requisite records for such
inspections shall be maintained by every contractor. Contractor shall also maintain records
of maintenance of all other site machinery (e.g. generators, rectifiers, compressors, cutters,
etc.) & portable tools/equipments being used at project related works (e.g. drills, abrasive
wheels, punches, chisels, spanners, etc.). The Contractor shall not make use of arbitrarily
fabricated ‘derricks’ at project site for lifting / lowering of construction materials.
 Site facilities /temporary. installations, e.g. batching plant, cement godown, DG-room,
temporary electrical panels/distribution boards, shot-blasting booth, fabrication yards, etc.
and site welfare facilities, like labour colonies, canteen/pantry, rest-shelters, motor
cycle/bicycle-shed, site washing facilities, First-aid centers, urinals/toilets, etc. should be
periodically inspected by Contractor (preferably utilizing HR/Admn. personnel to inspect
site welfare facilities) and records to be maintained.
3.1.6 Behaviour Based Safety
 The contractor shall develop a system to implement Behaviour-Based Safety (BBS)

through which work groups can identify, measure and change the behaviours of employees
and workers
 The BBS process shall include the following:
- Identify the behaviours critical to obtaining required safety performance.
- Communicate the behaviours and how they are performed correctly to all
- Observe the work force and record safe/at risk behaviours. Intervene with workers
to give positive reinforcement when safe behaviours are observed. Provide
coaching/correction when at risk behaviours are observed
- Collect and record observation data
- Summarize and analyze observation data
- Communicate observation data and analysis results to all employees
- Provide recognition or celebrate when safe behaviour improvements occur
- Change behaviours to be observed or change activators or change consequences as
appropriate.
- Communicate any changes to workforce
 Contractor through its own HSE committee shall implement the above process.
 The necessary procedures and reporting formats shall be developed by the contractor for
approval by EIL/Owner.
 The HSE committee of contractor shall observe individual’s behavior for safe practices
adapted for utilization/execution of work for following as a minimum:-
- PPE
- Tools & equipment
- Hazard Identification & control
Page 294 of 373
- House keeping
- Confined space entry
- Hot works
- Excavation
- Loading & unloading
- Work At height
- Stacking & storage
- Ergonomics
- Procedures
3.1.7 Awareness and Motivation
 The Contractor shall promote and develop awareness on Health, Safety and Environment
protection among all personnel working for the Contractor.
 Regular awareness programs and fabrication shop / work site meetings at least on monthly
basis shall be arranged on HSE activities to cover hazards/risks involved in various
operations during construction.
 Contractor to motivate & encourage the workmen & supervisory staff by issuing / awarding
them with tokens/ gifts/ mementos/ monetary incentives / certificates, etc.
 Contractor shall assess & recognize the behavioral change of its site engineers / supervisors
periodically and constantly motivate / encourage them to implement HSE practices at
project works
3.1.8 Fire Prevention & First-Aid
 The Contractor shall arrange suitable First-aid measures such as First Aid Box (Refer
Appendix-B for details), trained personnel/nurse (male) to administer First Aid, stand-by
Ambulance vehicle and
 The Contractor shall arrange installation of fire protection measures such as adequate
number of steel buckets with sand & water and adequate number of appropriate portable
fire extinguishers (Refer Appendix-C for details) to the satisfaction of EIL/Owner.
 The Contractor shall deploy trained supervisory personnel / field engineers to cater to any
emergency situation.
 In case the number of workers exceeds 500, the Contractor shall position an Ambulance /
vehicle and nurse on round the clock basis very close to the worksite.
 The Contractor shall arrange FIRE DRILL at each site at least once in three months,
involving site workmen and site supervisory personnel & engineers. The Contractor shall
maintain adequate record of such fire drills at project site
3.1.9 Documentation
The Contractor shall evolve a comprehensive, planned and documented system covering the
following as a minimum for implementation and monitoring of the HSE requirements and the
same shall be submitted for approval by owner/EIL.
- HSE Organogram
- Site specific HSE Plan
- Safety Procedures, forms and Checklist. Indicative list of HSE procedures is attached as
Appendix :H
- Inspections and Test Plan
- Risk Assessment & Job Safety Analysis for critical works.
 The monitoring for implementation shall be done by regular inspections and compliance of
the observations thereof. The Contractor shall get similar HSE requirements implemented
at his sub-contractor(s) work site/office. However, compliance of HSE requirements shall
Page 295 of 373
be the responsibility of the Contractor. Any review/approval by EIL/Owner shall not

absolve contractor of his responsibility/liability in relation to fulfilling all HSE
requirements.
3.1.10 Audit
The Contractor shall submit an Audit Plan to EIL/Owner indicating the type of audits and
covering following as minimum:
 Internal HSE audits regularly at least on quarterly basis by engaging internal qualified
auditors (viz safety officers/Construction personnel having 5 years experience in
construction safety and Lead Auditor Course :OSHA 18001certification).
 External HSE audits regularly at least on every six months by engaging qualified external
auditors (viz safety officers/Construction personnel having 10 years experience in
construction safety and Lead Auditor Course :OSHA 18001certification).
All HSE shortfalls/ non-conformances on HSE matters brought out during review/audit, shall be
resolved forthwith ( generally within a week) by Contractor & compliance report shall be
submitted to EIL/Owner.
In addition to above audits by contractor, the contractor’s work shall be subjected to HSE audit
by EIL/Owner at any point of time during the pendency of contract. The CONTRACTOR shall
take all actions required to comply with the findings of the Audit Report and issue regular
Compliance Reports for the same to OWNER/ EIL till all the findings of the Audit Report are
fully complied.
Failure to carry-out HSE Audits & its compliance (internal & external) by Contractor, shall
invite penalization.
3.1.11 Meetings
 The Contractor shall ensure participation of his top most executive at site (viz. Resident
Construction Manager / Resident Engineer / Project Manager / Site-in-Charge) in Safety
Committee / HSE Committee meetings arranged by EIL/Owner usually on monthly basis
or as and when called for. In case Contractor’s top most executive at site is not in a
position to attend such meeting, he shall inform EIL/Owner in writing before the
commencement of such meeting indicating reasons of his absence and nominate his
representative – failure to do so may invite very stringent penalization against the specific
Contractor, as deemed fit in Contract. The obligation of compliance of any observations
during the meeting shall be always time bound. The Contractor shall always assist
EIL/Owner to achieve the targets set by them on HSE management during the project
implementation.
 In addition, the Contractor shall also arrange internal HSE meetings chaired by his top most
executive at site on weekly basis and maintain records. Such internal HSE meetings shall
essentially be attended by field engineers / supervisors (& not by safety personnel only) of
the Contractor and its associates. Records of such internal HSE meetings shall be
maintained by the Contractor for review by EIL/Owner or for any HSE Audits.
 Agenda of internal HSE meeting should broadly cover: -
a) Confirmation of record notes / minutes of previous meeting

b) Discussion on outstanding subjects of previous points / subjects, if any
c) Incidents / Accidents (of all types) at project site, if any
d) Current topics related to site activities / subjects of discussion
e) House keeping
f) Behavioral Safety
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g) Information / views / deliberations of members / site sub Contractors

h) Report from Owner / Client
i) Status of Safety awareness, Induction programs & Training programs
The time frame for such HSE meeting shall be religiously maintained by one and all.
3.1.12 Intoxicating Drinks & Drugs and Smoking
 The Contractor shall ensure that his staff members & workers (permanent as well casual)
shall not be in a state of intoxication during working hours and shall abide by any law
relating to consumption & possession of intoxicating drinks or drugs in force.
 The Contractor shall not allow any workman to commence any work at any locations of
project activity who is/are influenced / effected with the intake of alcohol, drugs or any
other intoxicating items being consumed prior to start of work or working day.
 Awareness about local laws on this issue shall form part of the Induction Training and
compulsory work-site discipline.
 The Contractor shall ensure that all personnel working for him comply with “No-Smoking”
requirements of the Owner as notified from time to time. Cigarettes, lighters, auto ignition
tools or appliances as well as intoxicating drugs, dry tobacco powder, etc. shall not be
allowed inside the project / plant complex.
 Smoking shall be permitted only inside smoking booths exclusively designated &
authorized by the Owner/EIL.
3.1.13 Penalty
The Contractor shall adhere consistently to all provisions of HSE requirements. In case of non-
compliances and also for repeated failure in implementation of any of the HSE provisions,
EIL/Owner may impose stoppage of work without any cost & time implication to the Owner
and/or impose a suitable penalty.
The amount of penalty to be levied against defaulted Contractor shall be up to a cumulative

limit of
2.0% (Two percent) of the contract value for Item Rate or Composite contracts with an overall
ceiling of 1, 00, 00, 000 (Rupees One crore)
0.5% (Zero decimal five percent) of the contract value for LSTK, OBE, EPC, EPCC or Package
contracts with an overall ceiling of 10, 00.00.000 (Rupees ten crores)
This penalty shall be in addition to all other penalties specified elsewhere in the contract. The
decision of imposing stop-work-instruction and imposition of penalty shall rest with
EIL/Owner. The same shall be binding on the Contractor. Imposition of penalty does not make
the Contractor eligible to continue the work in unsafe manner.
The amount of penalty applicable for the Contractor on different types of HSE violations is
specified below:
Sl.
Violation of HSE norms Penalty Amount
No.
For not using personal protective equipment
1. (Helmet, Shoes, Goggles, Gloves, Full body Rs 500/- per day/ Item / Person.
harness, Face shield, Boiler suit, etc.)
2. Working without Work Permit/Clearance Rs 20000/- per occasion

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Execution of work without deployment of requisite

3 Rs. 5000/- per violation per day
field engineer / supervisor at work spot
Unsafe electrical practices (not installing ELCB,
using poor joints of cables, using naked wire
4. without top plug into socket, laying wire/cables on Rs 10000/- per item per day.
the roads, electrical jobs by incompetent person,
etc.)
Working at height without full body harness, using

non-standard/ rejected scaffolding and not
5. Rs. 10000/- per case per day.
arranging fall protection arrangement as required,
like hand-rails, life-lines, Safety Nets etc.
Unsafe handling of compressed gas cylinders (No
trolley, jubilee clips double gauge regulator, and
6. Rs 500/- per item per day.
not keeping cylinders vertical during
storage/handling, not using safety cap of cylinder).
Use of domestic LPG for cutting purpose / not
7. using flash back arresters on both the hoses/tubes Rs. 3000/- per occasion.
on both ends.
No fencing/barricading of excavated areas /
8. Rs. 3000/- per occasion.
trenches.
Not providing shoring/strutting/proper slope and
9. not keeping the excavated earth at least 1.5M away Rs.5, 000/- per occasion.
from excavated area.
Non display of scaffold tags, caution boards, list of
10. hospitals, emergency services available at work Rs.1000/- per occasion per day
locations.
Traffic rules violations like over speeding of
vehicles, rash driving, talking on mobile phones
during vehicle driving, wrong parking, not using
11. Rs. 2000/- per occasion per day
seat belts, vehicles not fitted with reverse horn /
warning alarms / flicker lamps during foggy
weather.
Absence of Contractor’s RCM/SIC or his
nominated representative (prior approval must be
taken for each meeting for nomination) from site
12. Rs10000/- per meeting.
HSE meetings whenever called by EIL/Owner &
failure to nominate his immediate deputy (in the
site-organogram) for such HSE meetings.
Failure to maintain HSE records by Contractor
13. Safety personnel, in line with approved HSE Rs 10000/- per month.
Plan/Procedures/Contract specifications..
Failure to conduct daily site safety inspection (by
Contractor’s safety engineers/safety officers),
internal HSE meeting, internal HSE
14. Rs.10000/- per occasion.
Awareness/Motivation Program, Site HSE
Training and HSE audit at predefined frequencies
(as approved in HSE Plan).
Failure to submit the monthly HSE report by 5th of
Rs. 10000/- per occasion and Rs.
15. subsequent month to Project’s Engineer-in-Charge
1000/- per day of further delay.
/ Owner
Rs. 5000/- per occasion per
16. Poor House Keeping
subject

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Failure to report & follow up accident (including

17. Near Miss) reporting system within specific time- Rs. 20000/- per occasion
frame.
Degradation of environment (not confining toxic

18. Rs10000/- per occasion
spills, spilling oil/lubricants onto ground)
Not medically examining the workers before

allowing them to work at height / to work in
confined space / to work in shot-blasting / to work
for painting / to work in bitumen or asphalt works, Rs 5000/- per occasion per
19.
not providing ear muffs while allowing them to worker
work in noise polluted areas, made them to work in
air polluted areas without respiratory protective
devices, etc.
Violation of any other safety condition as per job
HSE plan / work permit and HSE conditions of
contract (e.g. using crowbar on cable trenches,
improper welding booth, not keeping fire
20. Rs. 5000/- per occasion
extinguisher ready at hot work site, unsafe rigging
practices, non-availability of First-Aid box at site,
not using hood with respiratory devices by blaster
for shot//grit blasting, etc.)
Failure to carry-out Safety audit in time (internal &
21. external), close-out of identified shortfalls of Rs. 20,000/- per occasion
Observations of Safety Aspects(OSA),etc
Carrying out sand blasting instead of grit/shot
22. Rs. 50,000/- per day
blasting
Failure to deploy adequately qualified and
23. Rs. 10000/- per day per Officer
competent Safety Officer
Utilization of hydra/ back-hoe loader for material
24. shifting or any other unauthorized /unsafe lifting Rs 25,000/- per occasion
works
Any incident / accident at project site has been
caused because of willful negligence or gross
25. Rs 10,00,000/-per occasion
violation of safety measures / provisions on the
part of the Contractor or any of its sub-agencies
26. Any violation not covered above To be decided by EIL/Owner.
 The Contractor shall make his field engineers/supervisors fully aware of the fact that they
keep track with the site workmen for their behavior and compliance of various HSE
requirements. Safety lapses / defects of project construction site shall be attributable to the
concerned job supervisor / engineer of the Contractor, (who remains directly responsible
for safely executing field works). For repeated HSE violations, concerned job supervisor /
engineer shall be reprimanded or appropriate action, as deemed fit, shall be initiated (with
an information to EIL & Owner) by the concerned Contractor.
Contractor shall initiate verbal warning shall be given to the worker/employee during his first
HSE violation. A written warning shall be issued on second violation and specific training shall
be arranged / provided by the Contractor to enhance HSE awareness/skill including feedback on
the mistakes/ flaws. Any further violation of HSE stipulations by the erring individuals shall
call for his forthright debar from the specific construction site. A record of warnings for each
worker/employee shall be maintained by the Contractor, like by punching their cards / Gate
passes or by displaying their names at the Project entry gate. Warnings, penalizations,

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appreciations etc. shall be discussed in HSE Committee meetings by site Head of the
Contractor.
3.1.14 Accident / Incident Investigation
All accidents / incidents shall be informed to EIL/Owner at least telephonically by Contractor

immediately and in writing within 24 hours on Format No. HSE-2 as applicable , by Contractor.
Thereafter, a Supplementary Accident / Incident investigation Report on Format No. HSE-3
shall be submitted to EIL/Owner within 72 hours. Near Miss incident(s),Dangerous
accidents/incident shall also be reported on Format No. HSE-4 within 24 hours. The accident/
incident shall be investigated by a team of Contractor’s senior Site personnel (involving Site-in-
Charge or at least by his deputy) for establishing root-cause and recommending corrective &
preventive actions. Findings shall be documented and suitable actions taken to avoid
recurrences shall be communicated to EIL/Owner. Owner/EIL shall have the liberty to
independently investigate such occurrences and the Contractor shall extend all necessary help
and cooperation in this regard. EIL/Owner shall have the right to share the content of this report
with the outside world.
3.2 House Keeping
The Contractor shall ensure that a high degree of house keeping is maintained and shall ensure
inter alia; the followings:
a) All surplus earth and debris are removed/disposed off from the working areas to designated
location(s).
b) Unused/surplus cables, steel items and steel scrap lying scattered at different places within
the working areas are removed to identify location(s).
c) All wooden scrap, empty wooden cable drums and other combustible packing materials,
shall be removed from work place to identified location(s).
d) Roads shall be kept clear and materials like pipes, steel, sand, boulders, concrete, chips and
bricks etc shall not be allowed on the roads to obstruct free movement of men &
machineries.
e) Fabricated steel structural, pipes & piping materials shall be stacked properly for erection.
f) Water logging on roads shall not be allowed.
g) No parking of trucks/trolleys, cranes and trailers etc shall be allowed on roads, which may
obstruct the traffic movement.
h) Utmost care shall be taken to ensure over all cleanliness and proper upkeep of the working
areas.
i) Trucks carrying sand, earth and pulverized materials etc. shall be covered while moving
within the plant area/ or these materials shall be transported with top surface wet.
j) The contractor shall ensure that the atmosphere in plant area and on roads is free from
particulate matter like dust, sand, etc. by keeping the top surface wet for ease in breathing.
k) At least two exits for any unit area shall be assured at all times – same arrangement is
preferable for digging pits / trench excavation / elevated work platforms / confined spaces
etc.
l) Welding cables and the power cable must be segregated and properly stored and used .The
same shall be laid away from the area of movement and shall be free from obstruction.
m) Schedule for upkeep/cleaning of site to be firmed up and implemented on regular basis
The Contractor shall carry-out regular checks (minimum one per fortnight) as per format No:
HSE-11 for maintaining high standard of housekeeping and maintain records for the same.

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3.3 HSE Measures
3.3.1 Construction Hazards

The Contractor shall ensure identification of all Occupational Health, Safety & Environmental
hazards in the type of work he is going to undertake and enlist mitigation measures. Contractor
shall carry out Job Safety Analysis (JSA)/Risk Analysis specifically for high risk jobs/critical
jobs like
a) Working at height (+2.0 Mts height) for cold (incl. colour washing, painting, insulation
etc.) & hot works.
b) Work in confined space,
c) Deep excavations & trench cutting (depth > 2.0 mts.)
d) Operation & Maintenance of Batching Plant.
e) Shuttering / concreting (in single or multiple pour) for columns, parapets & roofs.
f) Erection & maintenance of Tower Crane.
g) Erection of structural steel members / roof-trusses / pipes at height more than 2.0 Mts. with
or without crane.
h) Erection of pipes (full length or fabricated) at height more than 2.0 Mts. height with Crane
of 100T capacity.
i) All lifts using 100T Crane plus mechanical pulling.
j) All lifts using two cranes in unison (Tandem Lifting).
k) Any lift exceeding 80% capacity of the lifting equipments (hydra, crane etc.).
l) Laying of pipes (isolated or fabricated) in deep narrow trenches – manually or
mechanically.
m) Maintenance of crane / extension or reduction of crane-boom on roads or in yards.
n) Erection of any item at >2.0 Mts. height using 100T crane or of higher capacity
o) Hydrostatic test of pipes, vessels & columns and water-flushing.
p) Radiography jobs (in-plant & open field)
q) Work in Live Electrical installations / circuits
r) Handling of explosives & Blasting operations
s) Demolishing / dismantling activities
t) Welding / gas cutting jobs at height (+2.0 Mts.)
u) Lifting / placing roof-girders at height (+2.0 Mts.)
v) Lifting & laying of metallic / non-metallic sheet over roof/structures.
w) Lifting of pipes, gratings, equipments/vessels at heights (+2.0 Mts) with & without using
cranes
x) Calibration of equipment, instruments and functional tests at yards / work-sites.
y) Operability test of Pump, Motors (after coupling) & Compressors.
z) Cold or Hot works inside Confined Space.
aa) Transportation & shifting of ODC consignments into project areas.
bb) Working in “charged/Live” elect. Panels
cc) Stress Relieving works (Electrically or by Gas-burners).
dd) Pneumatic Tests
ee) Card board blasting
ff) Chemical cleaning
and take feedback from EIL/Owner. The necessary HSE measures devised shall be put in to
place, prior to start of an activity & also shall be maintained during the course of works, by the
Contractor. Copies of such JSAs shall be kept available at work sites by the Contractor to enable
all concerned carrying out checks / verification.
A list of typical construction hazards along with their effects & preventive measures is given in
Appendix-E.

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3.3.2 Accessibility
 The Contractor shall provide safe means of access(in sufficient numbers) & efficient exit to
any working place including provisions of suitable and sufficient scaffolding at various
stages during all operations of the work for the safety of his workmen and EIL/Owner.
 The Contractor shall implement use of all measures including use of “life line”, “fall-
arresters”, “retractable fall arresters” , “safety nets” etc. during the course of using all safe
accesses & exits, so that in no case any individual remains at risk of slip & fall during their
travel.
 The access to operating plant / project complex shall be strictly regulated. Any person or
vehicle entering such complex shall undergo identification check, as per the procedures in
force / requirement of EIL/Owner.
 Accessibility to ‘confined space’ shall be governed by specific system / regulation, as

established at project site.
3.3.3 Personal Protective Equipments (PPEs)
 The Contractor shall ensure that all their staff, workers and visitors including their sub-
contractor(s) have been issued (records to be kept) & wear appropriate PPEs like nape strap
type safety helmets preferably with head & sweat band with ¾” cotton chin strap
(made of industrial HDPE), safety shoes with steel toe cap and antiskid sole, full body
harness (CЄ marked and conforming to EN361), protective goggles, gloves, ear muffs,
respiratory protective devices, etc. All these gadgets shall conform to applicable IS
Specifications/CE or other applicable international standards. The Contractor shall
implement a regular regime of inspecting physical conditions of the PPEs being issued /
used by the workmen of their own & also its sub-agencies and the damaged / unserviceable
PPEs shall be replaced forthwith.
 Owner/EIL may issue a comprehensive color scheme for helmets to be used by various
agencies. The Contractor shall follow the scheme issued by the owner/EIL and shall choose
any colour other than white (for Owner) or blue (for EIL) All HSE personnel shall
preferably wear dark green band on their helmet so that workmen can approach them for
guidance during emergencies. HSE personnel shall preferably wear such dresses with
fluorescent stripes, which are noticeable during night, when light falls on them.
 For shot blasting, the usage of protective face shield and helmets, gauntlet and protective
clothing is mandatory. Such protective clothing should conform relevant IS Specification.
 For off-shore jobs/contracts, contractor shall provide PPEs (new) of all types to EIL &
Owner's personnel, at his (contractor's) cost. All personnel shall wear life jacket at all time.
 An indicative list of HSE standards/codes is given under Appendix-A.

 Contractor shall ensure procurement & usage of following safety equipments/ accessories
(conforming to applicable IS mark / CE standard) by their staff, workmen & visitors
including their subcontractors all through the span of project construction / pre-
commissioning/ Commissioning:-
a. PPEs (Helmet, Spectacle, Ear-muff, Face shield, Hand gloves, Safety Shoes, Gum
boot)
b. Barricading tape / warning signs
c. Rechargeable Safety torch (flame-proof)
d. Safety nets (with tie-chords)
e. Fall arresters
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f. Portable ladders (varying lengths)

g. Life-lines (steel wire-rope, dia not less than 8.0 mm)
h. Full body harness (double lanyard)
i. Lanyard
j. Karabiner
k. Retractable fall arresters (various length)
l. Portable fire extinguishers (DCP type) – 5 kg capacity
m. Portable Multi Gas detector
n. Sound level meter
o. Digital Lux meter
p. Fire hoses & flow nozzles
q. Fire blankets / Fire retardant cloth (with eyelets)
3.3.4 Working at Height
 The Contractor shall issue permit for working (PFW) at height after verifying and
certifying the checkpoints as specified in the attached permit (Format No. HSE-6). He
shall also undertake to ensure compliance to the conditions of the permit during the
currency of the permit including adherence of personal protective equipments. Contractor’s
Safety Officer shall verify compliance status of the items of permit document after
implementation of action is completed by Contractor’s execution / field engineers at work
site. Job Safety Analysis (JSA) for specific works at height duly commented by
EIL/Owner, shall be kept attached with particular Permit for Work (PFW) at site for ready
reference & follow-up.
 Such PFW shall be initially issued for one single shift or expected duration of normal work
and extended further for balance duration, if required. EIL/Owner can devise block-permit
system at any specific area, in consultation with project specific HSE Committee to specify
the time-period of validity of such PFW or its renewal. This permit shall be applicable in
areas where specific clearance from Owner’s operation Deptt. /Safety Deptt. is not
required. EIL / Owner’s field Engineers/Safety Officers/Area Coordinators may verify and
counter sign this permit (as an evidence of verification) during the execution of the job.
 All personnel shall be medically examined & certified by registered doctor, confirming
their ‘medical fitness for working at height. The fitness examination shall be done once in
six months.
 In case work is undertaken without taking sufficient precautions as given in the permit, EIL
/Owner Engineers may exercise their authority to cancel such permit and stop the work till
satisfactory compliance/rectification is arranged made. Contractors are expected to
maintain a register for issuance of permit and extensions thereof including preserving the
used permits for verification during audits etc.
 The Contractor shall arrange (at his cost) and ensure use of Fall Arrester Systems by his
workers. Fall arresters are to be used while climbing/descending tall structures or vessels /
columns etc. These arresters should lock automatically against the anchorage line,
restricting free fall of the user. The device is to be provided with a double security opening
system to ensure safe attachment or release of the user at any point of rope. In order to
avoid shock, the system should be capable of keeping the person in vertical position in case
of a fall.
 The Contractor shall ensure that Full body harnesses conforming EN361 and having
authorized CЄ marking is used by all personnel while working at height. The lanyards and
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life lines should have enough tensile strength to take the load of the worker in case of a fall.
One end of the lanyard shall be firmly tied with the harnesses and the other end with life
line. The harness should be capable of keeping the workman vertical in case of a fall,
enabling him to rescue himself.
 The Contractor shall provide Roof Top Walk Ladders for carrying out activities on sloping
roofs in order to reduce the chances of slippages and falls.
 The Contractor shall ensure that a proper Safety Net System is used wherever the hazard of
fall from height is present. The safety net, preferably a knotted one with mesh ropes
conforming to IS 5175/ ISO 1140 shall have a border rope & tie cord of minimum 12mm
dia. The Safety Net shall be located not more than 6.0 meters below the working surface
extending on either side up to sufficient margin to arrest fall of persons working at different
heights.
 In case of accidental fall of person on such Safety Net, the bottom most portion of Safety
Net should not touch any structure, object or ground.
 The Contractor shall ensure positive isolation while working at different levels like in the
pipe rack areas. The working platforms with toe boards & hand rails shall be sufficiently
strong & shall have sufficient space to hold the workmen and tools & tackles including the
equipments required for executing the job. Such working platforms shall have mid-rails, to
enable people work safely in sitting posture.
3.3.5 Scaffoldings & Barricading
 Suitable scaffoldings shall be provided to workmen for all works that cannot be safely done
from the ground or from solid construction except such short period work that can be safely
done using ladders or certified (by 3rd party competent person) man-basket. When a ladder
is used, an extra workman shall always be engaged for holding the ladder.
 The Contractor shall ensure that the scaffolds used during construction activities shall be
strong enough to take the designed load. Main Contractor shall always furnish duly
approved construction-design details of scaffold & SWL (from competent designers) free
of charge, before they are being installed / constructed at site. Owner/EIL reserves the right
to ask the Contractor to submit certification and or design calculations from his Head office
/ Design/ Engineering expert regarding load carrying capacity of the scaffoldings.
 All scaffolds shall be inspected by a competent Scaffolding Inspector of the Contractor. He

shall paste a GREEN tag (duly signed by competent Scaffolding Inspector) on each
scaffold found safe and a RED tag (duly signed by competent Scaffolding Inspector) on
each scaffold found unsafe. Scaffolds with GREEN tag only shall be permitted to be used
and Scaffolds with RED ones shall immediately be made inaccessible. Work being found
continuing on scaffolds with RED tag shall be considered unauthorized work by Contractor
and may invite penalization from EIL/Owner. For every 120-125 m2 /m3 area / volume or
its parts thereof minimum one TAG shall be provided.
 The Contractor shall ensure positive barricading (indicative as well as protective) of the
excavated, radiography, heavy lift, high pressure hydrostatic & pneumatic testing and other
such areas. Sufficient warning signs shall be displayed along the barricading areas.
 Scaffolding shall be constructed using foot seals or base plates only.
3.3.6 Electrical Installations
 All electrical installations/ connections shall be carried out as per the provisions of latest
revision of following codes/standards, in addition to the requirements of Statutory
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Authorities and IE/applicable international rules & regulations:
- OISD STD 173: Fire prevention & protection system for electrical installations
- SP 30 (BIS) : National Electric Code
 All electrical installations shall be approved by the concerned statutory authorities.
 All temporary electrical installations / facilities shall be regularly checked by the

licensed/competent electricians of the Contractor and appropriate records shall be
maintained in format no: HSE-12” Inspection of temporary electrical booth/installation at
project construction site”. Such inspection records are to be made available to EIL/Owner,
whenever asked for.
3.3.6.1 The Contractor shall meet the following requirements:
a. Shall make Single Line Diagram (SLD) for providing connection to each equipments &
machinery and the same (duly approved by EIL/Owner) shall be pasted on the front face of
DBs (distribution boards) or JBs (Junction boxes) at every site. ( A typical Switch Board
Sketch is attached as Appendix -G )
b. Ensure that electrical systems and equipment including tools & tackles used during
construction phase are properly selected, installed, used and maintained as per provisions
of the latest revision of the Indian Electrical/ applicable international regulations.
c. Shall deploy qualified & licensed electricians for proper & safe installation and for regular
inspection of construction power distribution system/points including their earthing. A
copy of the license shall be submitted to EIL / Owner for records. Availability of at least
one competent (ITI qualified) / licensed electrician (by State Elec. authorities) shall be
ensured at site round the clock to attend to the normal/emergency jobs.
d. All switchboards / welding machines shall be kept in well-ventilated & covered shed/ with
rain shed protection. The shed shall be elevated from the existing ground level to avoid
water logging inside the shed . Installation of electrical switch board must be done taking
care of the prevention of shock and safety of machine.
e. No flammable materials shall be used for constructing the shed. Also flammable materials
shall not be stored in and around electrical equipment / switchboard. Adequate clearances
and operational space shall be provided around the equipment.
f. Fire extinguishers and insulating mats shall be provided in all power distribution centers.
g. Temporary electrical equipment shall not be employed in hazardous area without obtaining
safety permit.
h. Proper housekeeping shall be done around the electrical installations.
i. All temporary installations shall be tested before energizing, to ensure proper earthing,
bonding, suitability of protection system, adequacy of feeders/cables etc.
j. All welders shall use hand gloves irrespective of holder voltage.
k. Multilingual (Hindi, English and local language) caution boards, shock treatment charts and
instruction plate containing location of isolation point for incoming supply, name &
telephone No. of contact person in emergency shall be provided in substations and near all
distribution boards / local panels.

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l. Operation of earth leakage device shall be checked regularly by temporarily connecting

series test lamp (2 bulbs of equal rating connected in series) between phase and earth.
ELCB tester /test meter shall be used for testing ELCBs
m. Regular inspection of all installations at least once in a month. (Ref. Format HSE-12).
3.3.6.2 The following features shall also be ensured for all electrical installations during construction
phase by the contractor:
 Each installation shall have a main switch with a protective device, installed in an
enclosure adjacent to the metering point. The operating height of the main switch shall not
exceed 1.5 M. The main switch shall be connected to the point of supply by means of
armoured cable.
 The outgoing feeders shall be double or triple pole switches with fuses / MCBs. Loads in a
three phase circuit shall be balanced as far as possible and load on neutral should not
exceed 20% of load in the phase.
 The installation shall be adequately protected against overload, short circuit and earth
leakage by the use of suitable protective devices. Fuses wherever used shall be HRC type.
Use of rewirable fuses shall be strictly prohibited. The earth leakage device shall have an
operating current not exceeding 30 mA.
 All connections to the hand tools / welding receptacles shall be taken through proper
switches, sockets and plugs.
 All single phase sockets shall be minimum 3 pin type only. All unused sockets shall be
provided with socket caps.
 Only 3 core (P+N+E) overall sheathed flexible cables with minimum conductor size of 1.5
mm2 copper shall be used for all single phase hand tools.
 Only metallic distribution boxes with double earthing shall be used at site. No wooden
boxes shall be used.
 All power cables shall be terminated with compression type cable glands. Tinned copper
lugs shall be used for multi-strand wires / cables.
 Cables shall be free from any insulation damage.
 Minimum depth of cable trench shall be 750 mm for MV & control cables and 900 mm for
HV cables. These cables shall be laid over a sand layer and covered with sand, brick & soil
for ensuring mechanical protection. Cables shall not be laid in waterlogged area as far as
practicable. Cable route markers shall be provided at every 25 M of buried trench route.
When laid above ground, cables shall be properly cleated or supported on rigid poles of at
least 2.1 M high. Minimum head clearance of 6 meters shall be provided at road crossings.
 Under ground road crossings for cables shall be avoided to the extent feasible. In any case
no under ground power cable shall be allowed to cross the roads without pipe sleeve.
 All cable joints shall be done with proper jointing kit. No taped/ temporary joints shall be
used.
 An independent earthing facility should preferably be established within the temporary
installation premises. All appliances and equipment shall be adequately earthed. In case of
armoured cables, the armour shall be bonded to the earthing system.

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 All cables and wire rope used for earth connections shall be terminated through tinned
copper lugs.
 In case of local earthing, earth electrodes shall be buried near the supply point and earth
continuity wire shall be connected to local earth plate for further distribution to various
appliances. All insulated wires for earth connection shall have insulation of green colour.
 Separate core shall be provided for neutral. Earth / Structures shall not be used as a neutral
in any case.
 ON/OFF position of all switches shall be clearly designated / painted for easy isolation in
emergency.
3.3.7 Welding / Gas Cutting
 Contractor shall ensure that flash back arrestors conforming to BS: 6158 or equivalent are
installed on all gas cylinders as well as at the torch end of the gas hose, while in use.
 All cylinders shall be mounted on trolleys and provided with a closing key. Empty & filled-
up gas cylinders shall be stored separately with TAG, protecting them from direct sun or
rain. Minimum 2 nos. of Portable DCP type fire extinguishers (10 kg) shall be maintained
at the gas cylinder stores. Stacking & storing of compressed gas cylinders shall be arranged
away from DG set, hot works, Elect. Panels / Elec. boards, etc
 The burner and the hose placed downstream of pressure reducer shall be equipped with
Flash Back Arrester/Non Return Valve device.
 The hoses for acetylene and oxygen cylinders must be of different colours. Their
connections to cylinders and burners shall be made with a safety collar.
 At end of work, the cylinders in use shall be closed and hoses depressurized.
 Cutting of metals using gases, other than oxygen & acetylene, shall require written
concurrence from Owner.
 All welding machines shall have effective earthing at least at distinctly isolated two points.
 In order to help maintain good housekeeping, and to reduce fire hazard, live electrode bits
shall be contained safely and shall not be thrown directly on the ground.
 The hoses of Acetylene and Oxygen shall be kept free from entanglement & away from
common pathways / walkways and preferably be hanged overhead in such a manner which
can avoid contact with cranes, hydra or other mobile construction machinery.
 Hot spatters shall be contained / restricted appropriately (by making use of effective fire-
retardant cloth/fabric) and their flying-off as well as chance of contact with near-by
flammable materials shall be stopped.
 The Contractor shall arrange adequate systems & practices for accumulation / collection of
metal & other scraps and remnant electrodes and their safe disposal at regular interval so as
to maintain the fabrication and other areas satisfactorily clean & tidy.
 All gas cylinders must have a cylinder cap on at all times when not in use.
3.3.8 Ergonomics and Tools & Tackles
 The Contractor shall assign to his workmen, tasks commensurate with their qualification,
experience and state of health.
 All lifting tools, tackles, equipment, accessories including cranes shall be tested
periodically by statutory/competent authority for their condition and load carrying capacity.
Valid test & fitness certificates from the applicable authority shall be submitted to
Owner/EIL for their review/acceptance before the lifting tools, tackles, equipment,
accessories and cranes are used.
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 The contractor shall not be allowed to use defective equipment or tools not adhering to
safety norms.
 Contractor shall arrange non-sparking tools for project construction works in operating
plant areas / hydrocarbon prone areas.
 Wherever required the Contractor shall make use of Elevated Work Platforms (EWP) or
Aerial Work Platforms (mobile or stationary) to avoid ergonomical risks and workmen
shall be debarred to board such elevated platform during the course of their shifting /
transportation.
 Contractor shall ensure installation of Safe Load Indicator (SLI) on all cranes (while in use)
to minimize overloading risk. SLI shall have capability to continuously monitor and
display the load on the hook, and automatically compare it with the rated crane capacity at
the operating condition of the crane. The system shall also provide visual and audible
warnings at set capacity levels to alert the operator in case of violations.
 The contractor shall be responsible for safe operations of different equipments mobilized
and used by him at the workplace like transport vehicles, engines, cranes, mobile ladders,
scaffoldings, work tools, etc.
 The Contractor shall arrange periodical training for the operators of hydra, crane,
excavator, mobile machinery, etc. at site by utilizing services from renowned
manufacturers
3.3.9 Occupational Health
 The contractor shall identify all operations that can adversely affect the health of its
workers and issue & implement mitigation measures.
 For surface cleaning operations, sand blasting shall not be permitted even if not explicitly
stated elsewhere in the contract.
 To eliminate radiation hazard, Tungsten electrodes used for Gas Tungsten Arc Welding
shall not contain Thorium.
 Appropriate respiratory protective devices(hood with respiratory devices) shall be used to

protect workmen from inhalation of air borne contaminants like silica, asbestos, gases,
fumes, etc.
 Workmen shall be made aware of correct methods for lifting, carrying, pushing & pulling
of heavy loads. Wherever possible, manual handling shall be replaced by mechanical lifting
equipments.
 For jobs like drilling/demolishing/dismantling where noise pollution exceeds the specified
limit of 85 decibels, ear muffs shall be provided to the workers.
 To avoid work related upper limb disorders (WRULD) and backaches, Display Screen
Equipments' workplace stations shall be carefully designed & used with proper sitting
postures. Power driven hand-held tools shall be maintained in good working condition to
minimize their vibrating effects and personnel using these tools shall be taught how to
operate them safely & how to maintain good blood circulation in hands.
 The Contractor shall arrange health check up (by registered medical practitioner) for all the
workers at the time of induction. Health check may have to be repeated if the nature of duty
assigned to him is changed necessitating health check or doubt arises about his wellness.
EIL/Owner reserves the right to ask the contractor to submit medical test reports. Regular
health check-ups are mandatory for the workers assigned with Welding, Radiography,
Blasting, Painting, Heavy Lift and Height (>2m) jobs. All the health check-ups shall be
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conducted by registered Medical practitioner and records are to be maintained by the

Contractor.
 The Contractor shall ensure vaccination of all the workers including their families, during
the course of entire project span.
3.3.10 Hazardous Substances
 Hazardous, inflammable and/or toxic materials such as solvent coating, thinners, anti-
termite solutions, water proofing materials shall be stored in appropriate containers
preferably with lids having spillage catchment trays and shall be stored in a good ventilated
area. These containers shall be labeled with the name of the materials highlighting the
hazards associated with its use and necessary precautions to be taken. Respective MSDS
(Material Safety Data Sheet) shall be made available at site & may be referred whenever
problem arises.
 Where contact or exposure of hazardous materials are likely to exceed the specified limit or
otherwise have harmful effects, appropriate personal protective equipments such as gloves,
goggles/face-shields, aprons, chemical resistant clothing, respirator, etc. shall be used.
 The work place shall be checked prior to start of activities to identify the location, type and
condition of any asbestos materials which could be disturbed during the work. In case
asbestos material is detected, usage of appropriate PPEs by all personnel shall be ensured
and the matter shall be reported immediately to EIL/ Owner.
3.3.11 Slips, Trips & Falls
The contractor shall establish a regular cleaning and basic housekeeping programme that covers
all aspects of the workplace to help minimize the risk of slips, trips & falls. The contractor shall
take positive measures like keeping the work area tidy, storing waste in suitable containers &
harmful items separately, keeping passages, stairways, entrances & exits especially emergency
ones clear, cleaning up spillages immediately and replacing damaged carpet/ floor tiles, mats &
rugs at once to avoid slips, trips & falls.
3.3.12 Radiation Exposure
 All personnel exposed to physical agents such as ionizing & non-ionizing radiation,
including ultraviolet rays or similar other physical agents shall be provided with adequate
shielding or protection commensurate with the type of exposure involved.
 For Open Field Radiography works , requirements of Bhabha Atomic Research Centre
(BARC)/ Atomic Energy Regulatory Board (AERB) shall be followed.
 The Contractor shall implement an effective system of control (as described in the AERB
regulations) at site for handling radiography-sources & for avoiding its misuse & theft.
 The contractor shall generate the Format No: HSE-8 “Permit for radiation work” before
start of work.
 In case the radiography work has to be carried out at day time, suitable methodology to be
used so that other works, people are not affected.
3.3.13 Explosives / Blasting Operations
 Blasting operations shall be carried out as per latest Explosive Rules (Indian / International)
with prior permission. The Contractor shall obtain license from Chief Controller of
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Explosives (CCoE) for collection, transportation, storage of explosives as well as for

carrying out blasting operations.
 The Contractor shall prepare exclusive method statement (in cognizance with statutory
requirements) for diffusing unfired explosives, if any, at project site before carrying out
actual task. Nowhere blasting shall be carried out by the Contractor or its agency without
the involvement of competent supervisor and licensed blaster / shot blaster.
3.3.14 Demolition / Dismantling
 The contractor shall adhere to safe demolishing/ dismantling practices at all stages of work
to guard against unsafe working practices.
 The contractor shall disconnect service lines (power, gas supply, water, etc.)/ make
alternate arrangements prior to start of work and restore them, if required as directed by
EIL/ Owner at no extra cost.
 Before carrying out any demolition/ dismantling work, the contractor shall take prior
approval of EIL/Owner and generate the Format No.HSE-9. For revamp jobs in operating
plants where location of underground utilities is not known with certainty, the contractor
shall depute an experienced engineer for supervision and shall make adequate arrangements
for Fire fighting & First-Aid during the execution of these activities.
 The Contractor shall arrange approved Job Safety Analysis (JSA) / Method Statement for
the specific demolition / dismantling task and corresponding action plan commensurate
with hazards / risks associated therein. In no case any activity related to demolition /
dismantling shall be carried out by the Contractor without engaging own supervision / field
engineer.
3.3.15 Road Safety
 The Contractor shall ensure adequately planned road transport safety management system.
 The vehicles shall be fitted with reverse warning alarms & flashing lights / fog-lights and
usage of seat belts shall be ensured.
 The Contractor shall also ensure a separate pedestrian route for safety of the workers and
comply with all traffic rules & regulations, including maintaining speed limit of 20 kmph
or indicated by owner for all types of vehicles / mobile machinery. The maximum
allowable speed shall be adhered to.
 In case of an alert or emergency, the Contractor must arrange clearance of all the routes,
roads, access. The Contractor shall deploy sufficient number of traffic controllers at project
site routes / roads/ accesses, to alert reversing movement of vehicles & machinery as well
as pedestrians.
 Dumpers, Tippers, etc. shall not be allowed to carry workers within the plant area and also
to & from the labour colony to & from project sites.
 Hydras shall only be allowed for handling the materials at fabrication/ storage yards and in
no case shall be allowed to transport the materials over project / plant roads.
 The Contractor shall not deploy any such mobile machinery / equipments, which do not
have competent operator and / or experienced banks-man / signal-man. Such machinery /
equipments shall have effective limit-switches, reverse-alarm, front & rear-end lights etc.
and shall be maintained in good working order.
 The Contractor shall not carry-out maintenance of vehicles / mobile machinery occupying
space on project / plant roads and shall always arrange close supervision for such works.

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 For pipeline jobs, the contractor shall submit a comprehensive plan covering transportation,
loading / unloading of pipes, movement of side booms, movement of vehicles on the ROW,
etc.
 Contractor’s shall arrange /install visible road signs, diversion boards, caution boards, etc
on project roads for safe movement of men and machinery.
3.3.16 Welfare Measures
Contractor shall, at the minimum, ensure the following facilities at work sites:
 A crèche at site where 10 or more female workers are having children below the age of 6
years.
 Adequately ventilated / illuminated rooms at labour camps & its hygienic up-keeping.
 Reasonable canteen facilities at site and in labour camps at appropriate location depending
upon site conditions. Contractor shall make use of “industrial” variety of LPG cylinder &
satisfactory illumination at the canteens. Necessary arrangement for efficient disposal of
wastes from canteens & urinals /toilets shall also be made and regular review shall be made
to maintain the ambience satisfactorily hygienic & shall also comply with all applicable
statutory requirements.
 Adequately lighted & ventilated Rest rooms at site (separate for male workers and female
workers).
 Urinals, Toilets, drinking water, washing facilities, adequate lighting at site and labour
camps, commensurate with applicable Laws / Legislation.
3.3.17 Environment Protection
Contractor shall ensure proper storage and utilization methodology of materials that are
detrimental to the environment. Where required, Contractor shall ensure that only the
environment friendly materials are selected and emphasize on recycling of waste materials,
such as metals, plastics, glass, paper, oil & solvents. The waste that can not be minimized,
reused or recovered shall be stored and disposed of safely. In no way, toxic spills shall be
allowed to percolate into the ground. The contractor shall not use the empty areas for dumping
the wastes.
The contractor shall strive to conserve energy and water wherever feasible.
The contractor shall ensure dust free environment at workplace by sprinkling water on the
ground at frequent intervals. The air quality parameters for dust, poisonous gases, toxic releases,
harmful radiations, etc. shall be checked by the contractor on daily basis and whenever need
arises.
The contractor shall not be allowed to discharge chemicals, oil, silt, sewage, sullage and other
waste materials directly into the controlled waters like surface drains, streams, rivers, ponds. A
discharge plan suggesting the methods of treating the waste before discharging shall be
submitted to EIL/Owner for approval.
For pipeline jobs, top soil shall be stacked separately while making ROW through fields. This
fertile soil shall be placed back on top after backfilling.
For offshore construction barges, arrangements shall be made for safe disposal of human, food
& other wastes and applicable laws in this regard shall be followed.

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3.3.18 Rules & Regulations
All persons deployed at site shall be knowledgeable of and comply with the environmental laws,
rules & regulations relating to the hazardous materials, substances and wastes. Contractor shall
not dump, release or otherwise discharge or disposes off any such materials without the express
authorization of EIL/Owner. An indicative list of Statutory Acts & Rules relating to HSE is
given under Appendix-D.
3.3.19 Weather Protection
Contractor shall take appropriate measures to protect workers from severe storms, rain, solar
radiations, poisonous gases, dust, etc. by ensuring proper usage of PPEs like Sun glasses, Sun
screen lotions, respirators, dust masks, etc. and rearranging/ planning the construction activities
to suit the weather conditions. Effective arrangement (without creating inconvenience to project
facilities & permanent installations) for protecting workmen from hailstorm, drizzle in the form
of temporary shelter shall be made at site.
3.3.20 Communication
All persons deployed at the work site shall have access to effective means of communication so
that any untoward incident can be reported immediately and assistance sought by them.
All health & safety information shall be communicated in a simple & clear language easily
understood by the local workforce.
For information to all, typical subjects that should be communicated are: -
Inside the company (Top to down)
a. Quality Policy
b. HSE Policy contents
c. Environment Policy
d. HSE Objectives
e. Safety Cardinal Rules
f. HSE Target – reached or missed
g. Praises & Warnings to personnel for HSE Management
h. Safety Walk Through Reports and safety defects / shortfalls (by management)
i. HSE Audit results
j. Revised Statutory Health & Safety provisions, if any
k. H & S publicity
l. Suggestions
Inside the Company (Bottom to up)
a. Complaints
b. Compliances on safety defects / shortfalls
c. Suggestions
d. Proposals for changes & improvements
e. HSE Reports (including near-miss reports)

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3.3.21 Confined Space Entry
The contractor shall generate a work permit (Format No. HSE -7) before entering a confined
space. People, who are permitted to enter into confined space, must be medically examined &
certified by registered doctor, confirming their ‘medical fitness for working in confined space’.
All necessary precautions mentioned therein shall be adhered to. An attendant shall be
positioned outside a confined space for extending help during an emergency. All appropriate
PPEs and air quality parameters shall be checked before entering a confined space. It shall be
ensured that the piping of the equipment which has to be opened is pressure- free by checking
that blinds are in place, vents are open and volume is drained. Inside confined space works, only
electrical facilities / installations of 24V shall be permitted. Contactor shall ensure usage of safe
& suitable arrangement of oxygen supply for individual workmen (during the course of work in
confined space), if oxygen concentration is found to be less than 19.5% (v/v) there.
3.3.22 Heavy Lifts
 The contractor shall submit detailed rigging studies plan for EIL/ Owner approval prior to
lifting equipment which cannot be erected with a crane of approx. 100 MT capacity due to
constraints of its dimensions, location of foundation height, approach & weight.
 Contractor shall generate the format no:HSE-15 “Permit for heavy lift/critical erection”
 Prior to actual lifting activities, contractor shall check the validity of the crane inspection
certificate issued by statutory/ competent authority. This requirement shall also apply to all
rigging equipments utilized for the job.
 The contractor shall, at all times, be responsible for all rigging activities.
 The Contractor shall ensure medical fitness of all workmen who are engaged / involved in
erection of equipments, vessels etc. and such fitness checks shall be carried-out every six
months interval with the help of a registered medical practitioner & record shall be
maintained
 Adequate safety measures such as positive barricading, usage of appropriate PPEs, permit
to work, etc. shall be taken during all heavy or critical lifts.
 For lifting any material (irrespective of shape, size or volume), at any height, it is always
advisable to prepare a Plan of Erection (PoE) taking into consideration hazards & risks
associated therein – this can enable people to put their own experiences of various natures
& side-by-side establish a practical method for risk-free erection / lifts. The contractor shall
prepare PoE & shall document the same, when risks are identified as “medium” or “high”
and the same shall be approved by its competent / qualified engineer.
3.3.23 Key Performance Indicators
The contractor shall measure an activity in both leading & trailing indicators for statistical and
performance measurement. The activities pertaining to key performance indicators are covered
in Monthly HSE Report (Format No. HSE-5). The contractor shall try to achieve a statistically
fair record and strive for its continual improvement.
Leading Indicators viz:-:
- Number of Safety Inductions carried-out at site (for workmen & staff members)
- Number of HSE inspections carried out
- Number of “Safety Walk Through” carried-out by site-head.

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- Number of HSE shortfalls / lapses identified per contractor & closed-out in time.
- Number of Safety Meetings conducted (in-house / with contractors)
- Number of HSE Audits made (internal & external) vis-à-vis non conformances raised
- Number of HSE Awareness / Motivational program conducted by contractors
- Number of HSE Trainings conducted at site for supervisors & workmen
- Study of Near miss case reported
- Encouragements / Awards / Recognitions to workmen, job supervisors & field engineers.
- Suggestions for improvement
Trailing Indicators viz:-:
- Calculation of HSE statistics viz frequency rate, severity rate, LTA free manhours, etc.
- Analysis of incidents / accidents (nature, severity, types etc.)
- Study of Incident / Accident with respect to :-
 Variety
 Period of the year / project span
 Timings of the incident / accident
 Age profile of victims
 Body parts involved
 Penalty levied for causing incident / accident
3.3.24 Unsuitable Land Conditions
Contractor shall take appropriate measures and necessary work permits/clearances if work is to
be done in or around marshy areas, river crossings, mountains, monuments, etc. The Contractor
shall make right assessment and take all necessary action for developing work areas to make
them safe & suitable for crane operations or other vehicular movement before carrying out any
project related activity / operation. Contractor shall take all necessary actions to make the
surroundings of its site establishments (site office, stores, lay-down area etc.) work-worthy
safe and secure.
3.3.25 Under Water Inspection
Contractor shall ensure that boats and other means used for transportation, surveying &
investigation works shall be certified seaworthy by a recognized classification society. It shall
be equipped with all life saving devices like life jackets, adequate fire protection arrangements
and shall posses communication facilities like cellular phones, wireless, walkie-talkie. All
divers used for seabed surveys, underwater inspections shall have required authorized license,
suitable life saving kit. Number of hours of work by divers shall be limited as per regulations.
EIL/ Owner shall have the right to inspect the boat and scrutinize documents in this regard.
3.3.26 Excavation
The Contractor shall obtain permission from competent authorities prior to excavation wherever
required.
The Contractor shall locate the position of buried utilities (water line, cable route, etc.) by
referring to project / plant drawing / in consultation with EIL/Owner. The Contractor shall start
digging manually to locate the exact position of buried utilities & thereafter use mechanical
means.

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The Contractor shall keep soil heaps at least 1.5 M away from edge or a distance equal to depth
of pit (whichever is more)
The Contractor shall maintain sufficient “angle of repose” during excavation – shall also
provide slope or suitable bench as decided by EIL / Owner.
The Contractor shall arrange “battering” or “benching” wherever required for preventing
collapse of edge of excavations.
The Contractor shall identify & arrange de-watering pump or well-point system to prevent earth
collapse due to heavy rain / influx of underground water.
The Contractor shall arrange protective fencing / barricading with warning signal around
excavated pits, trenches, etc. along with minimum 2 (two) entries, exits / escape ladders.
The Contractor must avoid “underpinning” / under-cutting to prevent collapse of chunk of earth
during excavation
The Contractor shall use “stoppers” to prevent over-run of vehicle wheels at the edge of
excavated pits / trenches.
The Contractor shall arrange strengthening of “shoring” & “strutting” proactively to avoid
collapse of earth / edges due to vehicular movement in close proximity of excavated areas / pits/
trenches, etc.
3.4 Tool Box Talks (TBT)
Contractor shall conduct daily TBT with workers prior to start of work and shall maintain
proper record of the meeting. A suggested format is given below. The TBT is to be conducted
by the immediate supervisor of the workers
The Contractor shall conduct TBT before start of every morning or evening shift or night shift
activities, for alerting the workers on specific hazards and their appropriate dos & don’ts. The
Contractor shall provide sufficient rests to the site workmen and their foremen to avert fatigue
& thereby endangering their lives during the course of site works.
TOOL BOX TALK RECORDING SHEET

Date & Time
Work Location
Subject (Nature of work)
Presenter
Hazards involved
Precautions to be taken
Worker's Name Signature Section
Remarks, in any
The topics during TBT shall include
- Hazards related to work assigned on that day and precautions to be taken.

- Any forthcoming HSE hazards/events/instruction/orders, etc.
The above record can be kept in local language, which workers can read. These records shall be
made available to EIL/ Owner whenever demanded.
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3.5 Training & Induction Programme
 Initial induction of workers into Construction oriented activities and appraising them about
the methodology of works and how to carry-out safely and the same should not be inter
mixed with Tool Box Talks or HSE Training. In this regard careful action should be made
& maintained for imparting HSE induction to every individual, irrespective of his
task/designation/level of employment, whereas, HSE Training should be imparted to
specific person/group of people who are to carry-out that specific task more than once – for
example, Riggers must be trained for working at heights, welders must be trained for work
in confined space, fitters/carpenters, mesons must be trained for work at heights, etc.
 Contractor shall conduct Safety induction programme on HSE for all his workers and
maintain records. The Gate Pass shall be issued only to those workers who successfully
qualify the Safety induction programme.
 The Contractor shall brief the visitors about the HSE precautions which are required to be
taken before their proceeding to site and make necessary arrangements to issue appropriate
PPEs like Aprons, hard hats, ear-plugs, goggles & safety shoes etc., to his visitors. The
Contractor shall always maintain relevant acknowledgement from visitor on providing him
brief information on HSE actions.
 Contractor shall ensure that all his personnel possess appropriate training to carry out the
assigned job safely. The training should be imparted in a language understood by them and
should specifically be trained about
- Potential hazards to which they may be exposed at their workplace

- Measures available for prevention and elimination of these hazards
The topics during training shall cover, at the minimum: -
- Why safety should be considered during work - explanation

- Education about hazards and precautions required
- Employees’ duties & responsibilities
- Emergency and evacuation plan
- HSE requirements during project activities
- Fire fighting and First-Aid
- Use of PPEs
- Occupational health issues – dos & don’ts
- Local laws on intoxicating drinks, drugs, smoking in force
- Common environmental subjects – lighting, ventilation, vibration, smoke/fumes etc.
 Records of the training shall be kept and submitted to EIL/ Owner.
 The Contractor shall make regular program for conducting Safety Training on
various topics related to various activities & their safe-guarding utilizing experienced
persons / outside agency / faculty. A program for Safety Training (indicative list as
per Appendix –F) shall be furnished by the Contractor in its HSE Plan.
 For offshore and jetty jobs, contractor shall ensure that all personnel deployed have
undergone a structured sea survival training including use of lifeboats, basket
landing, use of radio communication etc. from an agency acceptable to Owner/EIL.

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3.6 Additional Safety Requirements for Working Inside a Running Plant
As a minimum, the contractor shall ensure adherence to following safety requirements while
working in or in the close vicinity of an operating plant:
a) Contractor shall obtain permits for Hot work, Cold work, Excavation and Confined Space
from Owner in the prescribed format.
b) The contractor shall monitor record and compile list of his workers entering the operational
plant/unit each day and ensure & record their return after completing the job.
c) Contractor’s workers and staff members shall use designated entrances and proceed by
designated routes to work areas only assigned to them. The workers shall not be allowed to
enter units' area, tanks area, pump rooms, etc. without work authorization permit.
d) Work activities shall be planned in such a way so as to minimize the disruption of other
activities being carried out in an operational plant/unit and activities of other contractors.
e) The contractor shall submit a list of all chemicals/toxic substances that are intended to be
used at site and shall take prior approval of the Owner.
f) Specific training on working in a hydrocarbon plant shall be imparted to the work force and
mock drills shall be carried out for Rescue operations/First-Aid measures.
g) Proper barricading/cordoning of the operational units/plants shall be done before starting

the construction activities. No unauthorized person shall be allowed to trespass. The height
and overall design of the barricading structure shall be finalized in consultation with the
Owner and shall be got approved from the Owner.
h) Care shall be taken to prevent hitting underground facilities such as electrical cables,
hydrocarbon piping during execution of work.
i) Barricading with water curtain shall be arranged in specific/critical areas where

hydrocarbon vapors are likely to be present such as near horton spheres or tanks.
Positioning of fire tenders (from owner) shall also be ensured during execution of critical
activities.
j) Emergency evacuation plan shall be worked out and all workmen shall be apprised about
evacuation routes. Mock drill operations may also be conducted.
k) Flammable gas test shall be conducted prior to any hot work using appropriate measuring
instruments. Sewers, drains, vents or any other gas escaping points shall be covered with
flame retardant tarpaulin.
l) Respiratory devices shall be kept handy while working in confined zones where there is a
danger of inhalation of poisonous gases. Constant monitoring of presence of Gas/
Hydrocarbon shall be done.
m) Clearance shall be obtained from all parties before starting hot tapping, patchwork on live
lines and work on corroded tank roof.
n) Positive isolation of line/equipment by blinding for welding/cutting/grinding shall be done.

Closing of valve will not be considered sufficient for isolation.
o) Welding spatters shall be contained properly and in no case shall be allowed to fall on the
ground containing oil. Similar care shall be taken during cutting operations.

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p) The vehicles, cranes, engines, etc. shall be fitted with spark arresters on the exhaust pipe
and got it approved from Safety Department of the Owner.
q) Plant air should not be used to clean any part of the body or clothing or use to blow off dirt
on the floor.
r) Gas detectors should be installed in gas leakage prone areas as per requirement of Owner's
plant operation personnel.
s) Experienced full time safety personnel shall be exclusively deployed to monitor safety
aspects in running plants.
3.7 Self Assessment and Enhancement
The contractor shall develop a method of check & balance through self assessment &
enhancement techniques and shall explore the opportunities for continual improvement in the
HSE system.
3.8 HSE Promotion
The contractor shall encourage his workforce to promote HSE efforts at workplace by way of
organizing workshops/seminars/training programmes, celebrating HSE awareness weeks &
National Safety Day, conducting quizzes & essay competitions, distributing pamphlets, posters
& material on HSE, providing incentives for maintaining good HSE practices and granting
incentives / bonus for completing the job without any lost time accident.
3.9 Lock Out and Tag Out (LOTO) for Isolation of Energy Source
 Contractor shall follow the LOTO/Isolation procedure of owner for all energy source
isolations installed/under purview by /of owner ie. “Brown field”
 For all the other energy source (not under purview of client/owner) i.e “Green field”
Contractor shall develop a system to ensure the isolation of equipments, pipelines, Vessel,
electrical panels from the energy source covering following as minimum:-
- Identification of all energy source viz electrical, mechanical, hydraulic, pneumatic,
chemical, thermal, gravitational, radiation and other forms of stored or kinetic
energy.
- Establishing the energy isolation devices viz: manually operated electrical circuit
breakers, disconnection switches, blind flanges, etc.
- Installation of Lock Out devices for preventing the inadvertent release of stored
energy and Tag Out devices ( “Danger”, “Do Not operate” or Do not Remove” tags)
to indicate that testing, maintenance or servicing is underway and the device cannot
be operated until the tag out device is removed.
- Lock Out and Tag out log book
- Permit for isolation and de-isolation of energy source as per format NO: HSE-16
- Availability of competent persons like experienced operators at substations, pump
house, units, etc, ; supervisors, etc.
 Contractor shall ensure that all the sources are locked out and tagged properly before
giving clearance to start the job.
 After the completion of job, contractor shall ensure all tools and tackles are removed and
nobody is present in the working area and signing on LOTO log book.
 Only on confirmation of above the contractor will remove their lock and tag from the
isolation points and give instructions for energizing the same. Only the person carrying out
the task shall himself carry the key for the lock in /Lock out.

Page 318 of 373
4.0 DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR
4.1 On Award of Contract
The Contractor shall submit a comprehensive Health, Safety and Environment Plan or
programme for approval by EIL/Owner prior to start of work. The Contractor shall participate in
the pre-start meeting with EIL/Owner to finalize HSE Plans which shall including the
following:
- HSE policy & Objectives

- Job procedure to be followed by the Contractor for construction activities including
handling of equipments, scaffolding, electric installations, etc. describing the risks
involved, actions to be taken and methodology for monitoring each activity. Indicative list
of procedures is enclosed as Annexure-H
- EIL/Owner review/audit requirement.
- Organization structure along with responsibility and authority, on HSE activities.
- Administrative & disciplinary steps involving implementation of HSE requirements
- Emergency evacuation plan/ procedures for site and labour camps
- Job Safety Analysis for high risk jobs
- Procedures for reporting & investigation of accidents and near misses.
- HSE Inspection
- HSE Training programmes at project site
- HSE Awareness programmes at project site
- Reference to Rules, Regulations and statutory requirements.
- HSE documentation viz reporting, analysis & record keeping.
4.2 During Job Execution
Contractor shall implement approved Health, Safety and Environment management programme
including but not limited to as brought out under para 3.0. Contractor shall also ensure:
 to arrange workmen compensation insurance, registration under ESI Act, third party
liability insurance, registration under BOCW Act, etc, as applicable.
 to arrange all HSE permits before start of activities (as applicable), like permits for hot
work, working at heights (Refer Format No. HSE-6), confined space (Refer Format No.
HSE-7), Radiation Work Permit (Refer Format No. HSE-8), Demolishing/ Dismantling
Work Permit (Refer Format No. HSE-9),Permit for erection/modification & dismantling of
scaffolding(Refer Format No:HSE-14), Permit for heavy lift/critical erection (Refer Format
No:HSE-15) ,Permit for energy Isolation & De-isolation” (HSE-16) ,storage of chemical /
explosive materials & its use and implement all precautions mentioned therein. In this
regard, requirements of Oil industry Safety Directorate Standard No. Std -105 "Work
Permit Systems” shall be complied with while working in existing Oil or Gas processing
plants.
 to submit, timely, the completed checklist on HSE activities in Format No.HSE-1, Monthly
HSE report in Format No.HSE-5 (use of web based package (www.eil.co.in/conthse) is
compulsory wherever the facility is available else a hard copy is to be submitted), accident/
incident reports, investigation reports etc. as per EIL/Owner requirements. Compliance of
instructions on HSE shall be done by Contractor and informed urgently to EIL/Owner.
 that his top most executive at site attends all the Safety Committee/HSE meetings arranged
by EIL/Owner and carries out safety walk through regularly. Only in case of his absence
Page 319 of 373
from site that a second senior most person shall be nominated by him, in advance, and
communicated to EIL/Owner for performing the above tasks.
 display at site office and at prominent locations HSE Policy, caution boards, list of
hospitals, emergency services available, safety signs like Men at work, Speed Limits,
Hazardous Area, various do’s & don’ts, etc.
 provide posters, banners for safe working to promote safety consciousness.
 identify, assess, analyze & mitigate the construction hazards & incorporate relevant control
measures before actually executing site works. (HIRAC = Hazard Identification, Risk
Analysis and Control).
 arrange testing, examination, inspection of own as well as borrowed construction

equipments / machinery (stationary & mobile) before being used at site and also at
periodical interval, through own resources and also by 3rd party competent agencies (as
deemed fit in statutes). Records of such test, examination etc. shall be maintained & shall
be submitted to EIL/Owner as & when asked for.
 carryout audits/inspection (internal & external) at his works as well as sub contractor works
as per approved HSE plan/procedure/programme & submit the compliance reports of
identified shortfalls for EIL/Owner review.
 arranging HSE training for site workmen (of his own & sub contractors) through internal or
external faculty at periodical intervals.
 assistance & cooperate during HSE audits by EIL/Owner or any other 3rd party and submit
compliance report.
 generate & submit of HSE records/report as per this specification.
 apprise EIL/Owner on HSE activities at site regularly.
 carry-out all dismantling activities safely, with prior approval of EIL/Owner representative.
 The Contractor shall ensure that “Hot works” and painting works do not continue at the
same place / location at project site for which chance or probability of “fire” incident
exists.
4.3 During Short Listing of the Sub-Contractors
The contractor shall review the HSE management system of the sub-contractors in line with the
requirements given in this specification. The contractor shall be held responsible for the
shortcomings observed in the HSE management system of the sub-contractor(s) during
execution of the job.
5.0 RECORDS
At the minimum, the contractor shall maintain/ submit HSE records in the following reporting
formats/:
Safety Walk Through Report HSE-1

Accident/ Incident Report HSE-2
Supplementary Accident/ Incident Investigation report HSE-3
Near Miss Incident Report HSE-4
Page 320 of 373
Monthly HSE Report HSE-5

Permit for working at height HSE-5
Permit for working in confined space HSE-7
Permit for radiation work HSE-8
Permit for demolishing/ dismantling HSE-9
Daily Safety checklist HSE-10
House keeping Assessment & compliance HSE-11
Inspection of temporary electrical booth/installation HSE-12
Inspection for scaffolding HSE-13
Permit for erection/modification &dismantling of scaffolding HSE-14
Permit for heavy lift/critical erection. HSE-15
Permit for Energy isolation and de-isolation. HSE-16
Permit for Excavation HSE-17
Inspection reports of Equipment/tools/tackles *
Report of Toolbox talks As indicated in
specification
PPE issue report/register *
Site inspection reports *
Training records *
(*) The formats shall be developed in consultation with EIL/Owner

Page 321 of 373
APPENDIX-A
(Sheet 1 of 2)
A. IS CODES ON HSE
SP: 53 Safety code for the use, Care and protection of hand operated tools.
IS: 838 Code of practice for safety & health requirements in electric and gas welding and
cutting operations
IS: 1179 Eye & Face precautions during welding, equipment etc.
IS: 1860 Safety requirements for use, care and protection of abrasive grinding wheels.
IS: 1989 (Pt -II) Leather safety boots and shoes
IS: 2925 Industrial Safety Helmets
IS: 3016 Code of practice for fire safety precautions in welding & cutting operation.
IS: 3043 Code of practice for earthing
IS: 3764 Code of safety for excavation work
IS: 3786 Methods for computation of frequency and severity rates for industrial injuries and
classification of industrial accidents
IS: 3696 Safety Code of scaffolds and ladders
IS: 4083 Recommendations on stacking and storage of construction materials and components
at site
IS: 4770 Rubber gloves for electrical purposes
IS: 5121 Safety code for piling and other deep foundations
IS: 5216 (Pt-I) Recommendations on Safety procedures and practices in electrical works
IS: 5557 Industrial and Safety rubber lined boots
IS: 5983 Eye protectors
IS: 6519 Selection, care and repair of Safety footwear
IS: 6994 (Pt-I) Industrial Safety Gloves (Leather & Cotton Gloves)
IS: 7293 Safety Code for working with construction Machinery
IS: 8519 Guide for selection of industrial safety equipment for body protection
IS: 9167 Ear protectors
IS: 11006 Flash back arrestor (Flame arrestor)
IS: 11016 General and safety requirements for machine tools and their operation
IS: 11057 Specification for Industrial safety nets
IS: 11226 Leather safety footwear having direct moulded rubber sole
IS: 11972 Code of practice for safety precaution to be taken when entering a sewerage system
IS: 13367 Code of practice-safe use of cranes
IS: 13416 Recommendations for preventive measures against hazards at working place

Page 322 of 373
APPENDIX-A
(Sheet 2 of 2)
B. INTERNATIONAL STANDARDS ON HSE
Safety Glasses : ANSI Z 87.1, ANSI ZZ 87.1, AS 1337, BS 2092,

BS 1542, BS 679, DIN 4646/ 58311
Safety Shoes : ANSI Z 41.1, AS 2210, EN 345
Hand Gloves : BS 1651
Ear Muffs : BS 6344, ANSI S 31.9
Hard Hat : ANSI Z 89.1/89.2, AS 1808 , BS 5240, DIN 4840
Goggles : ANSI Z 87.1
Face Shield : ANSI Z 89.1
Breathing Apparatus : BS 4667, NIOSH
Welding & Cutting : ANSI Z 49.1
Safe handling of compressed : P-1 (Compressed Gas Association Gases in cylinders

1235 Jefferson Davis Highway,
Arlington VA 22202 - USA)
Full body harness : EN-361
Lanyard : EN-354
Karabiner : EN-362 and EN-12275

Page 323 of 373
APPENDIX-B
DETAILS OF FIRST AID BOX
------------------------------------------------------------------------------------------------------------------------
SL. DESCRIPTION QUANTITY
NO.
------------------------------------------------------------------------------------------------------------------------
1. Small size Roller Bandages, 1 Inch Wide (Finger Dressing small) 6 Pcs.
2. Medium size Roller Bandages, 2 Inches Wide (Hand & Foot Dressing) 6 Pcs.
3. Large size Roller Bandages, 4 Inches Wide (Body Dressing Large) 6 Pcs.
4. Large size Burn Dressing (Burn Dressing Large) 4 Pkts.
5. Cotton Wool (20 gms packing) 4 Pkts.
6. Antiseptic Solution Dettol (100 ml.) or Savlon 1 Bottle
7. Mercurochrome Solution (100 ml.) 2% in water 1 Bottle
8. Ammonia Solution (20 ml.) 1 Bottle
9. A Pair of Scissors 1 Piece
10. Adhesive Plaster (1.25 cm X 5 m) 1 Spool
11. Eye pads in Separate Sealed Pkt. 4 pcs.
12. Tourniqut 1 No.
13. Safety Pins 1 Dozen
14. Tinc. Iodine/ Betadin (100 ml.) 1 Bottle
15. Polythene Wash cup for washing eyes 1 No.
16. Potassium Permanganate (20 gms.) 1 Pkt.
17. Tinc. Benzoine (100 ml.) 1 Bottle
18. Triangular Bandages 2 Nos.
19. Band Aid Dressing 5 Pcs.
20. Iodex/Moov (25 gms.) 1 Bottle
21. Tongue Depressor 1 No.
22. Boric Acid Powder (20 gms.) 2 Pkt.
23. Sodium Bicarbonate (20 gms.) 1 Pkt.
24. Dressing Powder (Nebasulf) (10 gms.) 1 Bottle
25. Medicinal Glass 1 No.
26. Duster 1 No.
27. Booklet (English & Local Language) 1 No. each
28. Soap 1 No.
29. Toothache Solution 1 No.
30. Vicks (22 gms.) 1 Bottle
31. Forceps 1 No.
32. Note Book 1 No.
33. Splints 4 Nos.
34. Lock 1 Piece
35. Life Saving/Emergency/Over-the counter Drugs As decided at site
-----------------------------------------------------------------------------------------------------------------
Box size: 14" x 12" x 4"
-----------------------------------------------------------------------------------------------------------------
Note : The medicines prescribed above are only indicative. Equivalent medicines can also be used.
A prescription, in this regard, shall be required from a qualified Physician.

Page 324 of 373
APPENDIX-C
TYPE OF FIRES VIS-À-VIS FIRE EXTINGUISHERS
Fire
Extinguisher
Fire Multi purpose
Water Foam CO2 Dry Powder
(ABC)
Originated from can control can control

  minor surface 
paper, clothes, wood minor surface
fires fires
Inflammable liquids
like alcohol, diesel,
    
petrol, edible oils,
bitumen
Originated from
gases like LPG,     
CNG, H2
Electrical fires     
LEGEND :  : CAN BE USED
 : NOT TO BE USED
Note: Fire extinguishing equipment must be checked at least once a year and after every use by an
authorized person. The equipment must have an inspection label on which the next inspection date
is given. Type of extinguisher shall clearly be marked on it.

Page 325 of 373
APPENDIX-D
List of Statutory Acts & Rules Relating to HSE
- The Indian Explosives Act and Rules

- The Motor Vehicle Act and Central Motor Vehicle Rules
- The Factories Act and concerned Factory Rules
- The Petroleum Act and Petroleum Rules
- The Workmen Compensation Act
- The Gas Cylinder Rules and the Static & Mobile Pressure Vessels Rules
- The Indian Electricity Act and Rules
- The Indian Boiler Act and Regulations
- The Water (Prevention & Control & Pollution) Act
- The Water (Prevention & Control of Pollution) Cess Act
- The Mines & Minerals (Regulation & Development) Act
- The Air (Prevention & Control of Pollution) Act
- The Atomic Energy Act
- The Radiation Protection Rules
- The Indian Fisheries Act
- The Indian Forest Act
- The Wild Life (Protection) Act
- The Environment (Protection) Act and Rules
- The Hazardous Wastes (Management & Handling) Rules
- The Manufacturing, Storage & import of Hazardous Chemicals Rules
- The Public Liability Act
- The Building and Other Construction Workers (Regulation of Employment and Condition of
service) Act
- Other statutory acts Like EPF, ESIS, Minimum Wage Act.

Page 326 of 373
APPENDIX-E
(Sheet 1 of 12)
CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES
TYPE OF EFFECT OF
ACTIVITY PREVENTIVE MEASURES
HAZARD HAZARD
(A) Falling into pit Personal injury Provide guard rails/ barricade with warning
EXCAVATIO signal
N Provide at least two entries/ exits.
Provide escape ladders.
Pit Excavation Earth Collapse Suffocation/ Provide suitable size of shoring and strutting, if
upto 3.0m Breathlessness required.
Buried Keep soil heaps away from the edge equivalent to
1.5m or depth of pit whichever is more.
Don't allow vehicles to operate too close to
excavated areas. Maintain at least 2m distance
from edge of cut.
Maintain sufficient angle of repose. Provide
slope not less than 1:1 and suitable bench of 0.5m
width at every 1.5m depth of excavation in all
soils except hard rock.
Battering/benching the sides.
Contact with Electrocution Obtain permission from competent authorities,
buried electric Explosion prior to excavation, if required.
cables Locate the position of buried utilities by referring
Gas/ Oil to plant drawings.
Start digging manually to locate the exact
Pipelines position of buried utilities and thereafter use
mechanical means.
Pit Excavation Same as above Can cause Prevent ingress of water
beyond 3.0m plus drowning situation Provide ring buoys
Flooding due to Identify and provide suitable size dewatering
excessive rain/ pump or well point system
underground
water
Digging in the Building/Structure Obtain prior approval of excavation method from
vicinity of may collapse local authorities.
existing Building/ Loss of health & Use under-pining method
Structure wealth Construct retaining wall side by side.
Movement of May cause cave-in Barricade the excavated area with proper lighting
vehicles/ or slides. arrangements
equipments close Persons may get Maintain at least 2m distance from edge of cut
to the edge of cut. buried. and use stop blocks to prevent over-run
Strengthen shoring and strutting

Page 327 of 373
APPENDIX-E
(Sheet 2 of 12)
CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES (…Contd.)
TYPE OF EFFECT OF
HAZARD HAZARD
Narrow deep Same as above May cause severe Battering/benching of sides
excavations for plus injuries or prove Provide escape ladders
pipelines, etc. Frequent cave-in fatal
or slides
Flooding due to May arise drowning Same as above plus
Hydro- static situation Bail out accumulated water
testing Maintain adequate ventilation.
Rock by Improper May prove fatal Ensure proper storage, handling & carrying of
excavation handling of explosives by trained personnel.
blasting explosives Comply with the applicable explosive acts &
rules.
Uncontrolled May cause severe Allow only authorized persons to perform
explosion injuries or prove blasting operations.
fatal Smoking and open flames are to be strictly
prohibited
Scattering of Can hurt people Use PPE like goggles, face mask, helmets etc.
stone pieces in
atmosphere
Rock Entrapping of May cause severe Barricade the area with red flags and blow siren
excavation by persons/ animals. injuries or prove before blasting.
blasting fatal
(Contd) Misfire May explode Do not return to site for at least 20 minutes or
suddenly unless announced safe by designated person.
Piling Work Failure of pile- Can hurt people Inspect Piling rigs and pulley blocks before the
driving beginning of each shift.
equipment
Noise pollution Can cause deafness Use personal protective equipments like ear
and psychological plugs, muffs, etc.
imbalance.
Extruding Can hurt people Barricade the area and install sign boards
rods/casing Provide first-aid
Working in the Can cause Keep sufficient distance from Live-Electricity as
vicinity of 'Live- electrocution/ per IS code.
Electricity' Asphyxiation Shut off the supply, if possible
Provide artificial/rescue breathing to the injured
(B) Air pollution by May affect Wear respirators or cover mouth and nose with
CONCRETING cement Respiratory System wet cloth.
Handling of Hands may get Use gloves & other PPE.
ingredients injured
Protruding Feet may get Use Provide platform above reinforcement for
reinforcement injured movement of workers.
rods.

Page 328 of 373
APPENDIX-E
(Sheet 3 of 12)
CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES (…Contd.)
TYPE OF EFFECT OF
HAZARD HAZARD
Earthing of Can cause Ensure earthing of equipments and proper
electrical electrocution/ functioning of electrical circuit before
mixers, asphyxiation commencement of work.
vibrators, etc.
not done.
Falling of Persons may get Use hard hats
materials from injured Remove surplus material immediately from work
height place.
Ensure lighting arrangements during night hours
Continuous Cause tiredness of Insist on shift pattern
pouring by same workers and may Provide adequate rest to workers between
gang lead to accident. subsequent pours.
Revolving of Parts of body or Allow only mixers with hopper
concrete mixer/ clothes may get Provide safety cages around moving motors
vibrators entrapped. Ensure proper mechanical locking of vibrator
Super-structure Same as above Shuttering/props Avoid excessive stacking on shuttering material
plus may collapse and Check the design and strength of shuttering
Deflection in prove fatal material before commencement of work
props or Rectify immediately the deflection noted during
shuttering concreting.
material
Passage to work Improperly tied and Ensure the stability and strength of passage
place designed before commencement of work.
props/planks may Do not overload and stand under the passage.
collapse
(C) REINFOR- Curtailment and Persons may get Use PPE like gloves, shoes, helmets, etc.
CEMENT binding of rods injured Avoid usage of shift tools
Carrying of rods Workers may get Provide suitable pads on shoulders and use safety
for short injured their hands gloves.
distances/at and shoulders. Tie up rods in easily liftable bundles
heights Ensure proper staging.
Checking of Rods may cut or Use measuring devices like tape, measuring rods,
clear distance/ injure the fingers etc.
cover with hands
Hitting projected Persons may get Use safety shoes and avoid standing
rods and injured and fell unnecessarily on cantilever rods
standing on down Avoid wearing of loose clothes
cantilever rods.

Page 329 of 373
APPENDIX-E
(Sheet 4 of 12)

(…Contd.)
TYPE OF EFFECT OF
HAZARD HAZARD
Falling of material May prove fatal Use helmets
from height Provide safety nets
Transportation of Protruded rods may Use red flags/lights at the ends

rods by trucks/ hit the persons Do not protrude the rods in front of or by the side
trailers of driver's cabin.
Do not extend the rods 1/3rd of deck length or
1.5m whichever is less
(D)WELDING Welding radiates Radiation can Use specified shielding devices and other PPE of
AND GAS invisible damage eyes and correct specifications.
CUTTING ultraviolet and skin. Avoid thoriated tungsten electrodes for GTAW
infra-red rays
Improper Explosion may occur Move out any leaking cylinder
placement of Keep cylinders in vertical position
oxygen and Use trolley for transportation of cylinders and
acetylene cylinders chain them
Use flashback arrestors
Leakage/ cuts in May cause fire Purge regulators immediately and then turn off
hoses Never use grease or oil on oxygen line
connections and copper fittings on acetylene lines
Inspect regularly gas carrying hoses
Always use red hose for acetylene & other
fuel gases and black for oxygen
Opening-up of Cylinder may burst Always stand back from the regulator while
cylinder opening the cylinder
Turn valve slowly to avoid bursting
Cover the lug terminals to prevent short
circuiting
Welding of tanks, Explosion may occur Empty & purge them before welding
container or pipes Never attach the ground cable to tanks, container
storing flammable or pipe storing flammable liquids
liquids Never use LPG for gas cutting

Page 330 of 373
APPENDIX-E
(Sheet 5 of 12)

…(Contd.)
TYPE OF EFFECT OF
HAZARD HAZARD
(E) Ionizing Radiations may react Ensure Safety regulations as per BARC/AERB
RADIOGRAPHY radiation with the skin and can before commencement of job.
cause cancer, skin Cordon off the area and install Radiation warning
irritation, dermatitis, symbols
etc. Restrict the entry of unauthorized persons
Wear appropriate PPE and film badges issued by
BARC/AERB
Transpor-tation Same as above Never touch or handle radiography source with

and Storage of hands
Radiog-raphy Store radiography source inside a pit in an
source exclusive isolated storage room with lock and
key arrangement. The pit should be approved by
BARC/AERB.
Radiography source should never be carried
either in passenger bus or in a passenger
compartment of trains.
BARC/AERB has to be informed before source
movement.
Permission from Director General of Civil
Aviation is required for booking radio isotopes
with airlines.
Loss of Radio Same as above Try to locate with the help of Survey Meter.
isotope Inform BARC/AERB (*)
(F) ELECTRICAL Short circuiting Can cause Use rubberized hand gloves and other PPE
INSTALLATION Electrocution or Fire Don't lay wires under carpets, mats or door ways.
AND USAGE Allow only licensed electricians to perform on
electrical facilities
Use one socket for one appliance
Ensure usage of only fully insulated wires or
cables
Don't place bare wire ends in a socket
Ensure earthing of machineries and equipments
Do not use damaged cords and avoid temporary
connections
Use spark-proof/flame proof type field
distribution boxes.
(*) Atomic Energy Regulatory Board (AERB),

Bhabha Atomic Research Centre (BARC)
Anushaktinagar, Mumbai – 400 094

Page 331 of 373
APPENDIX-E
(Sheet 6 of 12)

(…Contd.)
TYPE OF EFFECT OF
HAZARD HAZARD
Do not allow open/bare connections
Provide all connections through ELCB
Protect electrical cables/equipment's from water
and naked flames
Check all connections before energizing
Overloading of Bursting of system Display voltage and current ratings prominently
Electrical can occur which with 'Danger' signs.
System leads to fire Ensure approved cable size, voltage grade and
type
Switch off the electrical utilities when not in use
Do not allow unauthorized connections.
Ensure proper grid wise distribution of Power
Improper laying Can cause Do not lay unarmoured cable directly on ground,
of overhead and electrocution and wall, roof of trees
underground prove fatal Maintain at least 3m distance from HT cables
transmission All temporary cables should be laid at least 750
lines/cables mm below ground on 100 mm fine sand
overlying by brick soling
Provide proper sleeves at crossings/ inter-
sections
Provide cable route markers indicating the type
and depth of cables at intervals not exceeding
30m and at the diversions/termination
(G) FIRE Small fires can Cause burn injuries In case a fire breaks out, press fire alarm system
PREVENTION become big ones and may prove fatal and shout "Fire, Fire"
AND and may spread Keep buckets full of sand & water/ fire
PROTECTION to the extinguishing equipment near hazardous
surrounding locations
areas Confine smoking to 'Smoking Zones' only.
Train people for using specific type of fire
fighting equipments under different classes of fire
Keep fire doors/shutters, passages and exit doors
unobstructed
Maintain good housekeeping and first-aid boxes
(for details refer Appendix-B)
Don't obstruct assess to Fire extinguishers.
Do not use elevators for evacuation during fire.
Maintain lightening arrestors for elevated
structures
Stop all electrical motors with internal
combustion

Page 332 of 373
APPENDIX-E
(Sheet 7 of 12)

(…Contd.)
TYPE OF EFFECT OF
HAZARD HAZARD
Move the vehicles from dangerous locations
Remove the load hanging from the crane booms
Remain out of the danger areas.
Improper It may not Ensure usage of correct fire extinguisher meant
selection of Fire extinguish the fire for the specified fire (for details refer Appendix-
extinguisher C).
Do not attempt to extinguish Oil and electric
fires with water. Use foam cylinders/CO2/sand
or earth.
Improper storage Same as above Maintain safe distance of flammable substances
of highly from source of ignition
inflammable Restrict the distribution of flammable materials
substances to only min. necessary amount
Construct specifically designed fuel storage
facilities
Keep chemicals in cool and dry place away from
heat. Ensure adequate ventilation
Before welding operation, remove or shield the
flammable material properly
Store flammable materials in stable racks,
correctly labeled preferably with catchment
trays.
Wipe off the spills immediately
Short circuiting Same as above Don't lay wires under carpets, mats or door ways
of electrical Can cause Use one socket for one appliance.
system Electrocution Use only fully insulated wires or cables
Do not allow open/bare connections
Provide all connections through ELCB
Ensure earthing of machineries and equipments
(H) Crossing the Personal injury Obey speed limits and traffic rules strictly
VEHICULAR Speed Limits Always expect the unexpected and be a
MOVEMENT (Rash driving) defensive driver
Use seat belts/helmets
Blow horn at intersections and during
overtaking operations.
Maintain the vehicle in good condition
Do not overtake on curves, bridges and slopes
Adverse weather Same as Above Read the road ahead and ride to the left
condition Keep the wind screen and lights clean
Do not turn at speed.
Recognize the hazard, understand the defense
and act correctly in time.

Page 333 of 373
APPENDIX-E
(Sheet 8 of 12)

(…Contd.)
TYPE OF EFFECT OF
HAZARD HAZARD
Consuming Same as above Alcohol and driving do not mix well. Either
alcohol before choose alcohol or driving.
and during the If you have a choice between hitting a fixed
driving object or an on-coming vehicle, hit the fixed
operation object
Quit the steering at once and become a passenger.
Otherwise take sufficient rest and then drive.
Do not force the driver to drive fast and round the
clock.
Do not day dream while driving
Falling objects/ May prove fatal Ensure effective braking system, adequate
Mechanical visibility for the drives, reverse warning alarm..
failure Proper maintenance of the vehicle as per
manufacturer instructions
(I) PROOF Bursting of May cause injury Prepare test procedure & obtain EIL/owner's
TESTING piping and prove fatal approval
(HYDROSTATI Collapse of Provide separate gauge for pressurizing pump
C /PNEUMATIC tanks and piping/equipment
TESTING) Tanks flying off Check the calibration status of all pressure
gauges, dead weight testers and temperature
recorders
Take dial readings at suitable defined intervals
and ensure most of them fall between 40-60% of
the gauge scale range
Provide safety relief valve (set at pressure
slightly higher than test pressure) while testing
with air/ nitrogen
Ensure necessary precautions, stepwise increase
in pressure, tightening of bolts/nuts, grouting, etc.
before and during testing
Keep the vents open before opening any valve
while draining out of water used for hydro-testing
of tanks.
Pneumatic testing involves the hazard of released
energy stored in compressed gas. Specific care
must therefore be taken to minimize the chance
of brittle failure during a pneumatic leak test.
Test temperature is important in this regard and
must be considered when the designer chooses
the material of construction.

Page 334 of 373
APPENDIX-E
(Sheet 9 of 12)

(…Contd.)
TYPE OF EFFECT OF
HAZARD HAZARD
A pressure relief device shall be provided, having
a set pressure not higher than the test pressure
plus the lesser of 345 KPa (50 psi) or 10% of the
test pressure.
The gas used as test fluid, if not air, shall be
nonflammable and nontoxic.
(J) Person can fall May sustain severe Provide guard rails/barricade at the work place
WORKING AT down injuries or prove Use PPE like full body harness, life line, helmets,
HEIGHTS fatal safety shoes, etc.
Obtain a permit before starting the work at height
above 3 meters
Fall arrest and safety nets, etc. must be installed
Provide adequate working space (min. 0.6 m)
Tie/weld working platform with fixed support
Use roof top walk ladder while working on a
slopping roofs
Avoid movement on beams
May hit the Keep the work place neat and clean
scrap/material Remove the scrap immediately
stacked at the
ground or in
between
Material can fall May hit the workers Same as above plus
down working at lower Do not throw or drop materials or equipment
levels and prove from height. I.e. do not bomb materials
fatal All tools to be carried in a tool-kit
Bag or on working uniform
Remove scrap from the planks
Ensure wearing of helmet by the workers
working at lower levels
(K) CONFINED Suffocation/ Unconsciousness, Use respiratory devices, if reqd.
SPACES drowning death Avoid over crowding inside a confined space
Provide Exhaust fans for ventilation
Do not wear loose clothes, neck ties, etc
Fulfill conditions of the permit

Page 335 of 373
APPENDIX-E
(Sheet 10 of 12)

(…Contd.)
TYPE OF EFFECT OF
HAZARD HAZARD
Check for presence of hydrocarbons, O2 level
Obtain work permit before entering a confined
space
Ensure that the connected piping of the
equipment which is to be opened is pressure
free, fluid has been drained, vents are open and
piping is positively isolated by a blind flange
Presence of Inhalation can pose Same as above plus

foul smell and threat to life Check for hydrocarbon and Aromatic compounds
toxic before entering a confined space
substances Depute one person outside the confined space for
continuous monitoring and for extending help in
case of an emergency
Ignition/ flame Person may sustain Keep fire extinguishers at a hand distance
can cause fire burn injuries or Remove surplus material and scrap immediately
explosion may occur Do not smoke inside a confined space
Do not allow gas cylinders inside a confined
space
Use low voltage (24V) lamps for lighting
Use tools with air motors or electric tools with
max. voltage of 24V
Remove all equipments at the end of the day
(L) Failure of load Can cause accident Avoid standing under the lifted load and within
HANDLING lifting and and prove fatal the operating radius of cranes
AND moving Check periodically oil, brakes, gears, horns and
LIFTING equipments tyre pressure of all moving machinery
EQUIPMENTS Check quality, size and condition of all chain
pulley blocks, slings, U-clamps, D-shackles, wire
ropes, etc.
Allow crane to move only on hard, firm and
leveled ground.
Allow lifting slings as short as possible and
check gunny packings at the friction points
Do not allow crane to tilt its boom while moving
Install Safe Load Indicator
Ensure certification by applicable
authority

Page 336 of 373
APPENDIX-E
(Sheet 11 of 12)

(…Contd.)
TYPE OF EFFECT OF
HAZARD HAZARD
Overloading of Same as above Safe lifting capacity of derricks and winches
lifting written on them shall be got verified
equipments The max. safe working load shall be marked on
all lifting equipments
Check the weight of columns and other heavy
items painted on them and accordingly decide
about the crane capacity, boom and angle of
erection
Allow only trained operators and riggers during
crane operation.
Overhead Can cause Do not allow boom or other parts of crane to
electrical wires electrocution and come within 3m reach of overhead HT cables
fire Hook and load being lifted shall preferably
remain in full visibility of crane operators.
(M) Person can fall Person May sustain Provide guard rails for working at height
SCAFFOLDI down severe injuries and Face ladder while climbing and use both hands.
NG, prove fatal Ladders shall extend about 1m above landing for
FORMWOR easy access and tying up purpose
K Do not place ladders against movable objects and
AND maintain base at 1/4 unit of the working length of
LADDERS the ladder.
Suspended scaffolds shall not be less than 500
mm wide and tied properly with ropes
No loose planks shall be allowed
Use PPE, like helmets, safety shoes,etc
Failure of Same as above Inspect visually all scaffolding materials for
scaffolding stability and anchoring with permanent
material structures.
Design scaffolding for max. load carrying
capacity.
Scaffolding planks shall not be less than 50X250
mm full thickness lumber or equivalent. These
shall be cleated or secured and must extend over
the end supports by at least 150mm and not more
than 300mm
Don't overload the scaffolds
Do not splice short ladders to make a longer one.
Vertical ladders shall not exceed 6m.
Material can Persons working at Remove excess material and scrap immediately
fall down lower level gets Carry the tools in a tool-kit bag only
injured Provide safety nets

Page 337 of 373
APPENDIX-E
(Sheet 12 of 12)

(…Contd.)
TYPE OF EFFECT OF
HAZARD HAZARD
(N) Personal Can cause injury or Do not take rest inside rooms built for welding
STRUCTUR negligence and casualty machines or electrical distribution system.
AL WORKS danger of fall Avoid walking on beams at height
Wear helmet with chin strap and full body
harness while working at height.
Use hand gloves and goggles during grinding
operations
Cover or mark the sharp and projected edges
Do not stand within the operating radius of
cranes
Lifting/ slipping Same as above Do not stand under the lifted load
of material Stack properly all the materials. Avoid slippage
during handling
Control longer pieces lifted up by cranes from
both ends
Remove loose materials from height
Ensure tightening of all nuts & bolts
(O) Erection/ Can cause injury Do not stand under the lifted load
PIPELINE lowering failure Do not allow any person to come within the
WORKS radii of the side boom handling pipes
Check the load carrying capacity of the lifting
tools & tackles
Use safe Load Indicators
Use appropriate PPEs
Other Same as above Wear gum boots in marshy areas
Allow only one person to perform signaling
operations while lowering of pipes
Provide night caps on pipes
Provide end covers on pipes for stoppage of pigs
while testing/ cleaning operations
(P) Pollution in Can cause personal Ensure the blasting is done in enclosed shed.
GRIT neighboring injury Keep safe distance while blasting operations.
BLASTING area, hit by grits Wear positive pressure blast hood or helmet
and high with view –window, ear-muff/plug, gloves,
pressure air overall or leather coat /apron, rubber shoes.

Page 338 of 373
APPENDIX-F
TRAINING SUBJECTS / TOPICS

(For contractors’ personnel)
1. The Law & Safety – Statutory Requirement / Applicable statutes / Duties of employer / employee
2. Policy & Administration – Why HSE? / Duties & Responsibilities of Safety Personnel at project
site / Effect of incentive on accident prevention
3. HSE & Supervision – Duties of Supervisor / HSE integrated supervision / Who should be held
responsible for site accidents?
4. Safety Budget / Cost of Accidents – Direct costs / Indirect costs
5. Hazard Identification / Type of hazards / HIRAC
6. Behavioural Safety & Motivation
7. Housekeeping – Storage / Stacking / Handling of materials / Hydra handling
8. Occupational Health in Construction sector
9. Personal Protective Equipments – Respiratory & Non- respiratory
10. Electricity & Safety – ELCB / Fuse / Powered tools / Project illumination
11. Handling of Compressed Gas – Transportation / Storage / FBAs / Fire prevention
12. Machine Safety – Machine guarding / Maintenance
13. Transportation – Hazards & risks in transp. of materials / ODC consignments
14. Cranes & Other Lifting machinery – Legal requirements vis-à-vis essential safety requirements.
15. Communication – HSE Induction / TBTs / Safety Committee / Safety meeting / Safety
propaganda / Publicity.
16. Excavation – Risks & Dangers / Safety measures
17. Working at Heights – Use of ladder / Work on roofs / Scaffolds / Double harness lanyards / Life-
line / Fall arrester / Safety Nets / Floor openings
18. Hazards in Welding & important safety precautions
19. Gas Cutting – Hazards & safety measures
20. Fire prevention & fire protection

Page 339 of 373
APPENDIX - G
CONSTRUCTION POWER BOARD( typ)

Page 340 of 373
APPENDIX-H
LIST OF PROCEDURES (MINIMUM) TO BE FORMING PART OF HSE PLAN:-
A. HSE Management Procedures:
 HSE Risk Management (including JSA/HIRA)

 HSE Legal Compliance and Other Requirements
 HSE Objectives & Performance
 HSE Training and Competence (including Induction)
 HSE Motivation & Award Scheme
 HSE Audits
 HSE Meetings
 HSE Sub Contractor Management
 HSE Emergency Management
 HSE Incidents Reporting and Management
 HSE Reports
 HSE Management System Review
 HSE Change Management
 HSE procedure for Behaviour based Safety
 First Aid & Management
 Roles, Responsibility, accountabilities and Authorities
B. Job procedures/Safe Operating procedures
 Setting Up Site & Signage’s

 Handling of Electrical Appliances
 Working at Height
 Confined Space Entry
 Permit to Work (including hot works)
 Housekeeping
 Lifting Operations
 Transportation of materials including Manual Handling
 Compressed Air Tools and Units
 Earthmoving Operations & excavation
 Scaffolding
 Fire Prevention/Protection
 Hazardous Substance handling & Storage
 Radiation Hazard
 Personal Protective Equipment

Page 341 of 373
FORMAT NO. : HSE-1 REV 0

(Sheet 1 of 6)
SAFETY WALK-THROUGH REPORT
(Name & signature of walk through performer to be inserted at the bottom of each page)
Project : _____________ Report no. : ___________
Date : _____________ Contractor : ___________
Inspection by :_____________ Owner : ___________
Frequency : Monthly Job no. : ___________
Note : Write ‘NA’ wherever the item is not applicable

Satisafc Non
Sl.
Item tory/ Satisfac Remarks Action
No.
Yes tory/No
1. HOUSEKEEPING
a) Waste containers provided and used
b) Sanitary facilities adequate and Clean
c) Passageways and Walkways Clear
d) General neatness of working areas
e) Other
2. PERSONNEL PROTECTIVE EQUIPMENT
a) Goggles; Shields
b) Face protection
Hearing protection
Foot protection
e) Hand protection
f) Respiratory Masks etc.
g) Full body harness conforming to CЄ, EN 361
h) Hard hat (HDPE)
i) Other
3. EXCAVATIONS/OPENINGS
a) Openings properly covered or barricaded

b) Excavations shored
c) Excavations barricaded
d) Overnight lighting provided
e) Other
Safety walk-through performer (Name & Signature)……………………………………………..

Page 342 of 373

(Sheet 2 of 6)
Satisafc Non
Sl.
No.
Yes tory/No
4. WELDING & GAS CUTTING
a) Gas cylinders chained upright
b) Cables and hoses not obstructing
c) Screens or shields used
d) Flammable materials protected
e) Live electrode bits contained properly
f) Fire extinguisher (s) accessible
g) Other
5. SCAFFOLDING & BARRICADING
a) Fully decked platforms
b) Guard and intermediate rails in place
c) Toe boards in place
d) Adequate shoring
e) Adequate access
f) Positive barricading for critical activities
g) Installation of warning signs
h) Other
6. LADDERS
a) Extension side rails 1 m above
b) Top of landing
c) Properly secured
d) Angle + 700 from horizontal
e) Other
Safety walk-through performer (Name & Signature)……………………………………………..

Page 343 of 373

(Sheet 3 of 6)
Satisafc Non
Sl.
No.
Yes tory/No
7. HOISTS, CRANES AND DERRICKS
a) Condition of cables and sheaves OK
b) Condition of slings, chains, hooks and eyes O.K.
c) Inspection and maintenance log-books

maintained
d) Outriggers used
e) Reverse horn installed / active / coupled with

gear
f) Signs/barricades provided
g) Signals observed and understood
h) Qualified operators
i) Other
8. MACHINERY, TOOLS AND EQUIPMENT
a) Proper instruction
b) Safety devices
c) Proper cords
d) Inspection and maintenance
e) Other
9. VEHICLE AND TRAFFIC
a) Rules and regulations observed
b) Inspection and maintenance
c) Licensed drivers
d) Other
Safety walk-through performer (Name & Signature)…………………………………………

Page 344 of 373

(Sheet 4 of 6)
Satisafc Non
Sl.
No.
Yes tory/No
10. TEMPORARY FACILITIES
a) Emergency instructions posted
b) Fire extinguishers provided
c) Fire-aid equipment available
d) Secured against storm damage
e) General neatness
f) In accordance with electrical requirements
g) Other
11. FIRE PREVENTION
a) Personnel trained & instructed to make use of

facility
b) Fire extinguishers checked periodically & record
maintained
c) No smoking in Prohibited areas.
d) Fire Hydrants not obstructed Clear
e) Other Regular fire drill conducted
12. ELECTRICAL
a) Use of 3-core armored cables everywhere
b) Usage of 'All insulated' or 'double-insulated'

electrical tools
c) All electrical connection are routed through ELCB
d) Natural Earthing at the source of power (Main

DB)
e) Continuity and tightness of earth conductor
f) Effective covering of junction boxes, panels and

other energized wiring places
g) Ground fault circuit interrupters provided
h) Prevention of tripping hazards maintained
f) DCP extinguishers arranged & licensed electrician

engaged at site

Page 345 of 373

(Sheet 5 of 6)
Satisafc Non
Sl.
No.
Yes tory/No
14. HANDLING AND STORAGE OF MATERIALS
a) Safely stored or stacked
b) Passageways clear / free from obstructions
c) Fire fighting facility in place
15. FLAMMABLE GASES AND LIQUIDS
a) Containers clearly identified / protected from fire
b) Safe storage & transportation arrangement made
c) Fire extinguishers positioned nearby

d) Facilities kept away from electric spark, hot
spatters & ignition source.
16. WORKING AT HEIGHT
a) Approved Erection plan and work permit in place
b) Safe access, Safe work platform & Safety nets

provided
c) Life lines, Fall arrester, Full body harness and with
double lanyards used;
d) Health Check record available for workers going
up?
e) Protective handrails arranged around floor
openings
17. CONFINED SPACE
a) Work Permit obtained from requisite authority
b) Test for toxic gas and sufficient availability of
oxygen conducted & status
c) Supervisor present at site & at least one person
outside the confined space for monitoring deputed
d) Availability of safe means of entry, exit and
ventilation (register for entry & exit maintained)
e) Fire extinguisher and first-aid facility ensured
f) Lighting provision made by using 24V Lamp
g) Proper usage of PPEs ensured
18. RADIOGRAPHY
a) Proper storage and handling of source as per
BARC/ AERB guidelines (authorized radiographer
available)
b) Work permit obtained

Page 346 of 373

(Sheet 6 of 6)
Satisafc Non
Sl.
No.
Yes tory/No
c) Cordoning of the area done
d) Use of appropriate PPE's ensured
e) HSE training to workers/supervisors imparted
during the fortnight (indicate topic)
f) Minimum occupancy of workplace ensured
19. HEALTH CHECKS
a) All Workers medically examined and found be fit

for working at heights (slinging, rigging, painting
etc.)
in confined space
in excavation / trenching
in shot blasting
b) Availability of First Aid box with contents
c) Proper sanitation at site, office and labour camps
d) Arrangement of medical facilities.
e) Measures for dealing with illness at site & labour

camps.
f) Availability of Potable drinking water for workmen
& staff.
g) Provision of crèches for children.
h) Stand by vehicle / ambulance available for

evacuation of injured
20. ENVIRONMENT
a) Chemical and Other Effluents properly disposed
b) Cleaning liquid of pipes disposed off properly
c) Seawater used for hydro-testing disposed off as per

agreed procedure
d) Lubricant Waste/Engine oils properly disposed
e) Waste from Canteen, offices, sanitation etc disposed
properly
f) Disposal of surplus earth, stripping materials, Oily
rags and combustible materials done properly
g) Green belt protection

Page 347 of 373

(Sheet 1 of 3)
ACCIDENT / INCIDENT REPORT
(To be submitted by Contractor after every Incident / Accident within 24 hours to EIL/ Owner)
Report No.: ____________________________ Date: ______________________
Project site: ____________________________ Name of work: _______________________
Contractor’s name: ________________ Contractor’s Job Engineer (name) ________
Non-disabling injury (Non- Hospitalized but resumed duty before end of 48 hrs
LTA)
Disabling injury (other LTA) Hospitalized & failed to resume duty within next 48 hrs
Fatal (LTA): Death / Expiry
First Aid case (non LTA) Resume duty after first aid
Name of the injured: _______________________ Father's name of victim: _________________

Sub Contractor’s Name: ……………………………………………………………………………….
Gate Pass No.:……….. Age: _____Yrs. Victim’s medical fitness exam. (Pre-empl.) date: - ______
Date & time of Accident / Incident: _______________________________________________

Names of Witnesses: (1________________ (2)___________________ (3) ________________
Profession of victim:
Bar bender Carpenter Meson
Fitter Helper Gas cutter
Grinder Welder Electrician
Driver Rigger M/c.operator
Engineer Manager Other/specify
Qualification
No formal education Non-Matriculate Matriculate
Graduate Post- grad Other/specify
Job Experience
NIL Less than 2 yrs 2-5 yrs
5-10 yrs 11-15 yrs 15 years and above
Location where the incident happened: ___________________________________________

______________________________________________________________________________

Page 348 of 373

(Sheet 2 of 3)
Activity / Works that was continuing during incident / accident: -
Excavation Demolition Concrete carrying
Concrete pouring Transportation of materials Transportation of
(manually) materials (mechanically)
Work on or adjacent to water Work at height (+2.0 mts) Scaffold preparation
Scaffold dismantling Piling works Welding
Grinding Gas-cutting Pipe fit-ups & fabrication
Structural fabrications Machine works Hydro-testing works
Electrical works Erection activities Other/specify
What exactly the victim was doing just before the incident / accident? ....................................
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
Nature of injury:
Bruise or Contusion Abrasion (superficial wound) Sprains or strains
Cut or Laceration Puncture or Open wound Burn
Inhalation of toxic or Absorption Amputation
Poisonous fumes or gases
Fracture Other/specify
Parts of body involved in incident / accident

Head Face Eyes
Throat Arm (above wrist) Hand (including wrist)
Fingers Truck (Abdomen / Back / Throat
Chest / Shoulder)
Leg (above ankle) Foot (incl. ankle) Toes
Multiple Other/specify
Accident type:
Struck against Struck by Fall from Elevation
Fall on same level caught in caught under
caught in between Rubbed or abraded Contact with (Electricity)
Contact with (Temp./ Contact with chemicals or Vehicle accident

extremes) oils
Other/specify

Page 349 of 373

(Sheet 3 of 3)
Medical Aid provided: - (indicate specific aids / treatment etc.)-

………………………………………………………………………………………………………….
…………………………………………………………………………………………………………..
-------------------------------------------------------------------------------------------------------------------------
Actions taken to prevent recurrence of similar incident / accident: ………………………………
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
……………………………………………………………………………………………………………
………………………………………………………………………………………………………...
_____________________________________________________________________________
Intimation to local authorities (Dist Collector / Local Police Station / ESI authority): Yes / No / NA.
If yes, to whom ………………………………………………………………………………………..
Safety Officer Site Head / Resident Construction Manager

(Signature and Name) (Signature and Name)
Stamp of Contractor
To : Owner
: RCM/Site-in-charge EIL (3 copies)
Divisional Head (Constn) through RCM

Project Manager, EIL, through RCM

Page 350 of 373

(Sheet 1 of 5)
SUPPLEMENTARY INCIDENT / ACCIDENT INVESTIGATION REPORT

TICK THE APPROPRIATE ONE AS APPLICABLE (furnish within 72 hours)
Supplementary to Incident / Accident Report No: ______ (Copy enclosed)
Report No.: ____________________________ Date: ______________________
Project site: ____________________________ Name of work: _______________________
Contractor’s name: ________________ Contractor’s Job Engineer (name) ________
Non-disabling injury (Non- Hospitalized but resumed duty before end of 48 hrs
LTA)
Disabling injury (other LTA) Hospitalized & failed to resume duty within next 48 hrs
Fatal (LTA): Death / Expiry
First Aid case (non LTA) Resume duty after first aid
Name of the injured: _______________________ Father's name of victim: _________________

Sub Contractor’s Name: ……………………………………………………………………………….
Gate Pass No.:……….. Age: _____Yrs. Victim’s medical fitness exam. (Pre-empl.) date: - ______
Date & time of Accident / Incident: _______________________________________________

Names of Witnesses: (1________________ (2)___________________ (3) ________________
Profession of victim:
Bar bender Carpenter Meson
Fitter Helper Gas cutter
Grinder Welder Electrician
Driver Rigger M/c.operator
Engineer Manager Other/specify
Qualification
No formal education Non-Matriculate Matriculate
Graduate Post- grad Other/specify
Job Experience
NIL Less than 2 yrs 2-5 yrs
5-10 yrs 11-15 yrs 15 years and above
Location where the incident happened: ___________________________________________

______________________________________________________________________________

Page 351 of 373

(Sheet 2 of 5)
Activity / Works that was continuing during incident / accident: -

Excavation Demolition Concrete carrying
Concrete pouring Transportation of materials Transportation of
(manually) materials (mechanically)
Work on or adjacent to water Work at height (+2.0 mts) Scaffold preparation
Scaffold dismantling Piling works Welding
Grinding Gas-cutting Pipe fit-ups & fabrication
Structural fabrications Machine works Hydro-testing works
Electrical works Erection activities Other/specify
What exactly the victim was doing just before the incident / accident? ....................................
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
Particular of tools & tackles being used and condition of the same after incident/accident:
…………………………………………………………………………….........................................
………………………………………………………………………………………………………
Description of Incident/Accident (How the incident was caused):

……………………………………………………………………………………….
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
Nature of injury:
Bruise or Contusion Abrasion (superficial wound) Sprains or strains
Cut or Laceration Puncture or Open wound Burn
Inhalation of toxic or Absorption Amputation
Poisonous fumes or gases
Fracture Other/specify
Parts of body involved in incident / accident

Head Face Eyes
Throat Arm (above wrist) Hand (including wrist)
Fingers Truck (Abdomen / Back / Throat
Chest / Shoulder)
Leg (above ankle) Foot (incl. ankle) Toes
Multiple Other/specify

Page 352 of 373

(Sheet 3 of 5)
Accident type:
Struck against Struck by Fall from Elevation
Fall on same level caught in caught under
caught in between Rubbed or abraded Contact with (Electricity)
Contact with (Temp./ Contact with chemicals or Vehicle accident

extremes) oils
Other/specify
Name & Designation of person who provided First-Aid to the victim: ---------------------------------------
Name & Telephone number of Hospital where the victim was treated_________________________
Mode of transport used for transporting victim – Ambulance / Private car / Tempo / Truck / Others
How much time taken to shift the injured person to Hospital________________________________
In case of FATAL incident, indicate clearly the BOCW Registration No. of the victim
/Company……………………………………………………………………………………………
Comments of Medical Practitioner, who treated / attended the victim/injured (attached / described
here)_____________________________________________________________________
What actions are taken for investigation of the incident, please indicate clearly – (Video film /
Photography / Measurements taken etc……………………………………………………………..)
Immediate cause (Please tick the right applicable) –

Hazardous methods or Poor housekeeping Inadequate or improper
procedures inadequately PPE
guarded
Environmental hazards improper Working on dangerous
(excess noise/ space illumination/Moving on oval equipment
constraint/ inadequate surface
ventilation

Page 353 of 373

(Sheet 4 of 5)
Failure to secure Horse-play Failure to use PPE
Inattention to surroundings Improper use of hands & By-passing safety devices

body-parts
Unsafe mixing or placement Bypassing standard Failure in communication
of tools & tackles procedures
Operating without authority Improper use of equipment drug or alcoholic
or tools & tackles influence
excessive haste Others(specify)
Basic cause
Over confidence Impulsiveness over-exertion

Faulty judgement or poor Failing to keep attention Nervousness & Fear
understanding constantly
Fatigue Defective vision Ill health or sickness
Slow reaction Others(specify)
Root cause
Inadequate Engg Improper Design Inadequate Planning &

organization
Inadequate knowledge Inadequate skill Inadequate training
Inadequate supervision Improper work procedure Inadequate compliance
with standard
Substandard performance Inadequate maintenance Improper inspection
Others(specify)
Loss of man days and impact on site works, (if any) –
Remarks from Contractor’s Safety Officer / Engineer –
Was the victim performing relevant tasks for which he was engaged /employed? Yes / No
Was the Supervisor present on work-site during the incident? Yes / No
Have the causes of incident rightly identified? Yes / No
Cause of Accident was_____________________________________________________________

Page 354 of 373

(Sheet 5 of 5)
Remedial measures recommended by Safety Officer of Contractor for avoiding similar incident in
future
: ………………………………
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
……………………………………………………………………………………………………………
………………………………………………………………………………………………………...
Intimation to local authorities (Dist Collector / Local Police Station / ESI authority): Yes / No / NA.
If yes, to whom ………………………………………………………………………………………..
_____________________________________________________________________________
Safety Officer Site Head / Resident Construction Manager

Stamp of Contractor
To : Owner
: RCM// Site-in-charge of EIL (3 copies)
Project Manager EIL, through RCM

Page 355 of 373
NEAR MISS INCIDENT/ DANGEROUS OCCURRENCE SUGGESTED PROFORMA

(to be submitted within 24 hours)
 Near Miss : Human injury escaped & no damage to property, equipment

or interruption to work.
 Dangerous Occurrence: Damage to property, equipment or interruption of work, but not
resulting in personal injury/illness, e.g. Fire incident, collapse of structure, crane failure,
etc
Report No.: _________________
Name of Site: _________________________ Date: ______________________
Name of work: __________________________ Contractor: __________________
__________________________________________________________________________________
Incident reported by :
Date & Time of Incident :
Location :
__________________________________________________________________________________
Brief description of incident
__________________________________________________________________________________
Probable cause of incident
__________________________________________________________________________________
Suggested corrective action
__________________________________________________________________________________
Steps taken to avoid recurrence Yes No
To : Owner
: RCM/Site-in-charge EIL (3 copies)

Project Manager EIL, through RCM

Page 356 of 373

MONTHLY HEALTH, SAFETY & ENVIRONMENT (HSE) REPORT
(To be submitted by each Contractor)
Actual work start Date: _______________ For the Month of: __________________
Project: ____________________________ Report No: ________________________
Name of the Contractor: ______________ Status as on : ______________________
Name of Work : _____________________ Job No : __________________________
(Contractor in consultation with EIL shall generate the reports through web based
package(www.eil.co.in/conthse) only.
UPTO
THIS
ITEM PREVIOUS CUMULATIVE
MONTH
MONTH
1) Average number of Staff & Workmen
(average daily headcount, not man days)
2) Man-hours worked
3) Number of Induction programmes conducted
4) Number of HSE meetings organized at site
5) Number of HSE awareness programmes conducted at site
6) Number of Tool Box Talks conducted
7) Number of Lost Time Accidents (LTA) Fatal
Other LTA
8) Number of Loss Time Injuries (LTI) Fatalities
Other LTI
9) Number of Non-Loss Time Accidents
10) Number of First Aid Cases
11) Number of Near Miss Incidents
12) No. of unsafe acts/ practices detected
13) No. of disciplinary actions taken against staff/ workmen
14) Man-days lost due to accidents

15) LTA Free man-hours i.e. LTA free man-hours counted from the
Last LTA (enter date: ……….)
16) Frequency Rate (No. of LTA per 2 lacs man-hours worked)
17) Severity Rate (No. of man days lost per 2 lacs man-hours
worked)
18) Loss Time Injury Frequency (No. of LTI per 2 lacs man-hours
worked)
19) No. of activities for which Job Safety Analysis (JSA) completed
20) No. of incentives/ awards given
21) No. of occasions on which penalty imposed by EIL/ Owner
22) No. of Audits conducted
23) No. of pending NCs in above Audits

24) Compensation cases raised with Insurance
25) Compensation cases resolved and paid to workmen
26) Whether workmen compensation policy taken Yes No
27) Whether workmen compensation policy is valid Yes No
28) Whether workmen registered under ESI Act, as applicable Yes No
Remarks, if any
Date:
Prepared by Safety Officer Approved by Site Head / Resident Construction Manager
To : - OWNER
- RCM EIL (2 copies)

Page 357 of 373

PERMIT FOR WORKING AT HEIGHTS (ABOVE 2.0 METER)
(In duplicate to be issued daily for site and for office)
Permit No…………….. Name of Main Contractor……………………

Name of work executing agency / sub agency / vendor:…………………………………………………...
Date……………… Exact Location of work……………………………………
Nature of work ……………………………………..Duration of work (from) ………… (to) ……….......
Number of workers covered within this permit……………………………………………………………
(List may be enclosed with name & gate pass numbers.)
Sl. Status of compliance

Items / Subjects
No. (Yes / No)
1 Work areas / Equipments inspected
2 Work area cordoned off
3 Adequate lighting is provided
4 Precautions against public traffic taken
5 Concerned persons in & around have been alerted & cautioned
Hazards / risks involved in routine / non-routine task assessed and control
6
measures have been implemented at specific task
7 ELCB provided for electrical connection & found working
8 Ladder safely attached / fixed
9 Scaffoldings are checked and TAGs are found used correctly
10 Working platforms are provided and are found sound /safe for use
Safe access & egress arrangements (e.g. ladders, fall arresters, life-lines etc.)
11
are satisfactorily incorporated
12 Openings on platform / floors are effectively cordoned / covered
Use of following safety gadgets by people working at area under this permit, is
checked and found satisfactory -
Safety helmet
13 Safety harness (full body) with double lanyard
Safety Shoes
Safety gloves
Safety goggles
14 Housekeeping of work area found satisfactorily tidy / clean & clear
Adequate measures have been taken for works being continued at the ground
15
level, when simultaneous works are permitted overhead at that very location.
16 Materials are not thrown from heights on to ground
17 Medical examination of workers are made & found satisfactory
Responsible job engineer / supervisor found physically present at work spot for
18
overall administration of work as well as safety of people.
Above items have been checked & compliance has been found in place. Hence work is permitted to
start / continue at the above-mentioned location. Work shall not start till identified lapses are rectified.
Additional Precautions, if any …………………………………………………………….

……………………………………………………………………………………………..
Work Permit issued by Verification By

Contractor Engineer/RCM Contractor Safety Officer
AT THE END OF THE DAY/WORK:

All works at height are completed & workmen have returned safely from work location at
(time)………….. (date)……………
(Sig. Contractor Engineer)

Page 358 of 373
CONFINED SPACE ENTRY PERMIT
Project site ___________________________ Sr.No. _________________________

Name of the work ______________________ Date ___________________________
Name of Contractor ____________________ Nature of work ___________________
Exact location of work _____________
Safety Requirements POSITIVE ISOLATION OF THE VESSEL IS MANDATORY

(A) Has the equipment been ?
Y NR Y NR Y NR
  Isolated from   water flushed &/or   radiation sources
power/steam/air steamed removed
  isolated from liquid or   Man ways open &   proper lighting
gases ventilated provided
  depressurized &/or   cont. inert gas flow  
drained arranged
  blanked/ blinded/   adequately cooled  
disconnected
(B) Expected Residual Hazards
  lack of O2   combustible gas/ liquid   H2S / toxic gases
  corrosive chemicals   pyrophoric iron / scales   electricity / static
  heat/ steam / frost   high humidity   ionizing radiation
     
(C) Protection Measures
  gloves   ear plug / muff   goggles / face shield
  protective clothing   dust / gas / air line mask   personal gas alarm
  grounded air duct/blower   attendant with SCBA/air   rescue
/AC mask equipment/team
  Fire fighting arrangements   safety harness & lifeline   communication
equipment
     
Authorization / Renewal (It is safe to enter the confined space)
D Signature Time Signature
No. of
a
persons Name of persons allowed Contractor's Contractor's
t From To Workman
allowed Supervisor Safety Officer
e
Permit Closure :
(A) Entry  was closed  stopped  will continue on ...
(B)  Site left in a safe condition  Housekeeping done
(C) Multilock  removed  key transferred

 Ensured all men have come out  Man-ways barricaded
Remarks, if any:

Page 359 of 373
RADIATION WORK PERMIT
Project : Sr.No. :
Name of the work : Date :
Name of site contractor : Job No. :
Location of work :
Source strength :
Cordoned distance (m) :
Name of Radiography agency : Approved by Owner/EIL
No. of workers engaged :
The following items have been checked &compliance shall be ensured during currency of the
permit:
S. No. Item description Done

Safety regulations as per BARC/AERB ensured while source in use/in transit & during
storage
Area cordoned off / safe working platform provided
Lighting arrangements for working during nights ensured
Warning signs/ flash lights installed
Cold work permit taken (if applicable)
PPEs like film badges, dosimeters used
Additional precautions, if any ______________________________________________________
(Radiography Agency’s BARC/AERB authorized Supervisor)
Permission is granted.
Permit is valid from ___________ AM/PM ____________ Date to ___________ AM/PM _________
Date
(Signature of permit issuing authority of site contractor)
Name :Designation: Date:

Permit renewal:
Sign of issuing authority with
Permit extended up to Additional precautions required, if any
date (of site contractor)
Date Time
Work completed/ stopped/ area cleared at ________ Hrs of Date ______________

(Sign. of permit issuing authority)
Name & Signature of site contractor:

Page 360 of 373
DEMOLISHING/DISMANTLING WORK PERMIT
Project : Sr.No. :
Name of contractor : Job No. :
Name of sub-contractor : No. of workers to be engaged:
Line No./ Equipment No./ Structure to be dismantled :

Location details of dismantling/ demolition with sketch : (clearly indicate the area)
The following items have been checked &compliance shall be ensured during currency of the
permit:
S. Item description Done Not

No Applicable
.
Services like power, gas supply, water, etc. disconnected
Dismantling/ Demolishing method reviewed & approved
Usage of appropriate PPEs ensured
Precautions taken for neighbouring structures
First-Aid arrangements made
Fire fighting arrangements ensured
Precautions taken for blasting
(Contractor’s Supervisor) (Contractor’s Safety Officer)
Permission is granted.
(Permit issuing authority)
Name :
Date :
Completion report :
Dismantling/ Demolishing is completed on _____________ Date at ____________ Hrs.
Materials/ debris transported to identified location Tagging completed (as applicable)
Services like power, gas supply, water, etc. restored
(Permit issuing authority)
CONTRACTOR’s NAME

Page 361 of 373
DAILY SAFETY CHECKLIST

(To make use of before start of day’s work)
Project : Sr.No. :
Description of Job decided to perform : -
 Use of PPE / Safety Gadgets
Compliance Compliance
Sl. No PPEs Sl. No PPEs
(Yes / No) (Yes / No)
1 Safety Helmets 6 Face Shield
2 Safety Shoes 7 Full body harness
3 Hand Gloves 8 Fall Arrest System
4 Dust Musk 9 Safety net
Horizontal life-line made of steel
5 Safety Goggles 10
wire, (dia not less than 8.0 mm.)
(Serial No. 1 & 2 are compulsory for everyone. Specify & ensure use of other safety gadgets as required for the job)
 Identify following important unsafe conditions: -
Sl. No Conditions Yes / No

1 Access to work site / emergency escape clear
2 Soil / Loose earth kept away from excavated pit / slope / ladder provided
Electrical wire / welding lead lying entangled on ground / welding m/c. booth
3
accessible
4 Elevated work platform / open ends are protected
Ground area cordoned off before lifting works or erection at height / ground
5
area checked & cordoned-off before start of height works
Structural members / erected pipes / wooden boards/pieces etc. are safely
6 anchored at heights and are not likely to fall down on people when working
beneath
Rope ladders tied-up on tall steel structures, long before are removed to get
7
rid of their use
8 Any Other
 Indicate actions taken, if status of any of the above items is found “No” ………………………………
……………………………………………………………………………………………………………….
 Specific Safety guidelines / precautions, if any (communicated thro’ TBT) ……………………………

………………………………………………………………………………………………………………
………………………………………………………………………………………………………………
 Above conditions and PPE compliances are checked by undersigned and correct status are indicated after
verification
Inspected by Verification By
Contractor Engineer Contractor Safety Officer

Page 362 of 373
HOUSEKEEPING ASSESSMENT & COMPLIANCE

(Sheet 1 of 2)
Project : Sr.No. :
Name of contractor : Fortnightly
Sl Satisafctory/ Non
Subjects of Review Remarks Action
No. Yes satisfactory/No
1. Cleanliness at the Main entry / access of site
2. Ground condition / floor areas free from water-
logging / oil spillage
3. Ground & elevated floors free from rubbish /
wastes / accumulated debris / scraps.
4. Manholes / openings are covered / fenced
5. Trenches are barricaded / walkways are in
place
6. Drains are cleaned / not choked / not occupied
by dumped materials
7. Sufficient CAUTION boards / instructions
displayed
8. Construction machinery are maintained &
parked in orderly manner.
9. Movement of site people are not obstructed
because of dumping / storing of construction
materials
10. Access / egress to Electrical Distribution
Boards / Panels clear from wires / cables /
earth-strips etc.
11. Electrical panel rooms / sheds / MCC / Control
rooms / Substations etc. are clean & tidy and
not used for storing dress / clothes, tiffin-box or
bicycles.
12. Passage behind Elec. panels are free for access
13. Fire extinguishers / fire-buckets are accessible
without any difficulty.
14. Stair-steps, platforms & landings are clear &
tidy
15. Sheds / rooms & work areas have got sufficient
illumination as well as ventilation
16. Cables / Wires / welding leads are routed /
hanged appropriately & are not creating unsafe
condition.
17. Stacking / storing of insulation materials or
their packing.
18. Removal or cleanliness of left-over sand,
concrete, brick-bats, insulation-materials,
excess earth, wastes etc.
19. Storing / stacking of sand, metal chips, re-
bars, steel pipes, valves, fittings etc.
20. One escape route at ground & minimum two
escape routes at elevation available,

Page 363 of 373

(Sheet 2 of 2)
Sl Satisafctory/ Non
Subjects of Review Remarks Action
No. Yes satisfactory/No
21. Captions / Posters / Slogans on various safety
instructions are displayed legibly in local
language
22. Cable trenches are water-free or regular
arrangement for taking out accumulated water
exists.
23. Windows of rooms / offices are regularly
cleaned
24. Facilities for cycle sheds, drinking water,
washing, rest-rooms etc. are maintained in tidy
manner.
25. Toilet, Urinals, Canteen / kitchen / pantry etc.
are maintained & free from obnoxious smell.
26. Construction tools / tackles are stored
systematically - the items are tagged / tested /
certified by competent third party.
27. Sufficient numbers of Dust-bins / Waste-bins
found at site and are regularly emptied.
Additional remarks, if any -

………………………………………………………………………………………………………………
………………………………………………………………………………………………………………
……………………………………

Page 364 of 373
INSPECTION OF TEMPORARY ELECTRICAL BOOTH / INSTALLATION

Project : Sr.No. :
Sub Station No:/Booth No Location:
SL
SUBJECTS OBSERVATION (YES /NO) ACTION TAKEN
NO
Switchboards installed properly are in order and
1
protected from rain & water-logging.
Adequate illumination provided for switchboard
2 operation during night hours & the lamps are protected
from direct human contact.
Voltage ratings, DANGER signs, Shock-Treatment-
3
Chart displayed in the installation / booth
Fire extinguisher (DCP or CO2) & Sand Bucket kept in
4
close vicinity of Switchboards
Valid License & Competent Electrician / Wireman
5 available & name/ license no. displayed at booth /
installation.
General housekeeping in & around booth / installation
6
found in order.
7 Cable-route-markers for U/G cables provided.
Monthly inspection report of Electrical hand tools
8
available in booth / installation.
9 Insulated Mat provided in front of Elec. Panels.
10 Rubber hand gloves available/ used by Electricians
Availability of CAUTION boards for shutdown & / or
11
repairing works.
All incoming & outgoing feeders have proper MCCB /
12
HRC fuses / Switches.
Switchboards “earthed” at two distinctly isolated
13
locations.
Switchboards have adequate operating space at the front
14
face & at the rear face too.
15 All connections provided through 30mA ELCB.
16 Testing records of all ELCBs available at site
17 Only industrial type plugs & sockets are used.
Temporary connections are 3-core double insulated &
18 free from cuts & joints and 3rd core is earthed at both
ends
Socket boards are properly mounted on stand &
19
protected from water ingress.
Electrical equipments operating above 250V have two
20
earthing / double earthing.
All incoming / outgoing cables are properly glanded &
21
terminated with “lugs”.
22 Switch-boards are of industrial variety / type.
Sketch for installation / connection (SLD) made &
23
pasted & other safety labels/display boards
24 Labeling of incoming / outgoing feeders made.
25 All hand lamps are protected from direct contact.
26 All electrical cable / joints are in safe condition

Page 365 of 373
INSPECTION FOR SCAFFOLDING

(Sheet 1 of 2)
Project : Sr.No. :
Sl. Actions
Description Yes No N.A
No taken
1 Whether work permit is obtained to take up work at height above 1.5 Mts?
Whether atmospheric condition is “stormy” or “raining” and works at
2
heights have been permitted?
3 Whether steel pipes scaffoldings are used for units /off-site areas?
Whether scaffolding has been erected on rigid/firm/leveled surfaces /
4 ground? Whether “foot-seals” or “base-plates” are used beneath the up-
rights (vertical steel pipes)
Whether scaffold construction is as per IS specification with toe-board and
5
hand-rails (top-rail as well as mid-rail)?
Whether distance between two successive up-rights are less than 2.5 Mts
6 (height of scaffold & load carrying capacity governs the distance between
two uprights)
Whether all uprights are extended at least 900 mm above the top most
7
working platform (to enable fitting of handrails)?
Whether vertical distance of two successive ledgers is satisfactory?
8
(varying between 1.3 Mts. To 2.1 Mts)
Whether the peripheral areas of working at height are cordoned-off? (for
9
avoiding accident to people arising out of dropped / deflected materials)
10 Whether platform is provided? Is it safely approachable?
Whether end of scaffold platform / board are extended beyond transoms?
11
(125mm to 150 mm)
Whether CE / IS approved quality and worthy conditioned full-body safety
12 harness (with double lanyard & karabiners) are used while working at
heights?
Whether life-line of safety harness is anchored to an independent secured
13
support capable of withstanding load of a falling person?
Whether the area around the scaffold is cordoned off to prohibit the entry of
14
unauthorized person / vehicle?
Whether clamps used are of good condition, of adequate strength and free
15
from defects?
16 Whether ladder is placed at secured and leveled surface?
17 Whether water-pass and oil-spills are avoided around the scaffold structure?
18 Whether ladder is extended 1.5mts. above the landing point at height?
19 Whether more than one access/egress provided to the scaffold?
Whether ladder used are of adequate length and overlapping of short
20
ladders avoided?
Whether metallic ladders are placed much away from near-by electrical
21
transmission line?
22 Whether rungs of ladder are inspected and found in good order?
23 Whether fall-arresters provided on both the access/egress routes?
Whether diagonal (cross) bracings are provided at regular interval on the
24
scaffold?
Whether working platform on the scaffold has been made free from “jolt”
25
or “gap”?
Whether tools or materials are removed after completion of the day’s job at
26
heights?
Whether a valid Permit for Work (PFW) is obtained before taking up work
27
over asbestos or fragile roof?
28 Whether sufficient precaution is taken while working on fragile roof?

Page 366 of 373

(Sheet 2 of 2)
Sl. Actions
Description Yes No N.A
No taken
Whether provision is made to arrange duck ladder, crawling board for
29
working on fragile roof?
Whether scaffold has been inspected by qualified civil engineers prior to
30
their use?
Whether the scaffolding has been designed for the load to be borne by the
31
same?
Whether the erection and dismantling of the scaffolding is being done by
32
trained persons and under adequate supervision?
Whether safety net with proper working arrangement and life-line has
33
been provided?
Whether TAGS (Green for acceptable and Red for incomplete/unsafe
34
scaffolds) are used on scaffolds?
Whether sufficient illumination is provided in and around the scaffold
35
and access?
Whether emergency rescue / response arrangements are made in place
36

Page 367 of 373
FORMAT NO . : HSE-14 REV 0

PERMIT FOR ERECTION / MODIFICATION & DISMANTLING OF SCAFFOLDING
(Sheet 1 of 2)
Project : Sr.No. :
Nature of activities : Duration: From………To…………
Sl.
Subjects / Items Done Not Done Remarks
No.
Specific task of Erection / Modification / Dismantling of scaffolds,
1 identified & TAGGED accordingly (before as well as after
carrying-out jobs).
People engaged in doing the job are identified & are certified by Names to
2
Job Engineer of Main Contractor as experienced / trained. be noted
Concerned persons are alerted by the Job Engineer of Main
3 Contractor in connection with possible hazards & what the
workmen MUST do / MUST not do.
Verification by Job Engineer of Main Contractor made for
confirming that all persons permitted to carry-out the jobs are
4
making use of Helmet, Safety Shoes, Goggles, Gloves & Double
lanyard safety harness and other relevant PPEs.
5 Area of work is effectively cordoned-off / barricaded / illuminated.
For taking-up / lowering down Scaffolding members / clamps /
couplings etc. appropriate ropes / pulleys/ chains etc. have been
6
arranged for use (not to throw any item) & the same have been
verified as “fit for purpose”.
Items / members of scaffold, being lowered are removed from the
7
area & stacked correctly.
Ropes, chains, pulley blocks etc. being used for lifting or lowering
scaffold items, are inspected by the Job Engineer & their
8
certifications as well as physical conditions have been found O.K,
before signing this PERMIT.
Safety Net / Life-line / Fall Arresters etc. are arranged in position
9 and Job Engineer has found working conditions favourable for
activities to start.
Scaffold erection or dismantling tasks are being supervised by
10
Experienced Engineer / Competent person.
Only competent & experienced people have been selected /
11
engaged in Scaffolding erection, modification or dismantling tasks.
Adequate & effective actions for traffic and movement of people
12
around the cordoned-off area taken to avoid inadvertent incident
13 Working platforms are protected with handrails & toe-boards.
14 Access & Exit (for reach & escape) are safe for use by people.
Tools, tackles to be used for above jobs are verified by job
15 Engineers of Main contractor as genuinely good and tied-up at
height (to prevent their fall).
16 Site important Telephone Nos. are made known to everyone
SOP (Safe Operating Procedure) for the specific task is made &
17
followed too.
18 Emergency vehicle has been arranged at work locations.
 This permit for work shall be available at specific work location all the time.
 After completion of work, permit shall be returned to safety cell of main contractor, without fail.
 This Permit shall be issued maximum upto (Monday to Sunday).
 Additional Precautions, if any
…………………………………………………………………………………………………………………
 ACCORD OF PERMISSION (to be ticked) - YES ( ) / NO ( )

Page 368 of 373

(Sheet 2of 2)
Everyday Site working conditions & performance of workmen shall be assessed / checked by Contractor
Site Engr. and Safety Officer shall verify the same .
Name / sign. Monday Tuesday Wednesday Thursday Friday Saturday Sunday

Site
Engr.
Safety
Off.

Page 369 of 373
PERMIT FOR HEAVY LIFT/CRITICAL ERECTION
Project : Sr.No. :
Nature of activities : Duration: From………To…………
Location of work : Name /Type of crane :
Equipment/Structure to be erected: Wt. of equipment/ structure to be erected :
Compliance Status
SL.
Description of Item Remarks
NO. Yes No Not applicable
1) Is the crane type suitable for lift or as per erection
procedure?
2) Is the crane have the correct number of counterweights
fitted?
3) Availability of Load Certification of crane from
authorized agency.
4) Is the load chart of crane available in carne cabin/or with
Crane operator?
5) Is the device to check the Wind speed in crane is
working? Is the safety features in crane are working?
6) Availability of Load certification of slings and other
accessories from authorized agency
7) Availability of Licensee/certificate for crane operator
from authorized agency.
8) Availability of approved JSA for the subject activities.
9) Availability of approved erection/rigging procedures.
10) Availability of temporary gratings/ platforms for critical
lifting(as applicable)
11) Tool Box conducted before erection?
12) Has the area been cordoned off?
13) Are the authorized persons during erection are
identified?
14) Does each person identified for erection understand their
roles and responsibilities?
15) Is the ground on which crane will rest or outrigger
support are correct?
16) Is hard stand requirement (if any) complied?
17) Is the communication system (viz walkie talkies,etc are
working properly?
18) If more than one crane is lifting the load, is an
Intermediate rigger will supervise the lift?
19) If there is other obstruction within the operating radius
of the crane, have correct precautions been taken to
prevent collision?
20)
All the persons are wearing the requisite PPE?
Inspected & Issued by Verification By

Contractor Engineer/RCM Contractor Safety Officer

Page 370 of 373
PERMIT FOR ENERGY ISOLATION & DE-ISOLATION
Project : Sr.No. :
ENERGY ISOLATION PERMIT
 Clearance required from:…..Hrs ………Date To …. ..Hrs ….Date
 Name of equipment/ energy source etc ………………………………………………………………….
 Nature of job to be done: ……………………………………………………………………………….
 Area………………………….Location:…………………………………………………………………..
PERMIT VALIDATION PERFORMING AUTHORITY

I hereby authorize the …………..personnel(performer) The work and precautions will be carried out under my
to isolate the above equipment/energy source from all overall responsibility.(Testing/execution engineer)
sources of power and handover the equipment/energy
source for maintenance/repair.
Signature: Date:
Issuing authority Name:
Area –Incharge/RCM
Signature: Date:
Name:
SAFETY PRECAUTIONS FOR CLEARANCE NORMALISING AFTER CLEARANCE

1. Notify workers of intent to de- energize 1. Notify workers of intent to re- energize
2. Obtain lock,tag or locking/tagging devices 2. Conduct visual inspection to confirm that the
3. Shut down ,de energize, dissipate any danger zone is clear of workers
residual energies. 3. Conduct visual inspection to confirm that tools
4. Apply lock ,tag and locking and/or tagging ,equipments danger zone is clear of workers
devices 4. Reposition the safety devices(interlocks,
5. *Any other job specific precautions valves, guards, covers ,sensors, as applicable, etc)
6. Verify effectiveness of lockout by 5. *Any other job specific normalizing details
attempting to restart. 6. Remove lock, tag and locking and/or tagging
7. Proper PPE is ensured devices.
7. Re energize.
I certify that the energy source mentioned above is 8. Confirm system is operating properly& safely
isolated from all sources and is safe to start the work. 9. I certify that the energy source mentioned above is
isolated from all sources and is safe to start the work.
Tag No:…… Lock No:………….
Tag No:…… Lock No:………….
Issuing authority Issuing authority
Area –Incharge/RCM Area –Incharge/RCM
Signature: Date: Signature: Date:
Name: Name:
(*to be included by contractor in consultation with (*to be included by contractor in consultation with
EIL/owner) EIL/owner)
ENERGY DE-ISOLATION PERMIT
PERMIT VALIDATION PERFORMING AUTHORITY
I hereby authorize the …………..personnel(performer) I herby certify that the equipment/energy source
to de- isolate the above equipment/energy source from mentioned above has been de-isolated and is ready for
all sources of power and handover the equipment/energy normal operation.(Testing/execution engineer)
source for normal operation..
Issuing authority Signature: Date:

Area –Incharge/RCM Name:
Signature: Date:
Name: Countersigned by Issuing authority

Page 371 of 373
PERMIT FOR EXCAVATION (depth 2m and above)

(Sheet 1 of 2)
Project : Sr.No. :
Job Description : Location:
Size of excavation :
SL. Compliance Status

Description of Item
NO. Not Remarks
Yes No
applicable
1) Suitable and sufficient risk assessments and method
statements has been carried to ensure that the work shall be
undertaken in accordance with specification and standard.
2) Are plans/details of underground services available and the
same has been reviewed?
3) Has survey done to locate the services/obstacles, etc.
4) Has the live services (electrical, water line, air line,
telephone line,etc) has been disabled for carrying out the
job.
5) Is adequate barriers/fences to protect the excavation are in
place?
6) Is Adequate warning signs are in place?
7) Is Assessment of ground conditions done and remedial
action (if any) taken?
8) Safe access / egress (e.g. ramp / steps / ladders etc.)
provided for site workmen & supervisors.
9) Is the excavation work being undertaken in proximity of
structure, etc ? If Yes, it’s effect is considered?
10) Availability of competent person for supervising the
excavation work?
11) Adequate safe arrangement to prevent collapse of edges
(e.g. shoring / strutting / benching / sloping etc.) made at
site.
12) Hard barricades (at least 1.0M away from edge & for
excavation near site access roads) with warning
signs/caution boards are provided
13) Accumulation / passage-ways of water at periphery of
excavation / trench stopped/ restricted.
14) Is the equipment being used for excavation has been
checked for adequacy and is in good working condition
having all the safety features?
15) Age & fitness of workmen ensured by medical test before
engagement in job ?
16) Arrangement of Monitoring of possible oxygen deficiency
or obnoxious gases done & action taken?
PERMIT GRANTED - Yes / No
Name & Signature of Site Engr Name & Signature of Safety Officer
Contractor (Initiator) Contractor (Issuing authority)

Page 372 of 373
PERMIT FOR EXCAVATION

(Sheet 2 of 2)
NOTES: -
1. Slopes or benches for excavation beyond 2.0M depth shall be designed & approved by Contractor’s site
head.
2. Excavated earth to be kept at least 1.5M away from edges
3. Safety helmets, Safety shoes or gum-boots, gloves, goggles, Face shield, Safety Harness shall be essential
PPEs.
4. Permit shall be made in duplicate and original shall be available at site of work.
5. Permit shall be issued for maximum one week only (Monday to Sunday)
6. After completion of works, permit shall be closed & preserved for record purpose
GRANT OF PERMIT AND EXTENSIONS

Issuing authority
Initiator (site Review by EIL /
Sl. Validity period Working Time (Safety Officer
Engr. of Main Owner (Remarks
No. From ____To ____ From _____To _____ of Main
Contractor) with date
Contractor)
1.
2.
3.
4.
5.
6.
7.
Additional safety instructions if any: -

1.
2.
3.

Page 373 of 373

Instrumentation Design Basis

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Instrumentation Design Basis

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The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED.

A406 079 YA MR 2603 B 22/08/2013 16 51

JOB NO UNIT/ MAIN DOC. SR.NO. REV DIVN. DEPT.

REV DATE BY CHK APPD DETAILS

B 22/08/2013 AS SB SB Revised and issued for Bids

1 Design ,engineering,manufacture,procurement of materials and

1.01 GROUP-001 TCD Type Hydrogen Analysers 3 Nos

2 Unloading,handling,transportation to store and from store to work

Project : HPCL-TGTU REQUISITION No. REV

1 Vendor Data Requirement A406-079-YA-VD-2603 1 22/08/2013 2

2 Special Instruction to Vendor A406-079-YA-SI-2603 1 22/08/2013 7

3 Technical Questionarrie A406-079-YA-TM-2603 B 22/08/2013 1

4 Data Sheet Index A406-079-YA-ID-2603 0 17/04/2013 1

5 Scope of Work A406-079-YA-SOW-2603 0 17/04/2013 1

6 Spec. for quality management sys.req. 6-78-0001 0 04/06/2009 9

8 Standard specification forProcess Stream 6-52-0035 4 30/03/2012 22

11 Saftey Measures for electrical Installation 7-51-0332 0 17/04/2013 2

12 Utility Consumption A406-079-YA-OD-2613 0 17/04/2013 1

13 Calibration Gas Requirement A406-079-YA-OD-2614 0 17/04/2013 2

14 Format for Proven Track Record A406-079-YA-PTR-2603 0 17/04/2013 1

15 Compliance Format A406-079-YA-CF-2603 0 17/04/2013 1

16 Responsibility Defination A406-079-YA-RC-2603 0 17/04/2013 3

17 Deviation List Format A406-079-YA-OD-2615 0 17/04/2013 1

18 Logistic Support Format A406-079-YA-LSF-2603 0 17/04/2013 3

19 Standard Specification for HSE at 6-82-0001 0 17/04/2013 55

Project : HPCL-TGTU REQUISITION No. REV

Item Description:Analyser PR No.: Review Status Code:

Page 201 of 373

Anticipated (Ant) Date of submission by vendor

VENDOR DRAWING NO-

7. Process Connection 2” Flanged ANSI 150#, RF, facing 125 AARH,

sample probe, line isolation valve, sample pre-

A 17.04.13 AS SB SB MR: A406-079-YA-MR-2603 LEGEND :

REV DATE BY CHK APPD VENDOR: * - By Vendor

PLANT : TGTU SPECIFICATION REV

22. Electric Tracing of Sample Required

A 17.04.13 AS SB SB MR: A406-079-YA-MR-2603 LEGEND :

REV DATE BY CHK APPD VENDOR: * - By Vendor

PLANT : TGTU SPECIFICATION REV

4. In case external configurator is required, vendor shall supply the same.

6. All the Electrical/ Electronic components including sampling handling system,

8. Manufacturer shall be Western Research (Ametek) or equivalent.

A 17.04.13 AS SB SB MR: A406-079-YA-MR-2603 LEGEND :

REV DATE BY CHK APPD VENDOR: * - By Vendor

PLANT : TGTU SPECIFICATION REV

Sl No. Analyser Tag No. Sample Line No.

A 17.04.13 AS SB SB MR: A406-079-YA-MR-2603 LEGEND :

REV DATE BY CHK APPD VENDOR: * - By Vendor

PLANT : TGTU SPECIFICATION REV

A4. Acceptance Criteria

1 22/08/2013 AS SB SB REQ. NO. : A406-079-YA-MR-2603

0 17/04/2013 AS JJ SB ORDER NO. : Page 1 Of 7

REV DATE BY CHKD APPVD VENDOR :

PLANT : HPCL-TGTU SPECIFICATION REV

A5. MUST COMPLY REQUIREMENTS

Group-001:TCD Analysers Qty 3 No's

1 22/08/2013 AS SB SB REQ. NO. : A406-079-YA-MR-2603

0 17/04/2013 AS JJ SB ORDER NO. : Page 2 Of 7

REV DATE BY CHKD APPVD VENDOR :

PLANT : HPCL-TGTU SPECIFICATION REV

(iv) Codes & Standards.

B5.Hazardous Area Certification

B6. Analyser Requirements: