ANNEXURE-1
Central Tool Room & Training Center
Bhubaneswar
NOTICE INVITING TENDER FOR
“Design, Fabrication, Supply and Installation of Modern Advance Welding and Cutting
Workshop with Machineries and Equipment with booths / table, exhaust and Manifolding systems and
Training infrastructure”.
Sealed Tenders under Two Bid Systems i.e., “Techno-Commercial” (unpriced bid) and “Priced Bid” are
invited from OEM or their authorized dealer as per following details:
Tender documents for sale
Last date of receipt of tender
documents
Opening date of Tender in presence of
bidder’sauthorized representatives.
:
:
21.01.2015
25.02.2015
:
25.02.2015
Opening date of commercial
Bid of the technically qualified bidders in
presence of bidder’sauthorized
representatives.
:
Shall be intimated latter on
Tender Fee(Non refundable)
E.M.D.
Tender No.
Completion period
:
:
:
:
Rs. 1000/Rs. 100000/3 months
Description of Material& Scope of work
Materials description / specificationand bidder’s scope of work is as per the copy, attached annexure-1.
PRE-QUALIFICATION CRITERIA FOR THE BIDDERS (all points are mandatory)
1. The bidder should have executed similar type integrated welding workshop. Documentary
evidence must be submitted like Work order copy, completion certificate etc.
2. The bidder should have own training and demo center in different cities of India (minimum 4 metro
cities).
3
The Bidder must have executed similar type of set-up at least of Rs. 30 lakhseachwithin last
2years time.
3. The bidder should provide minimum 3 purchase order copy received for setting up the similar
welding lab in national level in Pan India basis.
4. The bidder in any form should have presence in welding technology field in India.
5. The bidder should have an Annual Turnover of Rs. 250 Lacs and above in last three financial
years. As a documentary proof for the same vendor’s copy of balance sheet etc. will be required.
In case copy of balance sheet cannotbe provided as documentary proof, the certificate in original
from chief executive officer should be provided by foreign bidders certifying minimum annual
turnover.
ANNEXURE-1
Important Instruction:
1) Only Original Equipment manufactureror their authorized dealercan participate.
2) Vendor to provide Material test certificate wherever applicable for all supplied products along with
supply.
3) Vendor to submit MSDS (Safety data sheet) for quoted products along with their quote.
EARNEST MONEY DEPOSIT
The tender should accompany with tender paper cost of Rs 1000/- if downloaded from Website & EMD
of Rs 100000/- in shape of Demand Draft drawn in favour of Central Tool Room & Training Centre,
Payable at Bhubaneswar .The EMD should valid for 45 days from the date of opening of technical bid.
The EMD shall be refunded to the unsuccessful bidder without interest within 30 days of finalization of
the tender. In case of the successful bidder the EMD shall be converted as security Deposit and shall be
refunded without any interest after successful materialization of contract. Bank Guarantee in lieu of
Demand Draft can be submitted on Non-Judicial stamp paper from any national/reputed Bank.
The format of bank guarantee(Annexure-II) can be downloaded from the CTTC, Website. However,
suppliers registered with DGS&D/NSIC for the particular item as per tender document need not submit
EMD/Bank Guarantee.
Tender(s) without EMD/Bank Guarantee/valid DGS&D or NSIC registration certificate shall be treated
as unresponsive and liable to be rejected.
PAYMENT:
70% with full taxes shall be paid on receipt of material in good condition at Kalinganagar. Balance
payment shall be released after installation and commissioning of complete laband on submission of
Performance Bank Guarantee for 10% of order value valid till 60 days beyond the warranty period.
Payment terms appearing anywhere else in the tender documents should be ignored.
LD Clause:
A penal charge @ ½% of order value for delay of every 15 calendar days beyond the agreed delivery
period to the extent of maximum 5% will be levied.
ANNEXURE-1
W E L D I N G W O R K S H O P S P E C I F I C AT I O N S
1. GENERAL NOTE :
“Design, Fabrication, Supply and Installation of Modern Advance Welding and Cutting
Workshop with Machineries and Equipment with booths / table, exhaust and Manifolding systems
and Training infrastructure”
2. BIDDER’S SCOPE OF WORK :
The Scope of the work of the bidders Includes following points:
1.
Bidder should design the workshop in specified space allocated and approved
byCentral Tool room and Training center.
2.
Bidder should set up welding workshop with all equipment mentioned in Annexure I.
3.
Bidder should Install and Commission all the machines / equipment’s supplied for
workshop as part of this tender.
4.
Bidder will shift existing light and fan positioning of ceiling for aesthetic looks and for
technical requirement of the workshop equipment as approved by CTTC.
ANNEXURE-1
3. BIDDER’S SCOPE OF SUPPLY
Bidder must provide the following items for the aforesaid job for the Welding workshop
Sr. No
1
2
ITEM
Arc Welding Booths of 3' x 2' x 6' size made of MS sheet with Glass wool &
DIN shade 13 protection glass approx. 4'' wide across the length,Provision for
fume extraction from top, Waste collection tray at the bottom of work place
aerosol cans,chipping hammer.
TIG Welding Booths of 3' x 2' x 6' size made of MS sheet with Glass wool &
DIN shade 13 protection glass approx. 4'' wide across the length,Provision for
fume extraction from top, Waste collection tray at the bottom of work place
aerosol cans,chipping hammer.
QTY
3
1
3
MIG Welding Booths of 3' x 2' x 6' size made of MS sheet with Glass wool &
DIN shade 13 protection glass approx. 4'' wide across the length,Provision for
fume extraction from top, Waste collection tray at the bottom of work place
aerosol cans,chipping hammer.
1
4
Master Welding Booth of required size with DIN 13 shade glasses on all the
three sides embedded in the Aluminumframe and Job Heating/Cutting
arrangement.
1
Heating Station with accessories and equipments:-
5
Standard Oxy Acetylene Gas Heating station with heating equipment’s.
Booths of 2' x 2' x 41/2' made of 40 x 40 x 5 mm square Iron pipe, complete
with fire bricks on both sides of working place, Heating handle, heating Insert,
Oxygen & DA gas antistatic hoses with clamps & connectors, with tapping
point regulator and Flashback arrestor for safety.
1
Cutting Station with accessories and equipments:-
6
Standard Oxy Acetylene Gas Cutting station with cutting equipment’s. Booths
of 2' x 2' x 41/2' made of 40 x 40 x 5 mm square Iron pipe, complete with fire
bricks on both sides of working place, Cutting torch of nozzle mixing
technology with nozzles, cutting capacity of 0-300 mm, Oxygen & DA gas
antistatic hoses with clamps & connectors, with tapping point regulator and
Flashback arrestor for safety.
1
Brazing Station with accessories and equipments:-
7
Standard Oxy Acetylene Gas Brazing station with brazing equipment’s.
Booths of 2' x 2' x 41/2' made of 40 x 40 x 5 mm square Iron pipe, complete
with fire bricks on both sides of working place, Brazing torch with nozzles ,
Oxygen & DA gas antistatic hoses with clamps & connectors, with tapping
point regulator and Flashback arrestor for safety.
1
ANNEXURE-1
Powder Spray Station:-
8
Standard Oxy Acetylene Powder spray stations of 2' x 2' x 41/2' made of 40 x
40 x 5 mm Angle Iron, complete with fire bricks on working place, Oxygen&
DA gas antistatic hoses with clamps & connectors, with tapping point
regulator and Flashback arrestor for safety.
1
9
Gas table for PUG cutting machine of (2 x 1) meter with fire bricks for plate
cutting
1
10
EWACMicromag 302 or equivalent light weighted portable capable of MMAW,
TIG and MIG in one Machine. specially designed for trainers
1
11
400 A MMAW Zuper 400 i machine or equivalent with complete package
2
12
Maxim Manual Metal Arc Welding Inverter Equipment Ready to Weld
Package.
1
13
PUG cutting machine with complete fittings and
accessories,FBA's,Torch,nozzles,hoses.
1
14
Bench Drilling machine with drilling bits.
1
15
Chop saw with grinders
1
16
Pedestal Grinder
1
17
21
Gas Manifold System for Industrial Gases
(5+5) Oxygen Gas Manifold system with SS 304 manifold header, Manifold
Regulators, FBA at header & tapping points, SS 304 Pipes, Clamps, Low
Pressure & High Pressure Valves, Tapping point Regulators, SS 304 sheets
and total distribution line
(4 + 4) DA Gas Manifold system with SS 304 manifold header, Manifold
Regulators, FBA at header & tapping points , SS 304 Pipes, Clamps, Low
Pressure & High Pressure Valves, Tapping point Regulators, SS 304 sheets
and total distribution line
(2+2) CO2 Gas Manifold system with SS 304 manifold header,
Heater,Manifold Regulators, SS 304 Pipes, Clamps, Low Pressure & High
Pressure Valves, Tapping point Regulators, SS 304 sheets and total
distribution line
(2+2) Argon Gas Manifold system with SS 304 manifold header,Manifold
Regulators, SS 304 Pipes, Clamps, Low Pressure & High Pressure Valves,
Tapping point Regulators, SS 304 sheets and total distribution line
Fume Extraction System for Arc Welding & Gas Brazing Booths complete with
Blower fans, Galvanized sheet pipes with Tee & joints, sealing arrangement,
complete with fittings .
Fire Extinguishers, First Aid box. Portable Electrode Oven
MS Square Frame (in Kg) for structural support for laying gas pipeline, fume
extraction system including fabrication charges of supports.
Welding defect and crack test stationwith6 nos. DP Test kits.
22
Tool & Tackles required for Workshop. The list is mentioned below -
17A
17B
17C
17D
18
19
20
1
1
1
1
1
2
800
1
Bench Vice
4
Welding *Tools kit for each trainee approx.
7
Hack Saw Frame
6
ANNEXURE-1
Metric Tap set of M8, M10, M12, M16
2
BSW Tap set of 1/4", 3/8", 1/2" & 5/8"
2
Tap wrench, 18" long for 5/8" tap
2
Tap wrench 12" long for 1/4" tap
2
Letter & Number Punch set, 6 mm size
2
Reamers, 1/2"
4
Dividers, 6" size,
6
Outside Caliper , 6" size
6
Inside Caliper , 6 " size
6
Odd leg caliper, 6" size, bent leg inside
6
Spanner Set Metric
3
Spanner Set British
3
Allen key set metric
3
Sledge Hammer - 5 Kgs.
2
Sledge Hammer - 2 Kgs.
2
Ball peen hammer -0.5 kg
6
Ball peen hammer -1 kg
6
Straight peen Hammer - 1kg
6
Straight peen Hammer 0.5 kg
6
Cross Peen Hammer - 1 kg
6
C Clamp -4" size
6
C Clamp -6" size
6
C Clamp -8" size
6
Hand drilling M/C - 1/4" Cap.
2
Auto Darkening Helmet
8
Angle Grinders, 9" disc size (Ralli - Fibre )
2
Angle Grinders, 5" disc size (Ralli -Fibre)
2
Straight Grinder, 4" wheel size (Ralli Metal)
2
Leather apron
30
Leather Gloves in pair
30
Gas cutting goggles
10
Welding Helmet with din 13 glass- (3M)
10
Safety Goggles (3M)
30
Safety helmet (3M)
30
Wire brush
30
ANNEXURE-1
ITEM WISE DETAILED SPECIFICATIONS ARE AS FOLLOWS
Maxim MachineMMAW Inverter based three phase welding machine with earth cable, welding cable- 1Nos
Specification
Technical Details
Input Supply
3 PHASE,330VAC TO 465 VAC
Switching Device
IGBT-Primary Switch, Half Bridge
Welding Current Range
10 – 400 Amps DC
Duty Cycle (10 min@ 40 Degree)
400 Amps @ 20%
250 Amp @ 100%
Input KVA @ 100% Duty Cycle
Input KVA @ 20% Duty Cycle
8.5 KVA
17.3 KVA
No load Power
50 Watt
Insulation Class
H
Class of Protection
21
Arc Force
Display of Current & Voltage
Adjustable from front Panel
Digital Display with selector switch
OCV
Safe Welding Device (SWD)
Output End Connectors
75 – 85 DC
10 V DC Built IN
Lug Connector
Weight (Approx.)
35 Kg
Dimensions W x L x H
305 x 460 x 535 mm
Recommended Dia. of Electrodes for Welding
UPTO 4mm,5mm@upto250amp
Input Connection Cable
2.5 Sqmm, 4 Core 4 Meter
Indication
OT,OC,Power Fault (Standard Indication)
Technical specifications for Inverter based MMAW –GTAW WeldingRectifier- 400 Amp
power source- 2 Nos
Specification
Technical Details
Input Supply
3 PHASE,330V TO 465 V
Switching Device
IGBT-Primary Switch, Full Bridge
Welding Current Range
10 – 400 Amps
Duty Cycle (10 min@ 40 Degree C)
400 Amps @ 60% DC
310 Amps @ 100%
Input KVA @ 100% Duty Cycle
13 KVA
No load Power
40 Watt
Insulation Class
H
International Protection
IP 23
Hot Start / Dynamic arc force
Adjustable from front Panel
Display of Current & Voltage
Digital Display
OCV
75 – 80 DC
Safe Welding Device (SWD)
10 V Built IN
Output End Connectors
Lug Connector
Weight (Approx.)
45Kgs.
MMAW Welding of all types of electrodes
5 mm dia.
Multi process portable synergic capable of MMAW, MIG and TIG, 300amps machine.
Digital pulsing, High productivity and flexibility, rugged and dedicated controls and low
spattering allows to get perfect welding – 1 No
Specifications
Input Supply
Current
Type of welding
Duty Cycle % 40
Degree
Current
Duty Cycle
Power
Current range
Voltage
Power Max
IP
Dimensions
Weight
Technical Details
35%
300A
-
3 x 400 VAC ± 15% @ 50-60 Hz
16 A
MIG-MAG
TIG-WIG
60%
100%
50%
60%
100%
40%
230A
200A
60%
100%
300
250
Amps
Amps
20 A – 300 A
250A
-
240A
-
210A
100%
250Amps
5A – 250 A
11 / 60 V
10.3 KVA – 9.7 KVA
23S
560 x 280 x 390 mm
24 kgs.
250A
-
MMA
60%
100%
220A
-
190A
100%
250
Amps
5A – 250 A
Welding Booths –
Arc Welding Booths – 3Nos
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ARC booths aremade of Square pipe with dimensions of 3’ X 2’ X 6’ with Glass wool embedded
between the MS Sheets of 16 gauge.
Provision of fumes collection from the top & spatter, slag, dust collection at the bottom of the work
place.
Storage facility with two compartments to be provided at the bottom of the waste collection tray.
Tube light provision with automatic light glow provision at the time of door opening should be
provided.
Tools & tackles required for arc welding is to be provided with the arc booths.
Booths should be Modular in design with DIN Shade 13 viewing area for viewing at the time of
training.
Provision for shielding gas to be provided with the booths.
Provision of keeping the welding machines at the side of the Booths.
TIG Welding Booths – 1 No


TIG booths aremade of Square pipe with dimensions of 3’ X 2’ X 6’ with Glass wool embedded
between the MS Sheets of 16 gauge.
Provision of fumes collection from the top & spatter, slag, dust collection at the bottom of the work
place.
Storage facility with two compartments to be provided at the bottom of the waste collection tray.
Tube light provision with automatic light glow provision at the time of door opening should be
provided.
Tools & tackles required for arc welding is to be provided with the arc booths.
Booths should be Modular in design with DIN Shade 13 viewing area for viewing at the time of
training.
Provision for shielding gas to be provided with the booths.

Provision of keeping the welding machines at the side of the Booths.





MIG Welding Booths – 1 No


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

MIG booths aremade of Square pipe with dimensions of 3’ X 2’ X 6’ with Glass wool embedded
between the MS Sheets of 16 gauge.
Provision of fumes collection from the top & spatter, slag, dust collection at the bottom of the work
place.
Storage facility with two compartments to be provided at the bottom of the waste collection tray.
Tube light provision with automatic light glow provision at the time of door opening should be
provided.
Tools & tackles required for arc welding is to be provided with the arc booths.
Booths should be Modular in design with DIN Shade 13 viewing area for viewing at the time of
training.
Provision for shielding gas to be provided with the booths.
Provision of keeping the welding machines at the side of the Booths.
Master Welding Booth – 1 No




Master Boothmade of Aluminum frame with DIN Shade 13 glass on three sides with a dimension of
3’ X 3’ X 6’.
Provision of fumes collection from the top & spatter, slag, dust collection at the bottom of the work
place.
Storage facility with two compartments to be provided at the bottom of the waste collection tray.
Tube light provision with automatic light glow provision at the time of door opening should be
provided.
Tools & tackles required for arc welding is to be provided with the arc booths.
Booths should be Modular in design.
Provision for Shielding, Oxygen & DA gas to be provided with the Master booths.

Provision of keeping the welding machines at the side of the Master Booths.



Gas Heating station - 1 No

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

Heatingstation aremade of Square pipe with dimensions of 2’ X 2’ X 4 1/2’ with Glass wool
embedded between the MS Sheets of 16 gauge.
Provision of fumes collection from the top. Fire Bricks to be provided at the work place.
Tools & tackles required for Gas heating is to be provided with the heating station.
Station should be Modular in design.
Provision for Oxygen & DA gas to be provided with the booths.
Gas Cutting station - 1 No





Cuttingstation aremade of Square pipe with dimensions of 2’ X 2’ X 4 1/2’ with Glass wool
embedded between the MS Sheets of 16 gauge.
Provision of fumes collection from the top. Fire Bricks to be provided at the work place.
Tools & tackles required for Gas cuttingis to be provided with the cutting station.
Station should be Modular in design.
Provision for Oxygen & DA gas to be provided with the booths.
Gas Brazing station - 1 No





Brazingstation aremade of Square pipe with dimensions of 2’ X 2’ X 4 1/2’ with Glass wool
embedded between the MS Sheets of 16 gauge.
Provision of fumes collection from the top. Fire Bricks to be provided at the work place.
Tools & tackles required for Gas Brazing is to be provided with the brazing station.
Station should be Modular in design.
Provision for Oxygen & DA gas to be provided with the booths.
Powder Spray station - 1 No




Powder spray station aremade of Square pipe with dimensions of 2’ X 2’ X 4 1/2’ with Glass wool
embedded between the MS Sheets of 16 gauge.
Provision of fumes collection from the top. Fire Bricks to be provided at the work place.
Station should be Modular in design.
Provision for Oxygen & DA gas to be provided with the booths.
PUG Cutting Machine table- 1 No





PUG Cutting table aremade of Square pipe with dimensions of 3’ X 6’ X 4’ with Fire bricks at the
work place.
Provision of fumes collection from the top.
Tools & tackles required for cutting with PUG machine is to be provided with the table.
Booth should be Modular in design.
Provision for Oxygen, DA gas to be provided with the booth for cutting purpose.
Fume Extraction System – 1 No
Fume Extraction Systemfor Arc Welding, cutting & Gas Brazing Booths complete with
exhaust fans, GI pipes with Tee & joints, sealing arrangement, complete with
fittings.Fume extraction system should be suitable for removing the welding fumes.
System to be made from good quality GI pipes with exhaust fans. The exhaust system
should becoated with epoxy coating paint so that there is no rust generation. There
should be no leakages from the joints. This should meet out the all individual Booths
requirements as per layout plan.
Standard Oxy-acetylene gas brazing / cutting equipment :
Specifications for Gas Brazing Torch






Injector Mixing Technology
Confirms to EN ISO 5175
Handle: Insulated Aluminum handle
Liver: Stainless Steel
Knobs: Forged Brass
Nipples : Forged Brass
Specifications For Gas Cutting Torch

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
Nozzle Mixing Technology
Confirms to EN ISO 5175
Head: 90 degree solid forged brass head
Tubes: Stainless Steel Tubes
Handle: Aluminum handle with heat resistant Anodized coating.
Liver: Stainless Steel
Knobs: Forged Brass
Nipples : Forged Brass
The torch should have replaceable gas inlet connection nipples.
Should be useful till 300 mm thick cutting
Should be capable for flame gouging
Absolute Safety :High resistance to back fires
Rugged design which ensures maximum strength
Balanced Weight :Comfortable for continuous operation
Accurate precise flow rates
Heavy duty applications even at low cylinder pressures
Cutting Quality: Reduced post cut grinding operation
Specifications for Flash Back Arrestors Regulator EndFor Oxygen & Fuel Gas










Dry type with Filter, Non return valve, flame arrestor & automatic thermo sensitive gas cut off valve.
The Thermo Sensitive cut off valve which cuts off gas before reaching ignition temperature to
eliminate incidence of fire should activate between 90-100 degree centigrade
Suitable for Inlet pressure of Oxygen :20 bars, Acetylene :1.5 bars, Hydrogen : 3.5 bars ,
LPG : 5.0 bars
Every unit should necessarily meet certificate no. BAM/ZBA/007/03 by the safety body BAM.
Connection : as per BSP standards
The flashback arrestors should comply with ISO5175, EN730, BS6158
The manufacturer should have ISO-9001 accreditation for manufacturing
Gas flow direction to be indicated on each Flash back arrestor
The working manual to be enclosed in each packing.
Supplier should have equipment for testing of flashback arrestors
Specifications for Flash Back Arrestors Torch End –
For Oxygen & Fuel Gas

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

Dry type with Filter, non return valve & flame arrestor
Suitable for Inlet pressure of Oxygen :20 bars, Acetylene:1.5 bars,Hydrogen:3.5 bars,LPG:5.0
bars
Every unit should necessarily meet certificate no. BAM/ZBA/007/03 by the safety body BAM.
Connection : as per BSP standards
The flashback arrestors should comply with ISO5175, EN730, BS6158
The manufacturer should have ISO-9001 accreditation for manufacturing
Gas flow direction to be indicated on each Flash back arrestor
The working manual to be enclosed in each packing.
Supplier should have equipment for testing of flashback arrestors
Oxy-Fuel Flame PUG Cutting Machine – 1 No
Semi-Automatic Oxy-Fuel Flame Cutting Machine
Flame cutting machine Useful for Straight, Strip, Curve, Circle, and Bevel cuts, having following
featuresandbenefits.
1. Rugged, heavy-duty design, tough machine construction-Maintenance free, long service life
of the machine.
2. Single cone speed changer (mechanical non-stage speed changer)Assures
constantlystable, vibration free machine travel – resulting in absolutely smooth, finish
cuts-Higher cutting speeds; 20% - 30% higher than conventional machines &Greater cutting
output in shorter time, savings on labour cost, higher productivity.
3. Precision cutting torch giving better cutting quality –minimum secondary machining / grinding
required. Savingson post-cutting activities and labour costs.
4. Energy efficient
5. Versatile - Useful for Straight, Strip, Circle, Bevel
Technical Specifications:
Drive
Single phase motor.
Speed control
Potentiometer.
Input voltage
230 V single phase 50 Hz.
Speed
200 mm/min to 1000mm/min.
Cutting range
3mm to 100 mm.
Cutter type
Nozzle Mixing (NM).
Gas type
Oxygen & Acetylene
.
Nozzle
3 seat ANME for acetylene.
Connections
¼” or 3/8” LH for Fuel and ¼” or 3/8” RH for Oxygen.
To be used with
Aluminum guide track.
Gas Manifold Systems- 4 Gases (Oxygen,DA,CO2 and Argon)
Gas manifold for gas welding stations
Details of Work:
Supply of the material, installation, commissioning and testing of Oxygen, DA, Argon and Carbon Dioxide
Manifold along with gas pipeline distribution system for supplying the gases to the booths installed.
Laying of 2” &1” NB steel pipes seam less phosphorus de oxidized, non arsenic degreased confirming to
IS1239-92 Schedule 40 part 1/ASTMA106 Gr.B suitable for 10 kg/cm2 and tested at 21kg/cm2 and laying
of 1’’ seamless steel pipelines for LPG conforming to IS1239-92 Schedule 40 part 1/ASTMA106 Gr. B
suitable for 10 kg/cm2 and tested at 21kg/cm2 pressure at a height of 5 to 6 meters from shop floor level.
Each down take outlet with fittings including 90 degree angle ball valves, tapping point regulators EN ISO
2503 approved, flash back arrestors EN 730 approved etc. shall be required to be placed with booths with
proper fixing.
All the pipelines should be properly fixed by suitable clamps with anti corrosive treatment. The pipes should
be coloured as per IS 4379-1967.
Pipeline should have the facility to check the line pressure of the system.
The welding of the pipes should be done by TIG welding process only.
Pipelines should be tested at 1.5 bar of the working pressure and should hold the same pressure
for 3 hrs.
For connecting cylinders to manifold, Stainless Steel 304 Braided Double wire hose pipes with
interchangeable SS 304 nuts & nipples for 250 bar working pressure & tested at 250 bar is to be provided.
The bending radius of the hose pipe should be 4’’.
All the manifolds shall be fitted with control panel of Stainless Steel 304 sheet which also includes safety
equipment’s like Non return valvesmade of Stainless Steel 304 material with micro filters of 5 microns
tested at 250 bar pressure to avoid any dust particles in the system. Flash Back Arrestors should be EN730
approved & BAM tested, High Pressure Ball valves should be of SS 304 with a working pressure 250 bar
for compressed gas & 100 bar for Liquefied gas, Low pressure Ball valves should be of SS304 with a
working pressure of 30 bar for compressed gas & 5 bar for Liquefied gas. Pressure regulators, Ball valves,
Non return valves, Flash back arrestors should be ISO approved. The manifolds shall be provided with
securing chains and cylinder bracket for each cylinder.
 Regulator with high flow rate with an Inlet pressure of 200 bar & Outlet pressure of 20 bar to be used
to provide continuous, flow and pressure in the pipelines. The regulator should be EN ISO 7291
approved with 100% leakage & function testing. Regulator should have unique facility of mechanical
locking of Outlet Pressure Limitation.
 Bypass facility in case regulator failure.
 Tapping point regulator should have outlet gauge for monitoring of working pressure.
Manifold should be equipped with digital gas pressure alarm system with low, medium, high indications
with Buzzer & mute facility.
A. Oxygen Gas Manifold system with SS 304 manifold header, Manifold Regulators, FBA at header &
tapping points,SS 304 Pipes, Clamps, Low Pressure & High Pressure Valves, Tapping point
Regulators,SS 304 sheets, Low content alarm signal.
B. DA Gas Manifold system with SS 304 manifold header, Manifold Regulators, FBA at header &
tapping points,SS 304 Pipes, Clamps, Low Pressure & High Pressure Valves, Tapping point
Regulators,SS 304 sheets.
C. Argon Gas Manifold system with SS 304 manifold header, Manifold Regulators, SS 304 Pipes,
Clamps, Low Pressure & High Pressure Valves, Tapping point Regulators, SS 304 sheets, Low
content alarm signal.
D. CO2 Gas Manifold system with SS 304 manifold header, Manifold Regulators,SS 304 Pipes,
Clamps, Low Pressure & High Pressure Valves, Tapping point Regulators, SS 304 sheets, Low
content alarm signal, Heater.
Specifications for Gas Regulators
Oxygen / Argon / CO2:
Max. Inlet Pressure: 150/200 bar / 2900 psi
Max. Outlet Pressure: 10 /15 bars / 145 psi
DA:
Max. Inlet Pressure: 10 bar/ 145 psi
Max. Outlet Pressure: 1.5 bar / 22 psi
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Confirming to EN ISO 2503
Stable Outlet Pressure
Steady Flow of Gas
Better Pressure Regulation
Forged Brass Body & Housing Cap
Sintered Filter at the inlet
Stainless Steel Sintered Central Micro Filter
Teflon Coated Valve Seat
Fire Retardant valve seat material
Diaphragm: Thick NBR supported by large backup plate & Teflon ring in Periphery.
Welding Auto Darkening Helmets – 8Nos
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Auto Darkening Welding Helmet
Light Shade: DIN 3 / DIN 4
Dark Shade: DIN9-14 (Step less Regulation)
Switching Time: >0.2 ms at Room Temperature
Delay Time: Rapid-0.5 seconds, Slow-1.5 seconds
Sensitivity Adjustment: Low/High
Solar Powered
Battery: Li & Solar Combination (Min. Lifetime : 5000 Welding Hours)
Operating Temperature: -5 degree C to 55 degree C
Viewing Area: 98 x 43 MM
Size of Welding Filter: 100 x 90 x 9 MM
Rate of Ultra Violet Transmittance: 210<Y<313 NM, T<0.00006%
313<Y<365 NM, T<0.000061%
Rate of Infra Red Transmittance: 780-1400 NM, T<0.003%
Weight: 430 Grams
Material: Polyamide
Electrode Drying Oven – 2 Nos.
Portable oven, rugged design of capacity 5 kg and heating up to 250°C, with natural convention circulation.
Other Eligibility Requirements:
1)
Standards of materials: All the items viz. pipes, safety equipment’s like gauges, valves, etc.
should be standard quality with ISI mark. All equipment’s and materials shall comply with
standard mentioned in the offer sheet as well as appropriate Indian Standard (latest) or
National Standard of the country of origin provided the latter are equivalent to or better than
former. The equipment should also comply with latest Indian Electricity Rules, as regards
safety requirements and other essential provision of the act applicable to the installation
and operation of the gas pipelines and other equipment’s. For items for which Indian
Standard are not published; national Standards of the Country of Origin shall be applicable.
2)
The bidder should provide training at CTTC after completion of work.
3)
Bidder should be a welding company having international presence and should provide the
following
4a
4b
4c
4d
4e
4f
Operational handover training and live demo for 3 days.
Safety poster with its arrangements and knowledge book.
Manual book for operational management of workshop.
Booklet of different base metal and WPS.
Booklet of job heating procedures - pre and post.
Booklet of basic welding and joints and international jargons.
4)
Complete gas pipeline shall be tested at 1.5 times of working pressure as mentioned in
scope of work before commissioning.
5)
All gas pipelines, fittings, erected structures and securing arrangements shall be given anti
corrosive treatment by painting with red oxide zinc chromate primer to IS: 2074 1992
followed by synthetic enamel exterior paint to IS: 8662 1998 in different colors for
identification as per norms of standard color scheme duly approved by competent authority.
6)
The all equipment and pipelines should be designed, selected and erected in such a way
that it shall be facilitated to carryout inspection, cleaning, replacement and repair.
7)
The pipelines shall be properly secured and laid at safe distance from Power cable, OHE
Cranes & DSL, Jib Cranes etc.
8)
Drawing, manuals and literatures: Firm shall supply all drawings of pipelines system,
literature of items supplied, Manuals, along with required Safety Certificates.
9)
Test Certificates: Safety equipment’s / items used in system shall be supported with test
certificate.
10)
Monitoring and inspection: Monitoring and inspection shall be done by representative of
CTTC.
Erection, Installation & Commissioning
Besides all the above material the bidder is also supposed to supply and consider the MS
angles for structural support for laying gas pipeline; fabrication charges of supports for
fume extraction system; Labour Charges for carrying out the above job; Oxygen, DA,
Argon, Nitrogen gas charges during installation; Welding machine, Painting charges for
the total installation; Electrical cables, Cable trays, Connection sockets with fittings. Job
should be completed in all respects
CTTC Scope of work / supply:
1. CTTC will provide suitable room for storage of material for team’s tools and
tackles coming for installation.
2. CTTC will provide single point power connection (415 V, 50 Hz) for the whole
package inside the room allocated for the setup.
3. CTTC will provide (O2, DA, CO2 and Ar2) Gas cylinders for commissioning of
manifold system and further using of the system.
4. Crane / Hydra for fixing the blower/other equipment and Ladder to work at height.
5. Water at site on free of cost basis.
DOCUMENT REQUIRED FROM VENDOR FOR CTTC APPROVAL
Besides giving the package details in the offer, the vendor shall be required to furnish the
following after placement of PO, for CTTC approval
a) Party to submit the detailed layout for CTTC approval.
b) Detailed GA drawings
FINAL DOCUMENTATION
The operational / Maintenance manuals and drawings should be on A-4 size paper laser printed
and not on your standards printed literature. This should be in a folder providing the following.
a) Drawing and details of welding workshop.
b) Details of supplies and specification.
c) Operation manuals.
SCOPE OF INSPECTION
Approval of Layout, GA drawings, all components of the entire package will be carried out by
CTTC after placement of order. Material will be inspected as per GC and TC at CTTC site after
material delivery.
The vendor will have to carry out the entire job and the same shall be checked by CTTC stage
wise.