Volume Vi

HARYANA POWER GENERATION CORPORATION LIMITED
1 X 660 MW SUPERCRITICAL DCRTPP YAMUNANAGAR, HARYANA
SPECIFICATION.NO. TCE.6417A-H-500-01
CIVIL REQUIREMENTS VOLUME VI
TATA CONSULTING ENGINEERS LIMITED TECHNOPOLIS, 5TH FLOOR, A-WING BP-4, SECTOR-V, SALT LAKE, KOLKATA 700 091 INDIA MARCH 2012
TATA CONSULTING ENGINEERS LIMITED

SPEC.NO. TCE.6417A-H-500-001
1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS
SHEET 1 OF 31
VOLUME (I) GENERAL CONDITION OF CONTRACT, PQR, ITB ETC SECTION NO. A1 A2 A3 A4 A5 SPECIFICATION NO. TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 REV. NO. R0 R0 R0 R0 R0 INTRODUCTION INSTRUCTION TO BIDDERS PRE QUALIFICATION REQUIREMENTS GENERAL CONDITIONS OF CONTRACT INFORMATION FORMS TITLE NO. OF SHEETS 2 32 6 146 29
ISSUE R0 TCE FORM NO. 329 R5

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SHEET 2 OF 31
VOLUME (II) GENERAL SCOPE OF ENQUIRY, PROJECT INFORMATION, SCHEDULE ETC SECTION NO. A B C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 SPECIFICATION NO. TCE.6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 REV. NO. R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 TITLE SCOPE OF ENQUIRY GENERAL PROJECT INFORMATION SCOPE OF SUPPLY, TERMINAL POINTS, EXCLUSIONS. CODES AND STANDARDS PERFORMANCE REQUIREMENTS AND PERFORMANCE GUARANTEES AVAILABILITY REQUIREMENTS LAYOUT REQUIREMENTS MAINTENANCE REQUIREMENTS SPARE AND MAINTANANCE TOOLS & TACKLES PRE OPERATIONAL REQUIREMENTS TENDER EVALUATION PERFORMANCE TESTS ERECTION REQUIREMENTS QUALITY ASSURANCE REQUIREMENTS PAINTING REQUIREMENTS LIST OF SKETCHES/DRAWINGS ENCLOSED INFORMATION TO BE FURNISHED WITH BID DATA TO BE FURNISHED AFTER AWARD OF CONTRACT CONTRACTORS HEALTH AND SAFETY PROGRAMS LIST OF SPARES LIST OF SUB VENDORS / SUB CONTRACTORS ENVIRONMENTAL MANAGEMENT DATASHEET A1 A3 NO. OF SHEETS 3 9 43 10 16 2 8 12 4 5 1 13 5 190 15 4 8 7 23 138 19 4 14 ISSUE R0 TCE FORM NO. 329 R5

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SHEET 3 OF 31
VOLUME (II) GENERAL SCOPE OF ENQUIRY, PROJECT INFORMATION, SCHEDULE ETC SECTION NO. SECTION E E1 E2 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 R0 R0 DOCUMENT DISTRIBUTION SCHEDULE STORAGE OF MECHANICAL AND ELECTRICAL EQUIPMENT AT SITE 1 10 SPECIFICATION NO. REV. NO. TITLE NO. OF SHEETS
SCHEDULES F F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 SCHEDULE OF PRICE OVERALL TIME SCHEDULE SCHEDULE OF PERFORMANCE GUARANTEES SCHEDULE OF DEVIATIONS FROM TECHNICAL SPECIFICATION SCHEDULE OF DEVIATIONS FROM GENERAL CONDITIONS SCHEDULE OF BIDDERS EXPERIENCE SCHEDULE OF START UP SPARES SCHEDULE OF MANDATORY SPARES SCHEDULE OF RECOMMENDED SPARES SCHEDULE OF MAINTENANCE TOOLS AND TACKLES SCHEDULE OF PLACES OF TEST AND INSPECTION SCHEDULE OF QUALITY PLAN. SCHEDULE OF CONSTRUCTION POWER REQUIREMENT SCHEDULE OF CONSTRUCTION WATER REQUIREMENT SCHEDULE OF CONSTRUCTION AREA REQUIREMENT SCHEDULE OF WEIGHT AND DIMENSIONS SCHEDULE OF MOTOR LOAD LIST SCHEDULE OF SUB-VENDORS LIST BIDDERS CHECK LIST 1 1 19 1 1 3 1 1 1 1 1 1 1 1 2 1 1 1 2 ISSUE R0 TCE FORM NO. 329 R5

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SHEET 4 OF 31
VOLUME (II) GENERAL SCOPE OF ENQUIRY, PROJECT INFORMATION, SCHEDULE ETC SECTION NO. F20 F21 F22 SPECIFICATION NO. TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 TCE. 6417A-H-500-001 REV. NO. R0 R0 R0 TITLE SCHEDULE OF CONTRACTORS RESOURCE DEPLOYMENT SCHEDULE OF THE PRESENT COMMITMENTS SCHEDULE OF FUEL REQUIREMENT TILL PG TEST NO. OF SHEETS 4 1 1

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SHEET 5 OF 31
VOLUME III SPECIFIC MECHANICAL REQUIREMENTS FOR BTG AND BOP PACKAGE VOLUME III (A) SPECIFIC MECHANICAL REQUIREMENTS FOR BTG PACKAGE SECTION NO. SPECIFICATION NO. REV. NO. TITLE NO. OF SHEETS
STEAM GENERATOR AND AUXILIARIES C1 TCE-6417A-H-500-001 R0 STEAM GENERATOR & AUXILIARIES 73
STEAM GENERATOR AND AUXILIARIES DATA SHEET-A A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A16 A18 A19 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 STEAM GENERATOR PRESSURE PARTS RAPH CENTRIFUGAL FANS-ID FANS AXIAL FANS-FD FANS AXIAL FANS-PA FANS SOOT BLOWING SYSTEM COAL BURNERS COAL MILLS COAL FEEDER & COAL PIPES FUEL OIL SYSTEM AND DAY TANKS FUEL OIL BURNER AND IGNITERS ELECTROSTATIC PRECIPITATOR DAMPERS & DUCTS STRAINERS SHELL AND TUBE HEAT EXCHANGER FLASH TANK SCAPH ID FANS - AXIAL SEAL AIR FANS 5 2 4 2 2 2 2 3 3 4 1 6 3 3 3 1 1 3 1
STEAM GENERATOR AND AUXILIARIES DATA SHEET-B ISSUE R0 TCE FORM NO. 329 R5

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SHEET 6 OF 31
VOLUME III SPECIFIC MECHANICAL REQUIREMENTS FOR BTG AND BOP PACKAGE VOLUME III (A) SPECIFIC MECHANICAL REQUIREMENTS FOR BTG PACKAGE SECTION NO. B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 SPECIFICATION NO. TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 REV. NO. R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 TITLE STEAM GENERATOR PERFORMANCE DATA HEAT RELEASE AND OTHER DATA STEAM GENERATOR PRESSURE PARTS REGENERATIVE AIR PREHEATER STEAM COIL AIR PREHEATER CENTRIFUGAL FANS FD & PA FANS-AXIAL FANS SOOT BLOWING SYSTEM FUEL OIL BURNERS AND IGNITORS COAL BURNERS COAL MILLS ROTARY GEAR SCREW PUMPS FUEL OIL HEATERS AIR AND FLUE GAS DUCTS AND DAMPER ELECTROSTATIC PRECIPITATOR THERMAL INSULATION AND REFRACTORY SEPARATOR DRAIN RECIRCULATION PUMP ATMOSPHERIC DRAIN TRANSFER PUMP HORIZONTAL CENTRIFUGAL PUMP DRAWINGS AND DETAILS FOUNDATION LOADING AT COLUMN BASES NO. OF SHEETS 17 4 7 4 2 3 3 3 3 2 3 2 2 2 3 2 1 1 1 4 1
STEAM TURBINE GENERATOR & AUXILIARIES C2 TCE.6417A-H-500-001 R0 STEAM TURBINE GENERATOR & AUXILIARIES 83
STEAM TURBINE GENERATOR AND AUXILIARIES DATA SHEET-A ISSUE R0 TCE FORM NO. 329 R5

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SHEET 7 OF 31
VOLUME III SPECIFIC MECHANICAL REQUIREMENTS FOR BTG AND BOP PACKAGE VOLUME III (A) SPECIFIC MECHANICAL REQUIREMENTS FOR BTG PACKAGE SECTION NO. A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 SPECIFICATION NO. TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 REV. NO. R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 TITLE UTILITY REQUIREMENTS STEAM TURBINE AND ACCESSORIES SURFACE CONDENSER AND ACCESSORIES CONDENSER AIR EVACUATION EQUIPMENT AND ACCESSORIES CONDENSATE EXTRACTION PUMPS AND ACCESSORIES CLOSED FEED WATER HEATER AND ACCESSORIES DEAERATING FEED WATER HEATER AND ACCESORIES BOILER FEED PUMP AND ACCESSORIES CENTRAL LUBE OIL SYSTEM FEED WATER CHEMICAL DOSING SYSTEM STRAINERS SHELL AND TUBE HEAT EXCHANGERS CONDENSATE STORAGE TANK ON-LOAD CONDENSER TUBE CLEANING SYSTEM NO. OF SHEETS 2 7 3 3 3 3 3 6 3 4 3 3 2 3
STEAM TURBINE GENERATOR AND AUXILIARIES DATA SHEET-B B1 B2 B3 B4 B5 B6 B7 B8 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 R0 R0 R0 R0 R0 STEAM TURBINE AND ACCESSSORIES SURFACE CONDENSER AND ACCESSORIES CONDENSER AIR EVACUATION EQUIPMENT AND ACCESSORIES CONDENSATE EXTRACTION PUMPS AND ACCESSORIES CLOSED FEED WATER HEATER AND ACCESSORIES DEAERATING FEED WATER HEATER AND ACCESSORIES BOILER FEED PUMP AND ACCESORIES ROTARY GEAR/ SCREW PUMPS 26 6 2 4 6 5 7 2 ISSUE R0 TCE FORM NO. 329 R5

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SHEET 8 OF 31
VOLUME III SPECIFIC MECHANICAL REQUIREMENTS FOR BTG AND BOP PACKAGE VOLUME III (A) SPECIFIC MECHANICAL REQUIREMENTS FOR BTG PACKAGE SECTION NO. B9 B10 B11 B12 B13 B14 B15 SPECIFICATION NO. TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 REV. NO. R0 R0 R0 R0 R0 R0 R0 TITLE HP/LP BYPASS VALVES GLAND STEAM CONDENSER AND ACCESSORIES OIL COOLER HEAT EXCHANGERS FEED WATER CHEMICAL DOSING SYSTEM VARIABLE SPEED HYDRAULIC COUPLINGS MISCELLANEOUS PUMPS CONDENSATE STORAGE TANK AND LP DRAIN CONDENSATE PUMP S (IF PROVIDED) PIPING C3 TCE.6417A-H-500-001 R0 PIPING 21 NO. OF SHEETS 1 4 4 3 2 1 2
PIPING DATA SHEET-A A1 A2 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 THERMAL INSULATION FOR HOT SURFACES MATERIAL SPECIFICATION FOR PIPING AND VALVES WATER SYSTEM C4 TCE.6417A-H-500-001 R0 WATER SYSTEM 3 3 9
WATER SYSTEM DATA SHEET-A A1 A2 A3 A4 A5 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 R0 R0 DMCW PUMPS SG FILL PUMPS HOTWELL MAKE UP PUMPS STATOR COOLING PUMPS PLATE HEAT EXCHANGERS 2 2 2 2 3
WATER SYSTEM DATA SHEET-B B1 B2 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 DMCW, SG FILL, HOTWELL MU, SW PUMPS PLATE HEAT EXCHANGERS 2 5 ISSUE R0 TCE FORM NO. 329 R5

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SHEET 9 OF 31
VOLUME III SPECIFIC MECHANICAL REQUIREMENTS FOR BTG AND BOP PACKAGE VOLUME III (A) SPECIFIC MECHANICAL REQUIREMENTS FOR BTG PACKAGE SECTION NO. SPECIFICATION NO. REV. NO. TITLE NO. OF SHEETS
CONDENSATE POLISHING UNIT C5 TCE.6417A-H-500-001 R0 CONDENSATE POLISHING UNIT 15
CONDENSATE POLISHING UNIT DATASHEET A A1 TCE.6417A-H-500-001 R0 DATA SHEET A1 5
CONDENSATE POLISHING UNIT DATAHSEET - B B1 TCE.6417A-H-500-001 R0 DATA SHEET B1 6

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SHEET 10 OF 31
VOLUME III SPECIFIC MECHANICAL REQUIREMENTS FOR BTG AND BOP PACKAGE VOLUME III (B) SPECIFIC MECHANICAL REQUIREMENTS FOR BOP PACKAGE SECTION NO. SPECIFICATION NO. REV. NO. WATER SYSTEM D4 D4.1 D4.2 D4.2 D4.3 D4.3 D4.3 D4.3 D4.3 D4.3 D4.4 D4.5 D4.6 D4.6 D4.7 D4.8 D4.9 D4.10 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 WATER SYSTEMS WRITE UP DATA SHEET A - RAW WATER & AHP PUMPS DATA SHEET A1- HYPO-CHLORINATION SYSTEM DATA SHEET A2 - PRE TREATMENT PLANTDATA SHEET A1 - ACF DATA SHEET A2 ACID ALKALI SYSTEM DATA SHEET A3 DM PLANT DATA SHEET A4 - DUAL MEDIA FILTERS DATA SHEET A5 DM STORAGE TANKS DATA SHEET A6 NEUTRALISING PIT DATA SHEET A RUBBER EXPANSION JOINTS DATA SHEET A MISC PUMPS WRITE UP CW/ACW PUMPS DATA SHEET A CW/ACW PUMPS DATA SHEET A BUTTERFLY VALVES DATA SHEET A STP WATER TREATMENT PLANT DATA SHEET A CHEMICAL DOSING & SIDE STREAM FILTERATION SYSTEM DATA SHEET A SELF CLEANING STRAINER 19 2 1 6 1 3 2 2 1 1 2 10 10 7 3 3 4 3 TITLE NO. OF SHEETS
WATER SYSTEM DATASHEET B D4.1 D4.2 D4.3 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 R0 R0 R0 DATA SHEET B - RAW WATER & AHP PUMPS DATA SHEET B - PRE TREATMENT PLANTDATA SHEET B - DM PLANT 2 2 11 ISSUE R0 TCE FORM NO. 329 R5

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SHEET 11 OF 31
VOLUME III SPECIFIC MECHANICAL REQUIREMENTS FOR BTG AND BOP PACKAGE VOLUME III (B) SPECIFIC MECHANICAL REQUIREMENTS FOR BOP PACKAGE SECTION NO. D4.4 D4.5 D4.6 D4.7 D4.8 SPECIFICATION NO. TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 TCE-6417A-H-500-001 REV. NO. R0 R0 R0 R0 R0 TITLE DATA SHEET B - RUBBER EXPANSION JOINTS DATA SHEET B - MISCELLANEOUS PUMPS DATA SHEET B CW/ACW PUMPS DATA SHEET B BUTTERFLY VALVES DATA SHEET B STP TREATMENT PLANT NO. OF SHEETS 2 2 1 2 3
WATER SYSTEM DATASHEET C D4.1 D4.2 TCE-6417A-H-500-001 TCE-6417A-H-500-001 R0 R0 DATA SHEET C - DRAWINGS/DOCUMENTS TO BE SUBMITTED DATA SHEET C PRE TREATMENT PLANT 1 1
EFFLUENT TREATMENT PLANT D5 D5 TCE-6417A-H-500-001 TCE-6417A-H-500-001 R0 R0 EFFLUENT TREATMENT PLANT WRITE UP EFFLUENT TREATMENT PLANT GENERAL REQUIREMENTS 3 2
EFFLUENT TREATMENT PLANT - A D5 TCE-6417A-H-500-001 R0 EFFLUENT TREATMENT PLANT 5
EFFLUENT TREATMENT PLANT - B D5 TCE-6417A-H-500-001 R0 EFFLUENT TREATMENT PLANT 9
FIRE PROTECTION SYSTEM D6 TCE-6417A-H-500-001 R0 WRITE UP ON FIRE PROTECTION SYSTEM 18
FIRE PROTECTION SYSTEM DATASHEET A D6 TCE-6417A-H-500-001 R0 FIRE PROTECTION SYSTEM 5
FIRE PROTECTION SYSTEM DATASHEET B D6 TCE-6417A-H-500-001 R0 FIRE PROETCTION SYSTE, PIPING D7 TCE.6417A-H-500-001 R0 PIPING 21 3
PIPING DATA SHEET-A ISSUE R0 TCE FORM NO. 329 R5

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SHEET 12 OF 31
VOLUME III SPECIFIC MECHANICAL REQUIREMENTS FOR BTG AND BOP PACKAGE VOLUME III (B) SPECIFIC MECHANICAL REQUIREMENTS FOR BOP PACKAGE SECTION NO. A1 A2 SPECIFICATION NO. TCE.6417A-H-500-001 TCE.6417A-H-500-001 REV. NO. R0 R0 TITLE THERMAL INSULATION FOR HOT SURFACES MATERIAL SPECIFICATION FOR PIPING AND VALVES NO. OF SHEETS 2 5
COAL HANDLING SYSTEM D8 D8.01 D8.1 D8.1 D8.1.1 D8.1.1 D8.1.2 D8.1.2 D8.2 D8.2 D8.3 D8.4 D8.4 D8.5 D8.5.1 D8.5.1 D8.5.2 D8.6 D8.6 D8.6.1 TCE.6417A-H-500-001 TCE-6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 WRITE UP COAL HANDLING SYSTEM PROPERTIES OF COAL WRITE UP ROTASIDE WAGON TIPPLER DATASHEET A ROTASIDE WAGON TIPPLER WRITE UP ACCESSORIES FOR WAGON TIPPLER DATASHEET A ACCESSORIES FOR WAGON TIPPLER WRITE UP SIDE ARM CHARGER DATASHEET A SIDE ARM CHARGER WRITE UP UNIDIRECTIONAL STACKER RECLAIMER DATASHEET A UNIDIRECTIONAL STACKER RECLAIMER DATASHEET A COAL CONVEYING, CRUSHING & BUNKER FEEDEING SYSTEM WRITE UP TRAVELLING TRIPPER DATASHEET A TRAVELLING TRIPPER DATASHEET A DUST EXTRACTION AND BUNKER VENTILATION SYSTEM WRITE UP CENTRIFUGALS FANS DATASHEET A CENTRIFUGALS FANS DATASHEET A TUNNEL VENTILATION SYSTEM WRITE UP DS SYSTEM DATASHEET A DS SYSTEM WRITE UP HORIZONTAL CENTRIFUGAL PUMPS 33 1 6 6 3 3 5 2 9 6 26 3 3 5 1 2 1 8 2 3 ISSUE R0 TCE FORM NO. 329 R5

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SHEET 13 OF 31
VOLUME III SPECIFIC MECHANICAL REQUIREMENTS FOR BTG AND BOP PACKAGE VOLUME III (B) SPECIFIC MECHANICAL REQUIREMENTS FOR BOP PACKAGE SECTION NO. D8.6.1 D8.6.2 D8.7 D8.7.1 D8.8 D8.9 D8.10 D8.10 D8.11 D8.12 D8.13 D8.14 SPECIFICATION NO. TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 REV. NO. R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 TITLE DATSHEET A HORIZONTAL CENTRIFUGAL PUMPS COMPUTATION OF AIR / WATER REQUIREMENT DATASHEET A - STOCK PILE RUN OFF WATER DISPOSAL SYSTEM COMMON COLLECTING POND DATASHEET A COAL PILE RUN OFF PUMPS WRITE UP WATER SYSTEM FOR COAL HANDLING SYSTEM DATASHEET A COAL SAMPLING UNIT WRITE UP BELT VULCANIZER DATASHEET A BELT VULCANIZER DATASHEET A SCREW COMPRESSOR DATASHEET A VENTILATION SYSTEM FOR MCC ROOM AND AC FOR CONTROL ROOMS DATASHEET A DOZERS DATASHEET A SUMP PUMPS NO. OF SHEETS 4 1 2 1 1 3 2 1 6 2 6 1
COAL HANDLING SYSTEM DATA SHEET B D8.1 D8.1.1 D8.1.2 D8.2 D8.3 D8.4 D8.5 D8.5.1 D8.6 D8.6.1 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 DATASHEET B ROTASIDE WAGON TIPPLER DATASHEET B ACCESSORIES FOR WAGON TIPPLER DATASHEET B SIDE ARM CHARGER DATASHEET B UNIDIRECTIONAL STACKER RECLAIMER DATASHEET B COAL CONVEYING, CRUSHING & BUNKER FEEDEING SYSTEM DATASHEET B TRAVELLING TRIPPER DATASHEET B DUST EXTRACTION AND BUNKER VENTILATION SYSTEM DATASHEET B CENTRIFUGALS FANS DATASHEET B DS SYSTEM DATSHEET B HORIZONTAL CENTRIFUGAL 1 2 2 9 7 2 2 2 4 2 ISSUE R0 TCE FORM NO. 329 R5

SPEC.NO. TCE.6417A-H-500-001
SHEET 14 OF 31
VOLUME III SPECIFIC MECHANICAL REQUIREMENTS FOR BTG AND BOP PACKAGE VOLUME III (B) SPECIFIC MECHANICAL REQUIREMENTS FOR BOP PACKAGE SECTION NO. SPECIFICATION NO. REV. NO. PUMPS D8.7 D8.10 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 DATASHEET B - STOCK PILE RUN OFF WATER DISPOSAL SYSTEM COMMON COLLECTING POND DATASHEET B BELT VULCANIZER 1 1 TITLE NO. OF SHEETS
ASH HANDLING SYSTEM D9 TCE.6417A-H-500-001 R0 ASH HANDLING SYSTEM 25
ASH HANDLING SYSTEM DATA SHEET A A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 TCE.6417A-H-500-001 A11 A12 A13 A14 A15 A16 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 R0 R0 R0 R0 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 R0 R0 R0 R0 R0 R0 AIR COMPRESSOR BOTTOM ASH HOPPER & GATE CLINKER GRINDER ASH DISPOSAL EQUIPMENT-SLURRY PUMP TWO STAGE PNEUMATIC CONVEYING SYSTEM FOR FLY ASH HANDLING VACUUM PUMP ASH DISPOSAL EQUIPMENT-JET PUMP WEIGH BRIDGE FLY ASH SILO & ACCESSORIES ASH DISPOSAL EQUIPMENT- DUST CONDITIONER, UNLOADER & ROTARY FEEDER VOID AIR BLOWER ASH DISPOSAL EQUIPMENT : SUMPS & TANKS ASH DISPOSAL EQUIPMENT -PIPING & FITTING SLURRY LINE VALVES ASH HANDLING SYSTEM CLARIFIERS 1 1 3 2 3 ISSUE R0 TCE FORM NO. 329 R5 6 3 2 5 7 2 2 2 3 3

SPEC.NO. TCE.6417A-H-500-001
SHEET 15 OF 31
VOLUME III SPECIFIC MECHANICAL REQUIREMENTS FOR BTG AND BOP PACKAGE VOLUME III (B) SPECIFIC MECHANICAL REQUIREMENTS FOR BOP PACKAGE SECTION NO. A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 SPECIFICATION NO. TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 REV. NO. R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 TITLE UNLOADING SPOUT FOR ASH HANDLING SYSTEM ASH HANDLING SYSTEM SUMP PUMPS VERTICAL TURBINE PUMP AIR DRYERS HOC TYPE BA HOPPER COOLING WATER OVER FLOW TANK FLUIDIZING AIR HEATER BUFFER HOPPER, WETTING UNIT & BAG FILTER VOID VOID ASH HANDLING SYSTEM - RECOVERY WATER PUMPS WATER PUMPS WATER LINE VALVES 3 4 2 NO. OF SHEETS 1 2 5 3 1 1 6
ASH HANDLING SYSTEM DATA SHEET B B1 B2 B3 B4 B5 B6 B7 B8 TCE.6417A-H-500-001 B9 B10 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 R0 R0 R0 R0 AIR COMPRESSOR AIR BLOWER AND HEATER AIR DRYERS HOC TYPE ASH DISPOSAL EQUIPMENT- ASH SLURRY LINE VALVES BOTTOM ASH HOPPER CLARIFIERS ASH HANDLING SYSTEM-CLINKER GRINDER ASH DISPOSAL EQUIPMENT CONTINUOUS DUST CONDITIONER UNLOADER & ROTARY FEEDER ASH DISPOSAL EQUIPMENT FLY ASH SILO AND ACCESSORIES ASH DISPOSAL EQUIPMENT FLY ASH VALVES 7 3 2 2 2 4 1 3 1 4 ISSUE R0 TCE FORM NO. 329 R5

SPEC.NO. TCE.6417A-H-500-001
SHEET 16 OF 31
VOLUME III SPECIFIC MECHANICAL REQUIREMENTS FOR BTG AND BOP PACKAGE VOLUME III (B) SPECIFIC MECHANICAL REQUIREMENTS FOR BOP PACKAGE SECTION NO. B11 B12 B13 B14 B15 B16 B17 B18 SPECIFICATION NO. TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 REV. NO. R0 R0 R0 R0 R0 R0 R0 R0 TITLE ASH DISPOSAL EQUIPMENT - JET PUMP ASH DISPOSAL EQUIPMENT PIPING & FITTINGS PRESSURE TYPE PNEUMATIC CONVEYING SYSTEM FOR FLY ASH HANDLING ALL SLURRY, WATER & SLUDGE PUMPS ASH DISPOSAL EQUIPMENT SUMPS/TANKS ASH DISPOSAL EQUIPMENT UNLOADING SPOUT VACUUM PUMP WETTING UNIT NO. OF SHEETS 1 2 2 3 1 1 1 1
EQUIPMENT HANDLING SYSTEM D10 D10 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 CRANES AND HOISTS EOT CRANES 8 16
EQUIPMENT HANDLING SYSTEM DATA SHEET - A A1 A2 A3 A4 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 R0 CHAIN PULLEY BLOCK MISC EOT CRANES TG HALL EOT CRANES ELECTRICALLY OPERATED HOISTS 2 3 3 2
EQUIPMENT HANDLING SYSTEM DATA SHEET - B B1 B2 B3 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 CHAIN PULLEY BLOCK EOT CRANES ELECTRICALLY OPERATED HOISTS 2 6 3
COMPRESSED AIR SYSTEM D11 TCE.6417A-H-500-001 R0 COMPRESSED AIR SYSTEM 12
COMPRESSED AIR SYSTEM DATA SHEET - A A1 TCE.6417A-H-500-001 R0 COMPRESSED AIR SYSTEM 5 ISSUE R0 TCE FORM NO. 329 R5

SPEC.NO. TCE.6417A-H-500-001
SHEET 17 OF 31
VOLUME III SPECIFIC MECHANICAL REQUIREMENTS FOR BTG AND BOP PACKAGE VOLUME III (B) SPECIFIC MECHANICAL REQUIREMENTS FOR BOP PACKAGE SECTION NO. A2 SPECIFICATION NO. TCE.6417A-H-500-001 REV. NO. R0 AIR DRYER TITLE NO. OF SHEETS 3
COMPRESSED AIR SYSTEM DATA SHEET - B B1 B2 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 COMPRESSED AIR SYSTEM AIR DRYER 7 2
AIR CONDITIONING & VENTILATION SYSTEM D12 TCE.6417A-H-500-001 R0 AIR CONDITIONING & VENTILATION SYSTEM 51
AIR CONDITIONING & VENTILATION SYSTEM DATA SHEET - A A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 CHILLER PAC/SPLIT AC FILTER FRESH AIR FAN AIR HANDLING UNIT THERMAL INSULATION CENTRIFUGAL PUMP COOLING TOWER AXIAL FLOW FAN CENTRIFUGAL FAN AIR WASHER UNITARY AIR FILTRATION ROOF EXTRACTOR 5 5 3 3 5 2 5 5 4 2 3 3 3
AIR CONDITIONING & VENTILATION SYSTEM DATA SHEET - B B1 B2 B3 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 CHILLER PAC/SPLIT AC FILTER 9 9 4 ISSUE R0 TCE FORM NO. 329 R5

SPEC.NO. TCE.6417A-H-500-001
SHEET 18 OF 31
VOLUME III SPECIFIC MECHANICAL REQUIREMENTS FOR BTG AND BOP PACKAGE VOLUME III (B) SPECIFIC MECHANICAL REQUIREMENTS FOR BOP PACKAGE SECTION NO. B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 SPECIFICATION NO. TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 REV. NO. R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 FRESH AIR FAN AIR HANDLING UNIT THERMAL INSULATION CENTRIFUGAL PUMP COOLING TOWER AXIAL FLOW FAN CENTRIFUGAL FAN AIR WASHER UNITARY AIR FILTRATION ROOF EXTRACTOR TITLE NO. OF SHEETS 3 9 3 6 6 6 5 5 5 4
EMERGENCY DG SETS D13 A B TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 EMERGENCY DG SETS EMERGENCY DG SETS DATA SHEET A EMERGENCY DG SETS DATA SHEET B FUEL OIL SYSTEM D14 TCE.6417A-H-500-001 R0 FUEL OIL SYSTEM 13 11 3 7
NATURAL DRAFT COOLING TOWER D15 TCE.6417A-H-500-001 R0 NATURAL DRAFT COOLING TOWER 19
MILL REJECT SYSTEM D16 TCE.6417A-H-500-001 R0 MILL REJECT SYSTEM 12
MILL REJECT SYSTEM DATASHEET - A A1 A2 A3 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 MRHS - PNEUMATIC CONVEYING SYSTEM PIPING & VALVES MRHS-AIR COMPRESSOR 4 2 7 ISSUE R0 TCE FORM NO. 329 R5

SPEC.NO. TCE.6417A-H-500-001
SHEET 19 OF 31
VOLUME III SPECIFIC MECHANICAL REQUIREMENTS FOR BTG AND BOP PACKAGE VOLUME III (B) SPECIFIC MECHANICAL REQUIREMENTS FOR BOP PACKAGE SECTION NO. A4 A5 A6 SPECIFICATION NO. TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 REV. NO. R0 R0 R0 MRSH-SILO MRHS-PYRITE HOPPER MRHS-COOLING/QUENCHING WATER PUMPS TITLE NO. OF SHEETS 3 7 3
MILL REJECT SYSTEM DATASHEET - B B1 B2 B3 B4 B5 B6 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 R0 R0 R0 MRHS - PNEUMATIC CONVEYING SYSTEM VOID MRHS-AIR COMPRESSOR MRSH-SILO MRHS-PYRITE HOPPER MRHS-COOLING/QUENCHING WATER PUMPS 7 1 1 1 2
MILL REJECT SYSTEM DATASHEET - C C TCE.6417A-H-500-001 R0 MRHS SILO ELEVATORS D17 TCE.6417A-H-500-001 R0 ELEVATORS 4 1
ELEVATORS DATASHEET A A1 A2 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 DATASHEET A1 ELEVATORS DATASHEET A2 ELEVATORS 3 1
ELEVATORS DATASHEET B B TCE.6417A-H-500-001 R0 DATASHEET B ELEVATORS 3
ELEVATORS DATASHEET C C TCE.6417A-H-500-001 R0 DATASHEET C - ELEVATORS 1

SPEC.NO. TCE.6417A-H-500-001
SHEET 20 OF 31
VOLUME IV SPECIFIC ELECTRICAL REQUIREMENTS SECTION NO. D1.0 D2.0 D2.1 D3.0 D3.1 D4.0 D5.0 D6.0 D7.0 D8.0 D9.0 D10.0 D11.0 D12.0 D13.0 D14.0 D15.0 D16.0 D17.0 D18.0 D19.0 D20.0 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 SPECIFICATION NO. TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 REV. NO. R0 R0 R0 R0 R0 TITLE ELECTRICAL SYSTEM BROAD SCOPE OF WORK AND DESCRIPTION GENERATOR & ACCESSORIES CONTROL & PROTECTION FOR GENERATOR AND ELECTRICAL AUXILIARIES 220kV SWITCH YARD EQUIPMENT & PROTECTIONS SWITCHYARD SCADA SYSTEM NOT USED POWER TRANSFORMERS RECTIFIER TRANSFORMERS ISOLATED PHASE BUS DUCT (IPBD) NGT & NGR SPBD & NSPBD SERVICE TRANSFORMERS HT SWITCHGEAR. LT SWITCHGEAR AND DISTRIBUTION BOARDS MOTORS AND ACTUATORS VARIABLE FREQUENCY DRIVE CABLES LIGHTING SYSTEM DC SYSTEM NOT USED NOT USED NOT USED 116 27 30 16 26 22 53 28 20 19 17 27 41 NO. OF SHEETS 16 66 26 115 34

SPEC.NO. TCE.6417A-H-500-001
SHEET 21 OF 31
D21.0 D22.0 D23.0 D24.0
TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001
R0 R0 R0 R0
ELECTRICAL EQUIPMENT INSTALLATION WORK. ELECTRICAL LABORATORY EQUIPMENT CONSTRUCTION POWER SUPPLY. COMMISSIONING CHECK LISTS.
34 44 4 18

SPEC.NO. TCE.6417A-H-500-001
SHEET 22 OF 31
VOLUME V SPECIFC CONTROL AND INSTRUMENTATION REQUIREMENTS FOR BTG & BOP PACKAGE VOLUME V (A) - SPECIFC CONTROL AND INSTRUMENTATION REQUIREMENTS FOR BTG PACKAGE SECTION NO. D5.1. D5.2. D5.3. D5.4. D5.5. D5.6. D5.7. D5.8. D5.9. D5.10. D5.11. D5.12. D5.13. D5.14. SPECIFICATION NO. TCE.6417A-H-500-001 REV. NO. R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 TITLE SYSTEM DESCRIPTION/ PLANT OPERATION PHILOSOPHY SYSTEM/EQUIPMENT/SERVICES TO BE FURNISHED. DESIGN, PERFORMANCE AND FUNCTIONAL REQUIREMENTS SPECIFICATION FOR DCS / INSTRUMENTS TO BE SUPPLIED TESTS AND INSPECTION FOR I&C SYSTEM EQUIPMENT SHEETS NO. 1 18 19 31 32 75 76 111 112 115 116 117 120 121 133 134 142 143 182 183 207 208 214 215 217 218 225 226 233
TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001
OTHER SERVICES
PERFORMANCE GUARANTEE CCTV SYSTEM AAMS & CMMS SYSTEM PLANT COMMUNICATION SYSTEM MAIN PLANT UPS SYSTEM CMIMS SYSTEM MANAGEMENT INFORMATION SYSTEM (MIS) INTELLIGENT ACTUATOR OPERATION AND CONTROL PHILOSOPHY AND SCOPE RESPONSIBILITY MATRIX CODES AND STANDARDS DATA TO BE FURNISHED WITH THE BID
TABLE - 1 TCE.6417A-H-500-001 TABLE - 2 TCE.6417A-H-500-001 TABLE - 3 TCE.6417A-H-500-001
234 235 236

SPEC.NO. TCE.6417A-H-500-001
SHEET 23 OF 31
VOLUME V SPECIFC CONTROL AND INSTRUMENTATION REQUIREMENTS FOR BTG & BOP PACKAGE VOLUME V (A) - SPECIFC CONTROL AND INSTRUMENTATION REQUIREMENTS FOR BTG PACKAGE SECTION NO. TABLE - 4 TABLE - 5 TABLE - 6 TABLE - 7 TABLE - 8 TABLE - 9 TABLE - 10 TABLE - 11 TABLE - 12 TABLE - 13 TABLE - 14 TABLE - 15 TABLE - 16 TABLE - 17 D 6.1. D 6.2. D 6.3. D 6.4. TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 SPECIFICATION NO. TCE.6417A-H-500-001 REV. NO. R0 TITLE DATA TO BE FURNISHED AFTER AWARD OF CONTRACT VOID LABORATORY AND TEST INSTRUMENTS SIZE, MATERIAL & RATING FOR IMPULSE PIPES / TUBES & FITTINGS GUIDELINES FOR PROVISION OF INSTRUMENTS GUIDELINES FOR SELECTION OF FLOW ELEMENTS CCR BACKUP PANEL DETAILS GUIDELINE FOR PROVISION OF ANALYTICAL MEASUREMENTS TESTS TO BE PERFORMED FOR DCS/PLC / PROGRAMMABLE CONTROL SYSTEM FACTORY ACCEPTANCE TESTS & INSPECTION FOR DCS/PLCs TESTS TO BE PERFORMED FOR INSTRUMENTS FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES) TRAINING TO BE PROVIDED FOR OWNERS PERSONNEL ERECTION, FIELD TESTING AND COMMISSIONING REQUIREMENTS SYSTEM DESCRIPTION/ PLANT OPERATION PHILOSOPHY SCOPE OF WORK SYSTEM/EQUIPMENT/SERVICES DESIGN, PERFORMANCE AND FUNCTIONAL REQUIREMENTS TECHNICAL SPECIFICATION FOR PLC 240 246 247 250 251 259 260 261 263 264 265 266 269 270 272 273 274 275 278 279 280- 285 286 296 297 304 305 319 320 330 ISSUE R0 TCE FORM NO. 329 R5 SHEETS NO. 237 239

SPEC.NO. TCE.6417A-H-500-001
SHEET 24 OF 31
VOLUME V (B) - SPECIFC CONTROL AND INSTRUMENTATION REQUIREMENTS FOR BOP PACKAGE SECTION NO. D 6.5. D 6.6. D 6.7. D 6.8. D 6.9. TABLE-1 TABLE-2 TABLE-3 TABLE-4 TABLE-5 TABLE-6 TABLE-7 TABLE-8 TABLE-9 TABLE-10 TABLE-11 TABLE-12 TABLE-13 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 R0 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 R0 SPECIFICATION NO. TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 REV. NO. R0 R0 R0 R0 R0 R0 R0 R0 R0 TITLE TESTS AND INSPECTION FOR INTEGRATED BOP AUTOMATION SYSTEM EQUIPMENT OTHER SERVICES PERFORMANCE GUARANTEE UPS SYSTEM FIRE DETECTION & ALARM SYSTEM OPERATIONAL & CONTROL PHILOSOPHY AND SCOPE RESPONSIBILITY MATRIX CODES AND STANDARDS I&C DATA TO BE FURNISHED WITH THE BID DATA TO BE FURNISHED AFTER AWARD OF CONTRACT VOID SIZE, MATERIAL & RATING FOR IMPULSE PIPES / TUBES & FITTINGS GUIDELINES FOR PROVISION OF INSTRUMENTS AND SPECIFICATIONS GUIDE LINES FOR SELECTION OF FLOW ELEMENTS VOID TESTS TO BE PERFORMED FOR PLC / PROGRAMMABLE CONTROL SYSTEM FACTORY ACCEPTANCE TESTS FOR AUTOMATION BOPs TESTS TO BE PERFORMED FOR INSTRUMENTS FORMAT FOR ENGINEERING DOCUMENTATION - 1 (LISTS & SCHEDULES) 420 423 424 426 427 428 429 434 389 394 395 418 419 SHEETS NO. 331 335 336 337 339 340 365 366 378 379 382 383 384 385 386 388

SPEC.NO. TCE.6417A-H-500-001
SHEET 25 OF 31
VOLUME V (B) - SPECIFC CONTROL AND INSTRUMENTATION REQUIREMENTS FOR BOP PACKAGE SECTION NO. TABLE-14 TABLE-15 TABLE-16 SPECIFICATION NO. TCE.6417A-H-500-001 TCE.6417A-H-500-001 TCE.6417A-H-500-001 REV. NO. R0 R0 R0 TITLE TRAINING TO BE PROVIDED FOR OWNERS PERSONNEL ERECTION, FIELD TESTING AND COMMISSIONING REQUIREMENTS FORMAT FOR ENGINEERING DOCUMENTATION - 2 SHEETS NO. 435 436 441 442 445

SPEC.NO. TCE.6417A-H-500-001
SHEET 26 OF 31
VOLUME VI SPECIFIC CIVIL REQUIREMENTS SECTION NO. SPECIFICATION NO. REV. NO. R0 R0 R0 TITLE NO. OF SHEETS 3 5 4
I. TCE.6417A-H-500-001 II. TCE.6417A-H-500-001 III. TCE.6417A-H-500-001
GENERAL SCOPE OF WORK DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID PERTAINING TO CIVIL WORKS DOCUMENTS TO BE SUBMITTED BY CONTRACTOR AFTER AWARD OF CONTRACT DESCRIPTION OF BUILDING, STRUCTURE, FACILITIES TECHNICAL SPECIFICATION PART A - GENERAL REQUIREMENTS PART B - LOADS AND LOAD COMBINATIONS PART-C - REINFORCED CONCRETE STRUCTURES AND FOUNDATIONS PART-D - STEEL STRUCTURES PART-E - OUT DOOR CIVIL WORKS PART-F - FINISHING WORKS PART-G - COOLING TOWER PART-H R.C.C. CHIMNEY PART-I - CODES, STANDARDS AND REFERENCES PART-J - TOWNSHIP
R0
IV. TCE.6417A-H-500-001 V. TCE.6417A-H-500-001 VI. TCE.6417A-H-500-001

R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0
4 39
12 12 26 18 7 30 42 52 5 6

SPEC.NO. TCE.6417A-H-500-001
SHEET 27 OF 31
VOLUME VII LIST OF DRAWING ENCLOSED SECTION NO. BID DRAWING NO. REV. NO. TITLE NO. OF SHEETS
LIST OF MECHANICAL DRAWINGS 1. 2. 3. 4. 5. 6. 7. TCE.6417A-100-GA-001 TCE.6417A-540-SK-002 TCE.6417A-511-SK-003 TCE.6417A-512-SK-004 TCE.6417A-562-SK-005 TCE.6417A-562-SK-006 TCE.6417A-201-GA-007 P1 P1 P1 P1 P0 P1 P0 PLOT PLAN TURBINE CYCLE SCHEME SCHEME OF STEAM AND WATER SYSTEM SCHEME OF AIR AND FLUE GAS SYSTEM SCHEME OF LDO UNLOADING SYSTEM SCHEME OF HFO UNLOADING SYSTEM MAIN PLANT CROSS SECTION GENERAL ARRANGEMENT TG EQUIPMENT FLOOR PLAN AT 0.00 M GENERAL ARRANGEMENT TG EQUIPMENT FLOOR PLAN AT 8.50 M GENERAL ARRANGEMENT TG EQUIPMENT FLOOR PLAN AT 17.0 M GENERAL ARRANGEMENT TG EQUIPMENT FLOOR PLAN AT 24.0 M, 32.8 M, 38.0 M / 41.0 M GENERAL ARRANGEMENT WATER BALANCE DIAGRAM FLOW DIAGRAM FOR COMPRESSED AIR SYSTEM FLOW DIAGRAM COAL HANDLING SYSTEM COAL HANDLING SYSTEM - CONVEYOR CROSS SECTION 1 1 1 1 1 1 1
8.
TCE.6417A-201-GA-008
P1
9.
TCE.6417A-201-GA-008A
P0
10.
TCE.6417A-201-GA-009
P0
11.
TCE.6417A-201-GA-009A
P1
12. 13.
TCE.6417A-610- SK -010 TCE.6417A-640-SK-011
P1 P1
1 1
14.
TCE.6417A-563-SK-012
P1
15.
TCE.6417A-563-GA-013
P0

SPEC.NO. TCE.6417A-H-500-001
SHEET 28 OF 31
VOLUME VII LIST OF DRAWING ENCLOSED SECTION NO. 16. 17. BID DRAWING NO. TCE.6417A-563-GA-014 TCE.6417A-570-SK-015 REV. NO. P0 P0 TITLE LAYOUT OF COAL HANDLING SYSTEM FLOW DIAGRAM FOR BOTTOM ASH AND ECO ASH HANDLING SYSTEM FLOW DIAGRAM FOR FLY ASH EVACUATION & WET DISPOSAL SYSTEM FLOW DIAGRAM FOR ASH WATER CUM ASH SLURRY SYSTEM FLOW DIAGRAM FOR FLY ASH SILO FLOW DIAGRAM FOR RECOVERY WATER SYSTEM FIRE PROTECTION SYSTEM FLOW DIAGRAM FOR MILL REJECT SYSTEM FLOW DIAGRAM FOR AIR CONDITIONING SYSTEM G.A. OF RAW WATER & ASH WATER PUMP HOUSE FLOW DIAGRAM FOR AIR WASHER UNIT FLOW DIAGRAM FOR UAF UNIT P&I DIAGRAM FOR CHEMICAL DOSING SYSTEM SCHEMATIC DIAGRAM OF CW & ACW SYSTEM (SHEET-1 OF 2 & 2 OF 2) P & I DIAGRAM OF EFFLUENT HANDLING SYSTEM NO. OF SHEETS 1 1
18.
TCE.6417A-570-SK-016
P1
19. 20. 21. 22. 23. 24.
TCE.6417A-570-SK-017 TCE.6417A-570-SK-018 TCE.6417A-570-SK-019 TCE.6417A-617-FD-020 TCE.6417A-570-SK-022 TCE.6417A-811-FD-023
P1 P1 P1 P1 P0 P1
1 1 1 1 1 1
25. 26. 27. 28.
TCE.6417A-811-FD-023 TCE.6417A-811-FD-024 TCE.6417A-811-FD-025 TCE.6417A-610-FD-026
P0 P1 P1 P1
1 1 1 1
29.
TCE.6417A-610-SK-027
P0
30.
TCE.6417A-610-FD-028
P0

SPEC.NO. TCE.6417A-H-500-001
SHEET 29 OF 31
LIST OF ELECTRICAL DRAWINGS SECTION NO. 31. 32. BID DRAWING NO. TCE.6417A-710-AU-3001 TCE.6417A-739-AU-3002 REV. NO. P1 P1 KEY SINGLE LINE DIAGRAM METERING & PROTECTION SLD FOR GENERATOR , GT AND UT INTERFACE DIAGRAM BETWEEN GRP, SWITCHGEAR AND DCS CONSTRUCTION POWER SLD SUBSTATION AUTOMATION SYSTEM ARCHITECTURE INSTALLATION NOTES AND DETAILS FOR EARTHING AND LIGHTNING PROTECTION SYSTEM INSTALLATION NOTES AND DETAILS FOR ILLUMINATION SYSTEM INSTALLATION NOTES AND DETAILS FOR CABLING SYSTEM DC SYSTEM CONFIGURATION METERING AND PROTECTION SLD FOR 220KV SWITCHYARD AND STATION TRANSFORMERS 220KV SWITCHYARD LAYOUT NO. OF SHEETS 1 1
33. 34. 35.
TCE.6417A-710-AU-3003 TCE.6417A-710-AU-3004 TCE.6417A-710-AU-3005
P1 P1 P1
1 1 1
36.
TCE.6417A-816-GL-3006
P0
37.
TCE.6417A-815-GL-3007
P0
38. 39.
TCE.6417A-818-CT-3008 TCE.6417A-718-AU-3009
P0 P0
1 1
40.
TCE.6417A-738-AU-3010
P1
41.
TCE.6417A-738-GA-3011
P0
LIST OF CONTROL AND INSTRUMENTATION SYSTEM DRAWINGS INSTRUMENTATION AND CONTROL SYSTEM CONFIGURATION FOR BTG ISLAND INTEGRATED BOP SYSTEM ARCHITECTURE CCTV SYSTEM ARCHITECTURE
42.
TCE.6417A-580-DA-0700
P1
43. 44.
TCE.6417A-500-DA-0701 TCE.6417A-500-DA-0702
P1 P1
1 1

SPEC.NO. TCE.6417A-H-500-001
SHEET 30 OF 31
45.
P1
TYPICAL DRIVE I/O INTERFACE FOR UNIDIRECTIONAL DRIVES ABOVE 120 KW (415V/3.3 KV & 11 KV) TYPICAL DRIVE I/O INTERFACE FOR UNIDIRECTIONAL DRIVES LESS THAN 120 kW (415 V) TYPICAL INTELLIGENT INTERFACE FOR LT BI-DIRECTIONAL DRIVES (WITH INTEGRAL STARTER) FOR BTG PACKAGE TYPICAL DRIVE I/O INTERFACE
46.
P1
47.
TCE.6417A-IC-500-SK-0703
P1
48.
P1
FOR SOLENOIDS TYPICAL DRIVE I/O INTERFACE FOR 415V BI-DIRECTIONAL DRIVE (NON INTELLIGENT INTEGRAL STARTER) FOR BOP AREA TYPICAL SAMPLING SCHEME FOR SWAS SCHEME FOR COMPUTERISED MAINTENANCE AND INVENTORY MANAGEMENT SYSTEM (CMIMS) SINGLE PHASE PARALLEL REDUNDANT UPS WITH STATIC SWITCH AND SERVO CONTROOLED BYPASS SUPPLY SCHEME FOR MAIN PLANT UPS SYSTEM SINGLE PHASE PARALLEL REDUNDANT UPS WITH STATIC SWITCH AND SERVO CONTROOLED BYPASS SUPPLY SCHEME FOR EACH BOP SYSTEM
49.
P0
50.
TCE.6417A-580-SK-0704
P1
51.
TCE.6417A-IC-500-0705
P1
52.
TCE.6417A-739-AU-3001
P1
53.
TCE.6417A-739-AU-3002
P1
LIST OF CIVIL DRAWINGS 54. TCE-6417A-100-GA-5001 P1 NATURAL DRAFT COOLING TOWER GENERAL ARRANGEMENT GA FOR 275M HIGH SINGLE STEEL FLUE CHIMNEY LAYOUT AND DETAILS OF ASH BUND GA AND DETAILS OF WAGON TIPPLER 1
55. 56. 57.
TCE-6417A-266-GA-5002 TCE-6417A-231-SI-5003 TCE-6417A-213-RC-5004
P1 P1 P1
1 1 1

SPEC.NO. TCE.6417A-H-500-001
SHEET 31 OF 31
58. 59.
TCE-6417A-231-SI-5005 TCE-6417A-231-SI-5006
P1 P1
LAYOUT AND DETAILS OF RAW WATER RESERVOIR COAL STOCK PILE DRAINAGE SCHEME
1 1

SPEC.NO. TCE.6417A-H-500-001
VOLUME:VI SECTION I SHEET 1 of 267
1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA GENERAL

SECTION I GENERAL
1.0
This specification covers the design, preparation of general arrangement drawings, fabrication drawings , supply of all labour, materials and construction of all civil, structural as well as architectural work on EPC basis for the proposed -1x660MW (Supercritical) DCRTPP Yamuna Nagar Unit-3 promoted by M/s. Haryana Power Generation Corporation Limited in the state of Haryana. Description of various items of works covered under this specification and nature of work in detail are given hereinafter. The complete work under this scope is referred to as CIVIL WORKS. Lists of various civil works to be covered under the scope of work given in SECTION II. The work to be performed under this specification consists of design, engineering and construction including providing all labour, materials, consumables, equipment, temporary works, temporary labour and staff township, constructional plant, fuel supply, transportation and all incidental works not shown or specified but reasonably implied or necessary for the completion and proper functioning of the plant, all in strict accordance with the specifications, including revisions and amendments thereto as may be required during the execution of the work. All materials including cement, reinforcement steel and structural steel shall be arranged by the BIDDER. The scope shall also include setting up by the BIDDER a complete testing laboratory in the field to carry out all relevant tests required for the civil works for the project. The work shall be carried out according to the design/drawings to be developed by the BIDDER and approved by the OWNER. For all buildings, structures, foundations, etc., necessary layout and details are to be developed by the BIDDER keeping in view the statutory & functional requirements of the plant and facilities and providing enough space and access for operation, use and maintenance. Certain minimum requirements are indicated in this specification for guidance purpose only. However, the BIDDERs offer shall cover the complete requirements as per the best prevailing practices and to the complete satisfaction of the OWNER. BIDDER shall inspect the site, examine and obtain all information required and satisfy himself regarding matters and things such as access to site, communications, transport, right of way, the type and number of equipment and facilities required for the work, availability of local labour, materials and their rates, local working conditions, weather, tidal / flood levels, subsoil conditions, natural drainage, etc. Ignorance of the site conditions shall not be accepted by the Owner as basis for any claim for compensation or extension of time. The submission of a bid by the BIDDER will be construed
ISSUE R0 TCE FORM 329 R5
2.0
3.0
4.0
5.0
6.0
7.0

SPEC.NO. TCE.6417A-H-500-001
as evidence that such an examination was made and any later claims / disputes in regard to price quoted shall not be entertained or considered by the OWNER on account of ignorance of prevailing site conditions. 8.0 GEOTECHNICAL INVESTIGATION Geotechnical Investigation carried out for the existing units is available with the OWNER and the same may be made available on request. However this report along with the recommendation given therein shall be considered by the BIDDER for reference only. OWNER does not take any responsibility for the correctness of the details given in this report. BIDDER is advised to verify the content of report by taking few boreholes at site and analyze the same before submission of bids. Alternatively BIDDER may make his own assessment for the type of foundations envisaged based on this report at his own risk. In any case, the BIDDER has to carryout detailed geotechnical investigation after the award of contract, through some approved / reputed agency and has to submit geotechnical investigation report with foundation recommendations for OWNERs review & approval. The recommendation given in approved final report becomes binding on the CONTRACTOR. The CONTRACTOR is not eligible to increase his cost or demand any extension of time because the final report is in variance from preliminary report furnished by OWNER. 9.0 9.1 SURVEY DATA The OWNER has not carried out a preliminary survey of the area. It is the responsibility of the BIDDER to verify the various features on his own before submission of bid. Detail Topography survey is to be done by the CONTRACTOR. STATUTORY REQUIREMENT BIDDER shall comply with all the applicable statutory rules pertaining to Factory act, Fire safety rule of Tariff Advisory Committee, Water act for Pollution control, Civil Aviation Authority, Explosives act etc. Provisions of Safety, health and welfare according to Factories act shall also be complied with. Statutory clearances and norms of State Pollution Control Board shall be followed. BIDDER shall obtain approval of Civil / Architectural drawings from concerned authorities i.e. HPGCL, Rail ways, Govt/Regulatory/Statutory agencies as the case may be before taking up the construction work.
10.0

SPEC.NO. TCE.6417A-H-500-001
11.0
12.0
QUALITY All the quality standards, tolerances, welding standards and other technical requirements shall be strictly adhered to. CONFLICT In case of any conflict between stipulations in various portions of the specification, most stringent stipulation would be applicable for implementation by the bidder.
13.0
CONSTRUCTION AND CONSTRUCTION SAFETY CONTRACTOR shall ensure that the work areas are free from water during construction and shall take all necessary precautions and measures to prevent ground water, storm water, etc., from entering the area so as to carry out the work in reasonably dry conditions in accordance with the construction schedule. The CONTRACTOR shall dewater and maintain reasonably dry, the excavation for structures and all other areas of the site, where build up of water (in the opinion of ENGINEER In-charge) is likely to obstruct the progress of work, or lead to insanitary conditions by stagnation, or retard the speed of construction, or is detrimental to the safety of men, materials and equipment or is undesirable due to any other reasons. Diversion of natural drains, nallah, roads, overground or underground utilities, temporary structures, roads for construction etc. shall be done and maintained as per the direction of the ENGINEER In-charge.
The contractor shall submit the details of construction safety procedures to be followed at site and also obtain the purchasers approval for each item of civil and structural works prior to execution of work. 14.0 DEMOBILISATION On completion of work, the CONTRACTOR shall promptly demobilise from the site and leave the place in a manner as directed by the OWNER/ENGINEER-In-Charge, including cleaning of the area. COTRACTOR shall start demobilisation only after the successful completion of the contract. 15.0 SCRAP AND PACKING MATERIAL All kinds of scraps generated from the construction materials including packing material shall be the properly accounted for and deemed to be property of the OWNER.

SPEC.NO. TCE.6417A-H-500-001
VOLUME:VI SECTION II SHEET 4 of 267
1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA SCOPE OF WORK SECTION II - SCOPE OF WORK
1.0
The works covered in this section consists of collection of all site related data, conducting site investigations, design, preparation of all construction drawings, supply of all labour & materials, construction, fabrication, erection, painting and testing where necessary, of all structures required for housing all equipment and civil works for all services required for the Power Plant defined in the specification document. The Civil works shall include those required for Installation, Commissioning, testing, operation and maintenance of the Power Plant. The Scope will cover but not limited to the following investigations/studies/buildings / structures / systems / facilities. The scope of work consists of all civil, structural and architectural works of the following:Site related investigations, and studies to freeze design parameters consisting of:(a) (b) (c) (d) (e) (f) (g) Topographical Surveying Geotechnical Investigation Hydro geological Surveying Hydrographic Surveying Wind tunnel studies for NDCT and RCC Chimney Surge Analysis for C.W. conduit. Sump model study for C.W. Pump.
2.0
2.1
2.2
Site development works, consisting of (a) (b) Site clearance. Site levelling and grading of complete plant area including excavation / filling with excavated/borrowed earth, compaction, levelling up to formation level and grading upto finished grade level for the plant. All roads, drains and culverts within the plant premises. Civil and structural works associated with plant potable water supply, storm water and sewage disposal system for entire plant areas.
(c) (d) 2.3
Construction enabling works (a) (b) (c) Construction water Construction Power Temporary Site Building/ Site office/stores

SPEC.NO. TCE.6417A-H-500-001
1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA SCOPE OF WORK
(d) (e) (f) (g) (h) 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18
Temporary workshop & Garage Fabrication Yard Quality Control Laboratory including soil testing, cement testing, cube testing facilities Fuel Storage Area Staff Welfare Facility
Steam turbine generator buildings / steam turbine foundations and complete civil and structural works in turbine building. Control room/ Electrical bay structure. Mill and bunker bay structure and foundation including coal bunkers, feeder floor, tripper floor and tripper roof. Mill foundations and civil and structural works /trenches associated with mill reject handling system, mill reject silo, connecting rack and foundation. Steam generator building/foundations. ESP structures and foundations ESP inlet and outlet duct supporting structures and foundations. Fan foundations and fan handling systems. ESP control room and switchgear room. Steam generator elevator supporting structure and foundations. RCC single flue (steel) Chimney. Steam generator area paving (from TG building upto chimney end) including all sumps, foundations, trenches and structures. Interconnection galleries between boiler structure and TG building. Interconnection galleries between boiler floors and feeder / tripper floor/roof Interconnection from TG building to service building. Complete civil and structural works in switch yard including switchyard control building, fencing, gravel paving, roads etc.
2.19 2.20 2.21
Transformer yard and associated works in the transformer yard. Rails shall be provided and laid by the Bidder. Transformer area paving. Civil and structural works for Coal handling system.

SPEC.NO. TCE.6417A-H-500-001
2.22
Civil and structural works for Ash handling system including ash disposal and ash dyke.
2.23 Civil and structural works for Fuel oil handling system. 2.24 Civil and structural works for D.M. Plant and DM water system. 2.25 Civil and structural works for Raw water/Make up water system consisting of clarifiers, clarified water reservoir and pump house etc. 2.26 Civil and structural works associated with raw water conveying to in-plant reservoir from STP including laying of pipeline. 2.27 Civil works associated with raw water conveying from STP water reservoir to RO Plant including laying of pipeline. 2.28 Civil l works associated with raw water conveying from WYC water reservoir to clarifier including laying of pipeline. 2.29 Condenser cooling water system including laying of CW pipes from CW pump house/ NDCT within TG building including anchor blocks. 2.30 Natural draft Cooling towers. 2.31 Critical pipe supporting structures. 2.32 Pipe and cable racks. Provision shall be made in pipe rack for routing pipes and cables. 2.33 Civil and structural works associated with Fire Protection system. 2.34 Earthing works for plant.
2.35 Lube Oil Storage Tank. 2.36 2.37 2.38 2.39 2.40 2.41 2.42 2.43 2.44 2.45 2.46 Air compressor + DG + Air washer building. AC plant building/room. Service building. Dozer shed Watch towers Parking shed Owner site office Effluent treatment system (ETP) All roads and drains within the plant boundary. Sewage system. Sewage treatment plant.

SPEC.NO. TCE.6417A-H-500-001
2.47 Lighting Mast. 2.48 Horticulture and landscaping. Green Belt Development as per provision of MoE&F Clearance. 2.49 Township (Bidder shall be required to furnish the price bid for Township separately. The work shall include Design, construction, installations, commissioning, supplying, transporting, storing, inspecting etc for all kinds of Architectural, Civil, Structural, plumbing, sanitary, sewage disposal, electrification works (11Kv transmission line from the plant) if required, which are required for making the township serviceable, functional, inhabitable to the satisfaction of the OWNER). 2.50 Workshop building. 2.51 Transformer foundations, trenches, maintenance pits, drain pits, sumps, fencing, paving etc associated with the building/system. 2.52 Potable water, Service water systems 2.53 Rain Water Harvesting Scheme including irrigation facility for plantation. 2.54 Railway siding and track laying complying latest railway norm. 2.55 Diesel locomotive shed. 2.56 CHP Office complex 2.57 Silo utility building 2.58 Condensate storage tank foundation 2.59 STP water pump house 2.60 RO Plant and RO permeate storage tank
3.0
It is not the intent to specify herein all the works in the scope of this contract. All other buildings, structures and works which are not specifically mentioned here but required for construction, operation and maintenance of the power plant are deemed to be included in the scope of the BIDDER without any extra liability to OWNER. The works shall conform to high standards of design, engineering and workmanship. Design and construction shall conform in every respect to all local and state regulations governing such works and to stipulations of Indian Standards unless stipulated otherwise in detail specification. EXCLUSIONS
4.0

SPEC.NO. TCE.6417A-H-500-001
4.01 Construction of main approach road from the State /National highway to the plant main gate. 4.02 Administrative buildings 4.03 Permanent stores
4.04 Canteen building 4.05 Plant boundary compound wall 4.06 Security house, gate complex. 4.07 Fire Station/First aid centre.

SPEC.NO. TCE.6417A-H-500-001
VOLUME:VI SECTION III
1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA

SHEET 9 of 267
DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID SECTION III - DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID PERTAINING TO CIVIL WORKS
1.0 A report on foundation proposed for various structures, buildings and facilities based on the data available with the OWNER and further data collected by the BIDDER. Allowable safe bearing capacity for open foundation, depth of foundation, need for pile foundations, type ,length and capacity of piles in case piling is required, soil improvement if any required, special precaution against aggressive soil etc shall also be covered in the report. List of software proposed to be used in various areas for analysis, design, drafting as well as project monitoring along with their sources and validation report for software. List of all sub-contractors including Engineering Consultants that the BIDDER proposed to employ, in case the contract is awarded to BIDDER, indicating their addresses with telephone number, experience on similar jobs, name, qualification and experience of persons who shall be employed in the job on behalf of the sub-contractor etc shall be submitted to the OWNER. Only the Sub Contractor, approved by the OWNER shall be engaged by the CONTRACTOR on the job. Details of quality control laboratory which will be set up at site along with a list of testing equipment shall be furnished. Schedule of unit prices duly filled in with rates for major items. After the award of contract during the execution of work, if there is any change in scope of work, the following rates furnished by the CONTRACTOR which would be reviewed and accepted by the owner would form the basis of payment of such changes. Only those works listed for addition or deletion from scope in writing by the owner would be the basis for addition or deletion from the contract value.
Item No. Brief Item Description Unit Rate (Rs)
2.0
3.0
4.0
5.0
1.
Excavation below existing ground/grade level at all depths, in all types of ordinary and hard soils (including soils intermixed with boulders, slag and slushy soils) including clearing away vegetation, shoring/strutting as required, de-watering wherever necessary, levelling and ramming the foundation stratum, loading, transporting and unloading the excavated material to stack or fill
cum.

SPEC.NO. TCE.6417A-H-500-001

SHEET 10 of 267
DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID

including all lifts, etc. and back filling with selected excavated material in layers around foundations, trenches, etc. compact to achieve 95% Proctor density all complete as per specifications and as directed by the Engineer a) within plant boundary b) 5KM from plant boundary MEASUREMENT Excavation shall be paid based on foundation dimension multiplied by depth from ground level. In other words payment will not be made for working space, berms, side slopes etc 2. Providing and laying in position plain cement concrete of grade in levelling course/fill under or around foundations pits, slabs on grade, sumps, manholes, etc. at any depth with 40 mm downgraded coarse aggregates including curing, compacting, dewatering wherever necessary, etc. complete but including cost of providing formwork wherever required for the following mixes of grade: a) M10 b) M15 Providing and placing reinforced cement concrete of following grade and with 20 mm downgraded coarse aggregates for all structures at all heights including formwork, vibrating, curing, dewatering wherever necessary leaving cut outs, pockets, providing inserts etc., complete but excluding cost of providing reinforcement, all as per specifications and as directed by Engineer. a) M20 b) M25 c) M30 d) M35 cum.
cum.
3.
cum.

SPEC.NO. TCE.6417A-H-500-001

SHEET 11 of 267

4.
Supplying, cleaning, cutting, bending, as per drawings and placing in position at all locations and levels including binding with soft annealed 16G black wire, etc. complete as shown on drawings. High yield strength deformed bars conforming to IS:1786 are as follows a) Fe415 b) Fe500 (No payment will be made for binding wires) Supplying, detailing, fabricating, transporting to site and erecting in position, with provision of erection bolts, nuts and washers, welding cleats, stiffeners, gussets, base plates and all other fixtures and splices etc. complete, including preparation of surfaces and applying painting as per specification and approved fabrication drawings. Structural steel members fabricated entirely from plates conforming to IS:2062 Grade A such as built-up columns, plate girders, gantry girders, box girders, etc. Structural steel members fabricated from rolled steel sections conforming to IS:2062 Grade A and rolled steel sections with cover / web plates such as columns (including those with battens/lacings), beams, girders, trusses, purlins and trestles etc.
MT
5.
MT
a)
MT
b)
MT
6.0
All deviations from bid document shall be furnished by BIDDER in the format given in the specification document. Deviation furnished elsewhere in the bid other than at the place titled Deviations will not be considered as deviations. Any exclusions from the scope mentioned and implied in these specifications, shall be clearly mentioned by the BIDDER separately in a section titled EXCLUSIONS. Only the details mentioned in this section shall be considered as exclusions. All works, other than these, shall be deemed to
7.0

SPEC.NO. TCE.6417A-H-500-001

SHEET 12 of 267

be in the scope of this contract and shall be executed by the CONTRACTOR at no extra cost to the OWNER. 8.0 List of equipment to be deployed by the Bidder and his associates is to be furnished. Bidders are requested to go through the bid documents carefully. In case of any contradiction/conflicts in various clauses given herein, the same shall be brought to the notice of the owner. Owners decision shall be binding on bidder and shall have no implication to Owner. Time being essence of contract, Bidder shall submit L-1, L-2 & L-3 schedule for engineering design and construction for each building/structure.
9.0
10.0

SPEC.NO. TCE.6417A-H-500-001
VOLUME:VI SECTION IV

SHEET 13 of 267
DOCUMENTS TO BESUBMITTED BY CONTRACTOR AFTER AWRAD OF CONTRACT SECTION IV DOCUMENTS TO BE SUBMITTED BY CONTRACTOR AFTER THE AWARD OF CONTRACT
The following documents are to be submitted for the approval/information of the OWNER/ OWNERS CONSULTANT, prior to commencement of fabrication & erection / construction. Category of Documents / Drawings under approval/ information shall be decided by the OWNER/ OWNERS CONSULTANT prior to start of design engineering. Approval of these documents by the OWNER/ OWNERS CONSULTANT shall not relieve the Contractor of his responsibility for any errors and fulfilment of Contract requirements. All drawings shall be of standard sizes (Metric system) and shall be made on latest version of AUTOCAD or MICROSTATION. The list is not exhaustive but indicative only: (a)General plant layout drawing with co-ordinates of roads, watch towers, buildings and facilities, piping / cable corridors, provision of landscaping and green belt development, diversion drains, equipment lay down areas etc. (b)Drawing showing underground facilities with co-ordinates of these facilities like buried pipes, buried cables, trenches, ducts, sewer, drains, sumps, pits, culverts, foundations etc. (c) Geotechnical investigation report based on additional geotechnical investigation carried out by CONTRACTOR along with foundation recommendation for various buildings / structures / facilities. (d)Topographical survey drawings along with location and details of Bench mark, grid and boundary pillars based on detailed survey conducted after the award of work. (e)Write up on proposed storm water drainage system furnishing layout of the drains, types of drains and suggested disposal system. (f) Write up on proposed sewage disposal system for the toilet in various buildings and scheme for usage/ disposal of the clear water. (g)Write up on proposed treatment and disposal of effluent/waste water generated in the plant and scheme for usage/disposal of clear water. (h) A write up on dewatering system proposed at the time of construction where deep underground construction such as for Wagon tippler pit, Conveyor tunnels, underground Transfer House, C.W. forebay and pump house etc. are to be executed. Where necessary, cofferdams, sheet piles, pump sumps, equipment and channels, troughs, inlet gutters, pipes and any other works required for the water control and discharge shall be considered. The write up shall include design calculations, drawings and shall be based on

SPEC.NO. TCE.6417A-H-500-001

SHEET 14 of 267
DOCUMENTS TO BESUBMITTED BY CONTRACTOR AFTER AWRAD OF CONTRACT

IS:3764 and/or standard book. The cost of dewatering to be borne by CONTRACTOR. (i) Study note on disposal of sewage and other effluent from the plant to satisfy the statutory requirement. (j) Design basis report for all buildings, facilities, services and structures. The design basis report shall cover the description of civil/ structural systems and their components, and design criteria for the major components. The contractor's detailed design shall comply with the requirements defined herein for each system. The contractor shall submit the DBR document based on relevant stipulations and design criteria of the tender specification and giving his own additional design parameters for each building / structure and obtain OWNERs approval before proceeding with detailed designs. The contractors detailed design and scope of supply shall include all co mponents and systems, whether included in the system descriptions or not but required to provide a complete and fully functional facility. (k) Architectural floor plans, elevations, cross sections and perspective view in colour of all buildings. For main plant building BIDDER shall submit two different schemes along with a report elaborating the underlying philosophy of the proposed architectural concepts. (l) Design calculations and drawings for foundations / substructure and superstructure of all buildings including Turbo generator building, Mill & Bunker building, Control & electrical building, service building, pump houses etc and other structures. (m) Design calculations including dynamic analysis and drawings for all foundations subjected to dynamic loads like foundations for TG, BFP, Mill, Fans (PA, FD, ID) etc. Design and drawing of vibration isolation system shall also be furnished in case such system is included along with supply of equipment. (n)Design calculations and drawings for all facilities and services like roads, culverts, bridges, paving, road / rail crossings, drainage pump house (if required), drains, sewers, sewage pump house, sewage treatment plant, water supply, water tank, sumps, tunnels, trenches, ducts etc. (o)Drawings of all architectural works including claddings, partitions finish schedule, colour scheme (both internal and external), doors and windows, flooring and false ceiling, etc. (p)Design calculations and drawings for plumbing & building drainage and execution for entire plant. (q)Design calculations and drawings for structures for raw water / make up water system such as, but not limited to, intake, raw water reservoir, pump house, over head tank, etc.

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SHEET 15 of 267

(r) Design calculations and drawings for structures and foundations in switchyard, transformer yard, etc. (s) Design calculations and drawings for structures pertaining to Cooling water system. (t) Design calculations and drawings for civil structures / works associated with fuel oil handling system, ash handling system, coal handling system etc. (u)All other designs, details / drawings or any other submissions as indicated elsewhere in this specification and as required by the OWNER. (v) Details of corrosion protection measures for all structures and their foundations. (w) All design and drawings for the Cooling towers. (x) All design and drawings for RCC chimney. (y) Schedule for total quantity of concrete (grade wise), reinforcement steel (diameter wise) and structural steel (section wise) in all construction drawings. (z) Design calculations for important joint / connections for structural steel works. (aa) Construction and erection procedure for all major structures with specific reference to main plant building, bunker structures, transfer towers, conveyor galleries, TG foundation and other machine foundations. (bb) Write up on various statutory requirements and their compliance for various buildings and facilities. (cc) Copies of all reports on investigation and studies carried out by the CONTRACTOR as per the scope. (dd) Sample design calculation and fabrication drawing of important structures, such as TG building main framing, bunker building main framing, coal bunkers, crane girders, typical gallery, typical trestle and typical Junction tower for CHP or any other structure specifically called for by OWNER. (ee) Design calculations and drawings shall be submitted and reviewed only after approval of corresponding Mechanical/Electrical/System general arrangement drawings. The contractor shall submit approved GA drawings along with three (3) copies of design documents and four (4) copies of design drawings for comments/approval of the OWNER/ OWNERS CO NSULTANT. Soft/electronic copy of 2D and 3D analysis file and drawing shall

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be submitted. On final approval of the drawing and design, Contractor shall submit three (3) copies of design calculation and six (6) copies of the drawing with one soft copy in CD each to the OWNER for distribution. (ff) Two (2) copies each of detailed drawings/ fabrication drawings for all structures along with bar bending schedule/bill of materials shall be furnished to OWNER/ OWNER.S CONSULTANT. Finally eight (8) copies of each drawing along with one soft copy in CD shall be submitted to the OWNER for their distribution. (gg) As Built Drawings: "As-built" drawings shall be prepared by the CONTRACTOR after completion of construction / erection incorporating all the changes, if any, done on Engineer's instruction/approval. After completion of construction, Contractor shall submit four (4) copies of the all drawings, irrespective of any changes during construction, marked As Built with one soft copy in CD each to the Owner. Two (2) copies of "As-built" drawings A3 size in bound form shall also be submitted. (hh) Design calculation and drawings for boiler and ESP foundation. (ii) Marking scheme identifying the equipment lay down areas. (jj) The contractor shall prepare bar bending schedules (BBS) based on the detailed reinforcement drawings. These shall be presented to the Engineer In-Charge for approval. Approval of these schedules by the Engineer In-Charge in no way absolves the contractor from full responsibility for their completeness and correctness in every way nor shall any claim for extra cost or time be allowed on the grounds of such errors or discrepancies which may arise between drawings and schedules. (kk) Each consignment of steel reinforcement shall be accompanied by a test certificate from the manufacturer showing that the steel has been tested and analysed and the date of such tests and analyses shall comply in all respects with the standards. The following tests shall be carried out on reinforcement if so directed for by Owner. a) Cast analysis b) Carbon equivalent value c) Tensile strength, yield stress, elongation d) Bend test e) Bond classification f) Chemical analysis

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INVESTIGATION/STUDIES, BUILDING, STRUCTURES AND FACILITIES SECTION V DESCRIPTION OF INVESTIGATION/STUDIES, BUILDINGS, STRUCTURES AND FACILITIES
The description against each item is indicative only and not exhaustive. Although most of the systems are covered herein, any other system (Civil, Structural and Architectural) required for successful completion of the project shall form a part of this contract and shall be deemed to be included in the scope of works. 1.0 SITE INVESTIGATIONS AND STUDIES TO FREEZE DESIGN PARAMETERS 1.1 1.1.1 TOPOGRAPHICAL SURVEYING Precision Surveying shall be carried out under the direction and control of a Licensed Land Surveyor. The Contractor shall mobilise and use appropriate and adequate number of precision instruments and equipment required for successful completion of the work. Self-aligning levels shall be used for precision level survey. All Bench Mark (BM) levels of the survey shall be established with reference to the nearest GTS bench mark available. Precision levelling shall be carried out for establishing the BM at site by carrying levels from GTS BM adopting double circuit levelling. All boundary lines shall be located with their distances, included angle and bearings and boundary pillars constructed. Number of pillars shall be adequate to mark the boundary limits without any dispute. A closed traverse survey shall be carried out to form the framework for the detailed survey work. Two reference line, North-South line and East-West line at right angles to each other shall be established with grid pillars constructed at 200 meters c/c in both directions in such a way that these pillars will not be disturbed during construction. Coordinates shall be painted on these grid pillars. Pillars shall also be painted using synthetic enamel paint for easy identification. Bench mark pillars shall be provided at least at 6 locations. MS plate of size 100x100x10 mm with 8mm dia MS lugs shall be fixed at the top of the benchmark pillar and Coordinates and elevation shall be punched on that plate. These pillars shall be properly protected to prevent their disturbance during construction activities. BM pillars shall be distinguished from grid pillars with different type of painting. Size of the pillars shall be 250x250.Length of BM pillars and grid pillars shall be 1000 (mimimum) mm below FGL and above FGL it shall be 600mm and 300mm respectively. All pillars shall be R.C.C.(Conc grade M20). Four nos. of 12 dia. reinforcement bars shall be provided for pillars with 8 dia. @ 250 c/c lateral ties. BM pillars
1.1.2
1.1.3

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shall rest on 690mmx690mmx300mm thick footing on 150 thick P.C.C (1:3:6). 8mm dia. HYSD bars @ 150mm c/c bothways (Top and bottom) shall be provided for footing. Grid pillars shall rest on 490mmx490mmx150mm thick PCC (1:3:6). 1.1.4 Spot levels shall be taken in a grid of 5 meters and contours shall be established at an interval of 0.25m or 0.5m depending on the terrain. All contour levels shall be with respect to MSL. The survey map should identify all topographical features such as but not limited to buildings, structures, burial grounds, wells, natural drains, roads footpaths, depressions, rock out crops, underground services, overhead transmissions lines, telephone lines or any other obstruction, trees and prominent vegetation. In addition, all wet land and marshy stretches shall also be identified. CONTRACTOR shall prepare contour map to a scale of 1 in 1000 in AUTOCAD. In addition, CONTRACTOR shall prepare longitudinal section and cross section of the site at suitable intervals to adequately represent actual topography. For natural drains and other water courses sections at closer intervals shall be provided. CONTRACTOR shall furnish softcopy of survey drawing in one CD along with six hard copies of all survey drawings to the OWNER for his reference. GEOTECHNICAL INVESTIGATIONSDetailed geotechnical investigation shall be carried out by the CONTRACTOR on award of work. Based on the plot plan developed, the CONTRACTOR shall identify proposed borehole location and obtain the approval of OWNER prior to commencing the investigation. In the power block area boreholes shall be spread judiciously to cover all major building as well as equipment foundations. Generally, a grid of 50 meters c/c both ways is recommended. In the offsite areas also it shall be ensured that the boreholes are provided near all major structures. Geotechnical Investigation shall be carried out in accordance with the provisions of relevant Indian Standards (latest). The bidder shall obtain approval on the agency for conducting geo-technical investigation work, field and laboratory testing, schedule proposed by the bidder etc from Owner before undertaking the geo-technical investigation work. Following field tests shall be conducted: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Bore Holes including collection of samples for tests Static Plate load tests Block vibration test Field Permeability tests California Bearing Ratio(CBR) test Electrical Resistivity test Standard penetration tests (SPT) Static Cone Penetration Test (SCPT) Trial pits Cross hole shear wave tests
1.1.5
1.1.6
1.2
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1.2.2 All bore holes shall be drilled up to a depth of 20 m to 40m as indicated in the Table below.
TABLE 1 SL NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 FACILITY MINIMUM NO. OF BORE HOLES (INDICATIVE) 1 2 2 2 6 6 4 3 2 2 1 2 3 2 10 DEPTH IN M (INDICATIVE) 40 40 40 40 30 40 40 2*30+1*40 30 40 30 40 30 30 2*40+8*30
TG A - ROW B - ROW C-ROW TRANSFORMER YARD BOILER, PA/FD FANS MILLS ESP AND ESP CONT. ROOM ID FANS CHIMNEY AWPH,ASPH COOLING TOWER CWPH,CW PIPES, DM PLANTS SWITCH YARD, CONTROLBUILDING CHP (WAGON TIPPLER, TPs, CONVEYORS ETC.) PWS RAW WATER RESERVOIR AWR FACILITIES AND ASH DYKE FO TANKS, FOPH, ETP ASH SILOS ASH PIPE RACK COMPRESSOR HOUSE & DG BUILDING SERVICE BUILDING
16 17 18 19 20 21 22 23
4 2 1 3 1 8 1 1
20 20 30 20 30 4*20+4*30 30 30
1.2.3
Standard penetration tests (SPT) and collection of undisturbed soil samples (UDS) shall be carried out alternatively at 1 m intervals and at significant change of strata. The interval shall be increased to 1.5 m below 5m depth of boring. UDS shall be replaced by SPT in cohesionless strata. Even in highly weathered / disintegrated rock, where core recovery is poor, SPT shall be conducted. The first SPT in any borehole shall be conducted at 1m depth. Generally rock strata is not envisaged. If rock strata are encountered, in rock strata, core recovery and Rock Quality Designation (RQD) shall be noted carefully for each run, immediately after cores are taken out of barrel.
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1.2.5 During boring, the level at which ground water is struck shall be carefully noted. Ground water samples shall be collected for chemical analysis. Boring shall be carried out without the use of water or drilling mud up to the depth of ground water table. Following laboratory tests shall be conducted: (a) Grain size analysis i. Hydrometer analysis ii. Sieve analysis Soil classifications Density and Moisture Content Specific Gravity Chemical Analysis of soil and Ground water including Sulphates, Chlorides, pH value, etc. Chemical Analysis of 2:1, Water: Soil extract of the samples giving SO3 content. Consistency Index: Liquid Limit, Plastic Limit, Plasticity Index, Shrinkage Limit and Shrinkage ratio. Consolidation test giving all relevant information. Swelling pressure and free swell index for expansive soils. Unconfined Compressive Strength on undisturbed soil samples Direct Shear Test Triaxial Compressive Strength Tests:
1.2.6
(b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l)
i. Unconsolidated Undrained Test ii. Consolidated Undrained Test iii. Consolidated Drained Test. (m) Moisture-density relations for Standard Proctor and Modified Proctor tests. (n) Tests to determine CBR values for design of roads at various locations and depths. 1.2.7 The geotechnical investigation report shall necessarily include but not limited to the following information: a) b) Recommended types of foundation. Allowable safe bearing capacities and settlement values in different strata for shallow foundations indicating relevant design criteria adopted, method of analysis adopted etc. If Pile Foundation is necessary, type of pile recommended with reasons for the same, length, diameter, allowable capacity (lateral, pullout and vertical) of individual and groups of piles, negative skin friction if any and magnitude of estimated negative skin friction.
c)

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d) e) f) Recommendations for values for modulus of subgrade reaction for foundation design by elastic method. Type of cement to be used for concrete with reference to the chemical nature of subsoil and ground water. Recommendations regarding excavations (shallow and deep), embankment, covering safe side slopes for excavation and embankment, dewatering, site drainage, etc. Recommended soil properties such as density, specific gravity, cohesion, angle of internal friction etc. for design. Precautions to be taken for design of lightly loaded structures when expansive soil is encountered with respect to swelling pressure and free swell index values obtained. CBR values for design of pavements Electricity resistivity values for design of earthing system Methods of improvement of Soil bearing capacity like provision of rammed stone columns/granular piles, provision of compaction of soft upper layers by driving timber piles etc. to withstand the lightly loaded structures. Special recommendations for concrete quality, cover to reinforcements, if any, considering chlorides, sulphates contents and pH value of soil and ground water.
g) h)
i) j) k)
l)
1.2.8
If expansive soil is met with, then recommendation for removal or retainment of the same under structures/roads etc shall be given. In the later case detailed specification of any special treatment required including specification for materials to be used, construction methods, equipments to be deployed etc shall be furnished. Susceptibility of sub soil strata to liquefaction in the event of earthquake. If so, recommendation for remedial measures.
1.2.9
1.2.10 Identification of corrective measures required for the improvement of subsurface conditions such as removal of poor sub soil/material, in-situ densification etc. If ground improvement is recommended then its detailed specification, specification for materials to be used, construction methodology, equipments to be deployed etc shall be furnished. 1.3 1.3.1 HYDROGEOLOGICAL SURVEY Hydro geological survey is to be carried out mainly to find out the availability of ground water for extraction through tube wells in any area and infiltration gallery / radial collector well in the river bed or by the side of river and also to decide the particular type of dewatering system. The hydro geological survey for any subsurface water source will generally cover any one or more of the following:

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a) b) c) Geological investigation Auger holes Slug tests and pump tests
1.3.2 The actual investigation may be preceded by a reconnaissance survey of the area by an expert hydro geologist to decide the type of investigations. For geophysical investigations, direct current electric resistivity method is normally employed. Vertical electrical sounding and horizontal profiling are to be carried out as part of investigations to find out information on the succession of different conducting zones and their thickness. Wherever possible auger holes and slug tests / pump out tests to be carried out to find out properties of the water bearing strata. On the basis of hydro geological investigations, aquifer characteristics like average thickness of strata, permeability, transmissivity and properties of the material like grain size etc. are arrived at. Based on this data the type of development shall be decided and the yield shall be estimated and furnished to the OWNER in the form of a report for his approval.
1.4 1.4.1
HYDROGRAPHIC SURVEY Hydrographic survey need to be carried out when intake well / pump house or any other structure is located inside or close to a water body like river, lake etc. This is essentially to find out the topography of the river bed / lake bed through soundings taken from surface of water body usually by employing boats. The hydrographic survey should be carried with proper datum so that topographic details on land outside the water body and the area submerged are linked appropriately. For locating and finalizing the details of drawl scheme, in addition to the topography of river bed / lake bed, data on maximum water level / minimum water level will be required. For drawl from river or streams, cross section of the river / stream at a few locations will be needed. For establishing the availability of required quantum of water throughout the year gauge discharge data / flow data for the river / stream has to collect. In case the stream / river are not gauged, the discharge availability has to be established by correlating the data available elsewhere or by correlating with rainfall data. A report on the studies conducted shall be submitted to the OWNER for his reference. WIND TUNNEL STUDIES The primary loading on tall structures such as RCC chimneys and Natural Draught Cooling Towers is the wind. The behaviour of the wind is not uniform and predictable. This will affect the behaviour of the chimney when the wind blows along and across the direction of the chimney .Generally the
1.4.2
1.4.3
1.5

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chimney is designed for the combined moment considering along and across wind loading. Also quite often the deflection of the chimney due to across the wind action exceed the permissible limits and to limit the deflection within permissible limits some devices such as strakes have to be provided on top one third height of the chimney. Presence of other tall structures in the vicinity also affect the wind loading on the chimney. Similarly in the case of NDCT wind load on the tower will be enhanced due to the presence of other towers in the group as well as due to other tall structures in the vicinity. All these aspects shall be studied with models of these structures and obstructions in a wind tunnel. The study shall be entrusted to reputed agency/ Instituition having necessary experience and expertise to carry out such studies and to interpret the results of such studies. From the study the following data shall be available to finalise the design of RCC Chimney and NDCT: a) Combined wind moment on the chimney taking into account the presence of other chimneys as well as other tall structures included in the model Need for providing devices such as Strakes to limit the deflection within permissible limits and constructional details of such devices In the case of NDCTs, enhancement factors for wind loading on account of turbulence, group action as well as on account of other tall structures in the vicinity. The results from the wind tunnel study shall be compared with the values assumed for the design based on factors available in the Codes of Practices and the conservative value shall be adopted for the final design of these structures.
b) c)
1.6
SURGE ANALYSIS OF HOT AND COLD WATER CONDUITS OF C. W. SYSTEM Cooling water will be pumped by the C.W pumps from the CW pump house to the condenser and from the condenser the hot water will be discharged to cooling tower by means of conduits. Sudden stoppage of pumps will cause sudden increase or decrease in pressure in the conduits and if these surge in positive pressure or vacuum is more than the values for which the conduits are designed, the safety of the conduits will be in danger. Hence, before construction of the conduits are taken up, surge analysis shall be carried out for the complete conduit system. Based on the findings of the study, necessary mitigating measures in the form of air release valves, vacuum breaker valves, stand pipes etc shall be incorporated in the system to limit the negative and positive pressures in the system within design values. CW pipe conduits shall be designed for full vacuum with surcharge load.
1.7
SUMP MODEL STUDY FOR C.W. PUMPS. To ensure that all C. W. pumps discharge the designed quantity of water, a sump model study will be conducted at the pump manufacturers works on a physical model after the design of pumps, and design of sumps, screens,

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trash racks etc are finalized. Based on the findings during the model study it may be necessary to relocate the screens and to provide measures such as flow dividers in the fore bay, anti swirl cones below the pumps etc to ensure satisfactory performance of all pumps under various operating conditions. Hence the study shall be completed before construction of the pump house commences. 2.0 2.1 SITE DEVELOPMENT WORK SITE CLEARANCE The site shall be cleared of all trees, shrubs or other vegetation, rubbish, slush etc. and other objectionable matters. If any roots or stumps of trees are met during excavation, they shall also be removed. All the trees having girth more than 30 cm measured from the ground level need to be accounted properly & jointly with OWNER and the same being owners property need to be transported & stored as directed by the OWNER. Where earth fill is intended, the area shall be stripped of all loose / soft patches or top soil containing objectionable matter before fill commence. Any structure or services existing at the site shall be removed / rerouted with the permission of the OWNER. Existing wells, pits, marshy areas etc shall be filled up with coarse grained soil or coarse sand of approved quality. 2.1.1 The CONTRACTOR shall be deemed to have visited and carefully examined the site and surroundings to have satisfied himself about the nature of the existing structures, underground services, general site conditions, the site for disposal of surplus materials, debris etc. and all other materials affecting the work. Claims due to ignorance of site condition will not be considered after submission of Bid. SITE GRADING Filling for raising ground level and levelling & grading shall be carried out to provide uniform grade level for the entire power plant site, by selected cutting and filling of existing ground surface and earth from excavation/ borrow pits from outside. Following levels may be adopted for the plant keeping in view the existing levels of the plant already commissioned:a) Grade level of the plant (FGL) 270.0M b) Road level of the plant - 270.25M c) Finished floor level of all building(FFL) 270.5M
2.2 2.2.1
2.2.2
Fills shall normally be made up of cohesive non swelling (CNS) material capable of being compacted up to 95% Standard Proctor density. Filling may also be made using dredged sand in which case a relative density of 85% shall be achieved. In case earth has to be borrowed from outside the plant boundary, the same shall be arranged by the CONTRACTOR himself at his own cost. Earth from Swamps, marshy as well as lagoons, expansive type

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of clays, peats, organic material, material susceptible for combustion, material which will react with other material already used in work shall not be used as borrow material. A minimum side slope of 1 vertical: 2 horizontal shall be maintained at all slopes. 2.2.3 2.3 Slopes shall be provided with proper protection to prevent erosion. FENCING AND WATCH TOWER
2.3.1
FENCING Minimum 3 m high fencing above the toe wall shall be provided around switch yard, transformer yard, auxiliary transformer yard, fuel oil tank farm, stores etc. where fencing is necessary due to security / safety / statutory requirements. Fencing shall comprise of 2.4 m high PVC coated galvanised chain link fence of minimum 8 gauge (including PVC coating) of mesh size 75 mm and galvanised barbed wire on inclined member to a height of 600 mm above the chain link fencing. 3 lines of 12 gauge high tensile spring steel wire shall be provided for the entire length of fencing. Also 50 X 6 galvanised MS flats shall be provided at every fifth post sandwiching the fencing with post using GI nuts and bolts. Top of toe wall shall be 200 mm above formation level. Fencing post shall be fabricated out of galvanised MS angle section of minimum size 65x65x6 and shall be spaced at a maximum spacing of 2.5 m with struts made up of galvanised MS angle at every fifth fencing post and at bends. Expansion joint shall be provided at every 60 m. Steel entry gates shall be provided for all fenced areas. Gates shall be formed out of tubular section conforming to IS: 1161. Removable type of fencing shall be provided at suitable location to permit entry and exit of equipment.
2.3.2
WATCH TOWER Watch towers shall be constructed with RCC framework. Floor of the tower shall be at least 6 m above grade level. Covered area for each tower shall be minimum 10 sq.m. Watch towers, if required shall be such that the complete periphery of the plant can be watched from these towers and as decided by the OWNER during detail engineering.
2.4 2.5
Not Used. Not Used.
2.6 2.7.1
SEWAGE / WASTE WATER DRAINAGE For plant area sanitary sewage disposal, a network of sewers with RCC manholes will be provided covering all buildings with toilets. The sewage will

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be led to a sewage treatment plant. The treated effluent shall conform to the requirement of Pollution Control Board. 2.7.2 Waste water generated from the plant shall be treated in a full scale Effluent treatment system. The treated effluent shall be used for maintenance of green belt area. Provision shall also be made for collection and disposal of solid waste. CONSTRUCTION ENABLING WORKS CONSTRUCTION WATER BIDDER has to reconnoitre the area and conduct necessary studies to identify the source of water for construction purposes. The source could be nearest watercourse or groundwater. Necessary permission to tap these sources shall be obtained by the CONTRACTOR from competent authorities. CONTRACTOR has to lay the pipeline from source to his water tank and further distribution of same to the worksite. Ground water to be used for construction purpose shall satisfy the provision of Cl. 5.4 of IS: 456. Cost of all connected works such as but not limited to / bore wells, pumps; pipeline, ground water reservoir etc. are to be borne by the CONTRACTOR. 3.2 CONSTRUCTION POWER Contractor has to arrange construction power from UHBVN as per their rules and regulations at his own cost. Necessary distribution of the power line to the various locations as required shall be executed by the CONTRACTOR at his cost. BIDDER has to make provision of D.G. sets as standby power source. This is especially essential in the case of structures involving deep dewatering as well as where uninterrupted concreting has to be resorted to. The BIDDER along with his Bid shall indicate his average and peak power demand. 3.3 TEMPORARY SITE BUILDING The Bidder shall provide at his cost the following building facilities for proper execution and quality control of the job, while meeting the provision stipulated by Factory Rules regarding staff welfare facilities. All these building shall have brick cladding, colour coated steel/GI / Al sheet roofing over steel roof truss with cement concrete flooring and false ceiling. 3.3.1 Site Office The site office shall be of size 15m x 25m (minimum) with electrical fixtures , toilets, water supply, cubicles as per the requirement of OWNER and shall have a provision of office area with A/C and false ceiling for the use of Owners engineer in addition to the CONTRACTORs requirement. An A/C
3.0 3.1

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Conference room to accommodate about 20 people shall also be provided in site office complex. 3.3.2 Stores A covered store shall be provided with brick cladding and Al. / G.I. / colour coated steel roof sheeting to store at least one month requirement of cement. Cement in bags shall be stored on a raised floor well away from outer walls and insulated from the floor to avoid moisture. Not more than 15 bags shall be stacked in any tier. Each consignment of cement shall be stored separately and consumed in its order of receipt. Storage of cement shall satisfy the requirement of IS: 4082 3.3.3 Covered storage area may also be provided to store other construction material which will be affected on exposure to wind, sun and rain. Storage shall satisfy the requirement of IS: 4082 3.3.4 Reinforcement shall be stacked on top of timber sleepers to avoid contact with ground / water. 3.3.5 Storage yard, paved or unpaved shall be provided within the stores complex for storage of other material. 3.3.6 Proper fencing and security arrangement shall be provided for the stores complex. TEMPORARY WORKSHOP AND GARAGE The CONTRACTOR shall provide a temporary workshop and garage to attend to routine maintenance and repair of the construction equipments as well as his fleet of vehicles used for construction activities. 3.5 FABRICATION YARD Depending on the extent of fabrication envisaged at site, the CONTRACTOR should establish a fully fledged structural fabrication yard with adequate handling facility during and after the fabrication. A fully equipped testing laboratory providing radiography, ultrasonic, dye penetration, magnetic particle test facilities shall be ensured adjacent to the fabrication yard to ensure strict quality control. Portion of the yard shall have covered shed with H.O.T / E.O.T cranes so that fabrication work can proceed even during inclement weather. 3.6 QUALITY CONTROL LABORATORY A fully equipped quality control laboratory shall be established at site with qualified personnel to conduct acceptance test on all construction material, concrete cubes, soil and rock samples etc. This laboratory shall be housed in a covered building with A/C facility as required by the testing facility. All
3.4

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testing equipment shall be periodically calibrated to the satisfaction of the OWNER. The contractor shall submit and obtain owners approval of detailed Quality Assurance Plan (QAP) for workmanship, material testing & approval for the item of work, prior to execution. If OWNER desires to carry out conducting any test for verification of test results or conformity to the approved QAP, the same has to be arranged by the CONTRACTOR at his own cost. Conducting any test as per the directive of OWNER arising out due to faulty construction/ non conforming to quality shall be CONTRACTORS responsibility at his own cost. The material if found rejected shall be removed from the site within a period as instructed by the OWNER. In case, contractor does not remove the rejected material from the site the same shall be removed by the owner and the cost shall be deducted from the running bill. 3.7 FUEL STORAGE AREA CONTRACTOR shall obtain necessary permission from competent authorities and establish and operate a POL outlet with proper storage, dispensing and adequate fire fighting facility. Such outlets for petroleum product are required only if no regular petrol bunk is available in the near vicinity. 3.8 3.8.1 STAFF WELFARE FACILITY CONTRACTOR shall provide adequate facility for his staff inside the plant boundary such as toilets for gents and ladies, canteen, drinking water facility, rest places, crches etc. Necessary approach roads to the construction facility complex and internal roads within the complex as well as proper drainage of the area shall be the CONTRACTORs responsibility. He shall also provide for proper disposal of sewage and other wastewater to meet with the requirement of Pollution Control Board. CONTRACTOR shall identify sufficient area outside the plant boundary to locate his staff and labour township. Construction and maintenance of the staff and labour township to satisfy all statutory requirements is the sole responsibility of CONTRACTOR. STEAM TURBINE GENERATOR BUILDING Turbine building framing shall be of structural steel with moment connection framing in the transverse direction and bracing in the longitudinal direction. Cross section of the building showing spans of various bays /roofs and elevations of various floors/roofs crane capacity and crane rail elevation etc is enclosed in the mechanical section of this document. Service and maintenance bays will not have any intermediate floors; however, 2500 mm wide RCC passage with hand rails shall be given along B
3.8.2
3.9
4.0 4.1
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row and 1500 mm wide along A row and gable ends at operating and mezzanine floor levels shall be provided. 4.3 Crane capacity and crane rail level will be fixed based on the equipment to be lifted and the method of lifting generator stator or as specified elsewhere in the specification. At crane girder top flange level a crane walkway will be provided in line with Factory rules. Access shall be provided to crane walkway through staircase from operating floor in addition to cage ladder at two ends. Bottom level of roof framing will be decided by the crane clearance required duly taking into account clearance required for mounting light fixtures. For framing, cladding, roofing, waterproofing and other detail refer to Table-2 specified elsewhere. Staircases protected on all sides with fireproof enclosure shall be provided to satisfy TAC regulations. All the doors leading to the inside of the power house from staircase shall be automatically closing fire proof door satisfying TAC regulations. Access cage ladders shall be given in B-C bay to access T.G. building and deaerator roof. Medium class galvanised MS pipe min 150mm dia NB conforming to IS 1239 / 3589 shall be provided to drain off the rain water from roof. They shall be suitable hidden from the facade. Thickness of structural RCC floor shall be minimum 150 mm above the steel floor beams with 50 mm floor finish which will be applied later. All the intermediate floors shall be provided with proper drainage. Catch pit with C.I. grills shall be provided near the internal column in a regular pattern and the floor shall be sloped towards the catch pit by varying the thickness of the bedding concrete for the floor finish. Catch pits shall be at the same coordinate for all floor levels. 80 NB galvanised M.S. pipes conforming to IS:1239 shall be provided to carry the drainage down. The pipes shall be clamped on to the intermediate column. Sumps shall be provided in ground floor to receive the water. Proper drainage arrangement shall be provided in the ground floor by means of RCC gravity channels with M.S. grills on top. The drainage shall be led to sumps from where the water shall be pumped to plant drainage arrangement. Around equipment liable to frequent drainage, concrete kerb shall be provided to isolate the area and water shall be led through sump and channels to the floor drainage system. Oil water separator should be provided as required to isolate oil from the drainage water where the water is mixed with oil. 4.8 In operating floor the design live load shall be painted on the floors prominently showing the extent of the area where such loading is permitted. Wherever openings are provided in the floor for handling of equipments using EOT cranes such openings shall be covered with gratings provided over removable steel beams.
4.4
4.5
4.6
4.7
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4.10 Expansion joint shall be provided in the building to satisfy the requirements of IS:800 and IS:3414 Foundations for major equipments like Turbo generator and boiler feed pump shall be designed as dynamic foundation. Such foundations shall rest on vibration isolation system (VIS) and deck shall be designed as dynamic foundation. The foundation shall be isolated from the building frame work. Continuous walkway of minimum width 1500 mm shall be provided at crane level at the gable ends. CONTROL ROOM / ELECTRICAL BAY STRUCTURES The building framing shall be structural steel with moment connection in the transverse direction and bracing in longitudinal direction. It shall be ensured that in front of control room no cross bracing is provided. A minimum clear headroom of 2200 mm shall be given in the cable vaults. In control room false ceiling bottom level shall be kept 3500 mm above floor level. All floors shall be of in-situ RCC slab provided over structural steel beams. Minimum thickness of structural concrete shall be 150 mm above steel floor beams with 50 mm provided for finish. No openings shall be permitted on the roof of control room excepting possible opening for A/C duct to exercise proper control on air conditioning. No openings shall be permitted on the roof also, as this will interfere with effective water proofing. Windows from switchgear room and control room / electronic cubicle room shall not normally be allowed on the Boiler side to avoid coal dust nuisance. Walls shall normally be supported on floor beams. If wall beams cannot be avoided they shall preferably be given at the level of floor beams and shall be encased in concrete. Portion of the structural steel column projecting into the room shall be encased with brick masonry to shield it from fire hazards. Cable vault shall be provided with minimum two numbers fire rated (min 2 hrs) doors. The doors shall be flush steel doors. No windows shall be provided on the turbine bay side for the cable vaults. Control room wall up to the false ceiling level will be of aluminium glazed partition on either side of air lock. In other area cladding will be of brick wall. UPS room shall be provided with brick cladding all round to reduce sound nuisance. Staircase properly enclosed to satisfy TAC regulations should be provided at either ends of unit. All doors leading to staircase shall be automatic closing
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fireproof doors. Staircase shall not be provided around the passenger lift. Staircase shall extend up to roof. Toilets shall be provided at the control room level and near staircases as per floor plan drawings. 5.9 Control room and electronic cubicle room shall be provided with false ceiling. False ceiling shall be designed aesthetically properly arranging, supply air diffuser, return air grill, fire protection sprinklers, fire detectors and lights. Aluminium ceiling system shall be provided. Under deck insulation shall be provided on the ceiling, on the walls and beams above false ceiling. Under deck insulation shall be provided for Air washer room also. For framing, cladding, roofing, waterproofing and other detail refer to Table-2 specified elsewhere. Floor above control room where APRDS/AHU and other pipes, if any are located as well as floor below the deaerator area shall be provided with proper slope and drains to prevent any accumulation of water. This is very important to prevent seepage of water into the control room. All openings in floor for switchgear and other panels shall be sealed with fire proof material after cables are connected. Adequately designed RCC storm water drains shall be provided to lead the roof drainage on to the plant drainage system. These drains shall have precast RCC slotted cover. Plinth protection shall be given on the side of the drain up to the brick wall. STEAM GENERATOR / ESP / DUCT SUPPORTING STRUCTURE Criteria for designing the steel structure is described elsewhere in this section. For framing, cladding, roofing, waterproofing and other detail refer to Table-2 specified elsewhere. Proper drainage of the Steam Generator and ESP roof shall be provided by means of gutters and down take pipes. Down take pipe shall conform to IS:1239 / 3589 class medium. Type of foundation for the structures are covered under separate section based on the subsoil condition and recommendation based on detailed geotechnical investigation. In addition to foundations for structure other major foundation in the area are those for Primary Air fan, Forced Draft fan and Induced Draft fan. The above foundation shall be designed as dynamic foundations except where VIS is used as per relevant Bureau of Indian standards. MILL AND BUNKER BAY BUILDING The framing shall be of structural steel. This shall be designed as a moment connection framing in the transverse direction and braced in the longiISSUE R0 TCE FORM 329 R5
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tudinal direction. These structures primarily support coal bunkers, coal feeders and tripper arrangement to feed the coal into coal bunker. The bunker shall be circular in plan depending on location of mill bay and shall have the capacity as per the requirement stipulated elsewhere under Mechanical section. Stainless steel liner of 5.14mm thickness conforming to AISI 304, finish grade 2B (cold rolled, annealed & pickled and skin passed) on M.S plate for inside surface of hopper and mouth of hopper of bunker shall be provided. For inside vertical surface of bunker stainless steel liner of 3.14mm thickness conforming to AISI 304, finish grade 2B (cold rolled, annealed & pickled and skin passed) on M.S plate shall be provided. 7.2 Mills are to be located on the ground floor. Mill foundations are to be designed with vibration isolation system if such systems are included in equipment package. Otherwise Mill foundation shall be designed as dynamic foundation as per the relevant BIS Codes. In addition to Mill foundations provision has to be made in the Mill bay ground floor for trenches accommodating Mill reject system conveyors. A Mill maintenance platform shall be provided at appropriate elevation to attend to routine maintenance. This shall be a platform with chequered plate or gratings over steel framing with handrail all round. Above this floor a framing shall be provided to support under slung crane used for handling mill maintenance work. The crane runway girders shall extend to the full length of Mill bay to enable approach to the service bay also. Above this framing, feeder floor is provided. The extent of the feeder floor shall be decided by the BIDDER based on his maintenance requirements. Feeder floor will be of RCC supported on structural steel framework. Handrails shall be provided on all the sides. A steel staircase shall be provided for access to feeder floor from ground floor. Access shall so be provided to feeder floor from boiler elevator. Frame work for supporting the circular/ rectangular bunker shall be provided above the feeder floor based on geometry of the hopper. Bunker shall be provided with a top steel cover with slit openings for entry of coal. Seal plate shall be provided on the periphery of bunker from top of bunker to bottom of tripper floor. Necessary provision shall be made with flexible neoprene pads to ensure that no vertical load is transferred from tripper floor to bunker. Chute shall be provided from tripper floor to cover plate. On sides of the bunker necessary openings shall have to be provided for bunker ventilation / dust extraction. Tripper floor shall be immediately above the bunker. This floor shall be of RCC supported on structural steel framework.
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7.8 Tripper roof supports bunker ventilation / dust supporting structure. An RCC parapet or steel handrail shall be provided for the tripper roof. An access stair shall be provided from tripper floor to roof. In addition to the above, framing arrangement for structural steel platform at various levels around the bunker shall be provided with proper access ladder, for poking, striking and attending to air cannons. Tripper floor shall be given access through Boiler staircase/elevators. For framing, cladding, roofing, waterproofing and other detail refer to Table2 specified elsewhere. MS galvanised Rain water down take pipes of min 150 mm diameters conforming to class medium of IS: 1239 / 3589 shall be provided. All structural steel work shall be painted as specified elsewhere. Expansion joint shall be provided to the structure as required by IS: 800. STEAM GENERATOR ELEVATOR SUPPORTING STRUCTURE Capacity and number of the elevator shall be as stipulated elsewhere. The elevator supporting structure shall be of structural steel braced in both directions. Plan bracings shall be provided at all the landing locations. Where landing locations are far apart, plan bracings shall consider at least at every 8 m centres. For framing, cladding, roofing, waterproofing and other detail refer to Table-2 specified elsewhere. Lift pit of elevator shaft shall be of RCC. Ground floor entry shall be kept about 500 mm above general graded / paved level with a ramp for approach. A sump for drainage and Aluminium ladder shall be provided in the lift pit. Machine room floor shall be of chequered plate. Adequate window shall be provided for admitting natural light. Adequate / designed monorail with equipment hatch in the machine room floor shall be provided to lift heavy machinery. Steel staircase shall be given to the M/C room from last landing i.e pent house level. Landing levels are generally governed by the floor levels in the Boiler but maximum gap between two landings shall not exceed 6m. Landings must be provided at feeder floor, burner floor and tripper floor levels. Structural steel gallery (two at each level) shall be provided from the elevator landing platforms to feeder, tripper and roof of tripper floor. ESP CONTROL ROOM
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9.1 This shall be of steel framed structure. An auxiliary transformer yard with fencing and gate shall be provided adjoining to the building. Staircase area shall be protected from fire safety angle as per TAC regulations. Main door to switchgear room shall be steel sliding door having adequate area to admit switchgear. There shall be minimum two doors to the switchgear room of flush welded steel type. Control room should have one swing type aluminium glazed double panel door and one single panel door. Main entrance of the building shall be of rolling shutter with appropriate ramp approach. False ceiling shall be provided in the Control room. Under deck insulation shall be provided above false ceiling and Air washer room. For framing, cladding, roofing, waterproofing and other detail refer to Table2 specified elsewhere. Roof shall be given access by means of stair. An equipment hatch shall be given with lifting beam to lift the switch gear / control panel. Adequate number of rain water down take pipe shall be provided using medium class MS pipe conforming to IS: 1239. Garland drain as well as plinth protection shall be given around the building. Transformer yard shall be provided with 3 m high chain link fencing and gates. In case of more than one transformer firewall shall be given to separate the transformer. Soak pit shall be provided below the transformer. Burnt oil pit shall be provided connecting the soak pits with RCC pipes. The transformer area shall be provided with paving as specified elsewhere. STEAM GENERATOR AREA PAVING Entire steam generator area from the Electrical bay up to the end of chimney shall be provided with RCC paving over rubble soling. Paving shall be carefully planned such that maintenance access roads minimum 4 m wide to all major equipment are available. This area shall be designed for heavy loads similar to design of roads. Such approach road shall be provided to the S.G. elevator also to enable handling of equipment at higher level during maintenance. Such roadways shall be clearly identified with kerbs / painting. All drain / trench covers in these areas shall be designed to withstand truck loading. The drainage of the entire SG area shall be properly planned. Network of RCC drains with RCC cover with slotted holes or MS grills shall be provided covering the entire area which leads the storm as well as process leakage water to the peripheral drains, which in turn will lead to plant drainage system. Where open drains are not permitted underground pipes may be provided in which case at all junctions and ends proper manholes shall be provided to permit periodic cleaning of the pipes. All structural steel columns base plate are below paving level, it shall be provided with encasing to a height of minimum 200 mm above paving level. The maximum paved level
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in S.G. area shall be kept a 200 mm below the finished ground floor level in Turbine building area. 10.4 The top of paving at STG area shall be kept 200 mm below reference 0.00m (which corresponds to 270.5m above MSL, i.e. FFL of STG building). Top of concrete for boiler and auxiliaries foundations shall be such that no part of base plate stiffener shall project above paved level. MILL REJECT HANDLING SYSTEM The mill reject trenches shall be of RCC, designed as water retaining structures and shall be covered with precast concrete cover. The floor of the trench shall be sloped towards a sump located in the junction pits. The pipe support structure above ground shall be of structural steel. Silo shall also be of structural steel. Silo shall be designed as per IS: 9178 RCC CHIMNEY Refer part H of specification. 13.0 13.1 TRANSFORMER YARD Generator transformer, station transformer, unit auxiliary transformer and service transformer are located in front of the turbine building. Transformers are founded on RCC foundations with rails on the top with oil soak pits filled with blue metal aggregate. RCC pipes are provided to convey leaked oil from the soak pit to the burnt oil pit. RCC blast wall / RCC framed brick wall of adequate thickness and height to satisfy TAC regulations shall be provided in between transformers. RCC foundations shall be provided with rail to transport transformer out of transformer yard during maintenance. Entire area shall be surrounded with 3 m high chain link fencing with gates. Where rails cross the fencing, fencing shall be made of removable type to facilitate transport of transformer. Floors shall be paved with RCC paving over rubble soling and shall be sloped towards peripheral drains, which shall lead to a sump from which the drainage is led through an oil water separator. SWITCH YARD Extent of the Switch yard will depend on the layout of the switch yard which has been outlined in the plot plan. 14.1 GALVANISED STEEL STRUCTURE
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14.1.1 All steel structure for the Switch yard shall be hot double dip galvanised structure with welded / bolted connection at shop and bolted connection at site. All bolts and nuts shall also be galvanised. Minimum zinc consumpISSUE R0 TCE FORM 329 R5

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tion shall be 610 grams per square meters of exposed surface. Design criteria of Switch yard structure are furnished elsewhere in this document. 14.1.2 Major steel structures are towers, beams, lighting masts etc. They are all of latticed construction using angle sections. In addition supporting structure for equipment, such as isolator, lightning arresters, etc shall also be provided. These structures may be of tubular section or latticed as the case may be. Towers, beams etc. shall be trial assembled at shop, keeping in view the actual site condition, prior to dispatch to erect at site so that they can be conveniently pre-assembled before erection or conveniently assembled during erection. Lighting masts shall be provided with cage ladder. Where platforms are provided on lighting masts for mounting of lighting fixtures, they shall have protection hand rails formed of galvanised section. Platforms shall be of galvanised gratings. 14.2 FOUNDATIONS FOR STRUCTURES AND EQUIPMENTS Foundations may be open foundation or on piles (RCC/ Timber) based on soil condition. 14.3 TRENCHES / PAVING / FENCING
14.3.1 All trenches shall be of RCC. Trench wall shall be designed to withstand a surcharge load of 1500 kg / sq.m. Trench wall shall project 150 mm above the paved / graded level to prevent ingress of storm water. All trenches shall be given a slope of minimum 1 in 750 and the slope shall lead to a sump, where pump can be installed for drainage. 14.3.2 The complete area within the fencing shall be provided with a mild slope towards peripheral RCC drains, which in turn shall be connected to the plant drainage system. About 75 mm thick paving shall be provided using blue granite aggregate 20 to 40 mm in size. 14.3.3 Fencing around switch yard area shall comprise of PVC coated chain link fencing of minimum 8 G (including PVC coating) of mesh size 75 mm and of height 2400 mm above toe wall with 600 mm high galvanised anti-climbing device with barbed wire (8 rows) such that total fence height of 3 m above toe wall is achieved. Other details of fencing such as anti-climbing device, fencing, toe wall etc. shall be given elsewhere in the specification. 14.4 SWITCH YARD CONTROL ROOM
14.4.1 Switch yard control room will be a two storied RCC framed structure. The building shall accommodate cable vault, Stores, Offices, Staircase, panel handling arrangements, battery rooms, relay panels and offices etc. Floor elevation shall be decided by the BIDDER to suit his requirement of operation and maintenance.

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14.4.2 For framing, cladding, roofing, waterproofing and other detail refer to Table2 specified elsewhere. Pleasing architecture shall be provided for the building. 15.0 COAL HANDLING SYSTEM This section covers the general requirements for concept, design, construction / fabrication and erection of various structures, buildings and facilities for the coal handling system, covering complete Civil and Structural works. Some of the important areas of works are described below. 15.1 WAGON TIPPLER PIT AND SHED:
15.1.1 This section covers two wagon tippler pits, sheds and a common control room. Wagon tippler pit shall be constructed of RCC. This structure shall be designed as Coal handling system substructure. Proper provision shall be made while constructing to provide structural water proofing after the concreting of the pit is complete. Sump shall be provided to collect and pump out water which enters through coal/tunnels/ tunnel drains etc. RCC access shaft accommodating staircase as well as monorail for handling of machinery shall be provided. Control and switchgear room shall be of RCC framed construction with brick cladding. RCC staircase shall be provided for access to the control room. Hopper shall be provided with lining as specified in the mechanical section of specification. 15.1.2 Wagon tippler shed shall be steel framed structure with rigid framing in the transverse direction and bracing in the longitudinal direction. Roofing shall be of colour coated galvanised sheet of minimum thickness 0.8 mm and side cladding shall be of similar sheet but with 0.6 mm thickness above 3 metres high brick wall. Roof shall be given a minimum slope of 1 vertical : 4 horizontal. G.I. rain water gutters of matching colour shall be provided to convey the rain water through galvanised M.S. pipe type medium conforming to IS: 1239. RCC drains shall be given on either side along with plinth protection all round. 50mm thick granolithic flooring with ironite topping shall be provided. Wagon trippler structure shall be analysed for the worst load combination. (a.) Load Combination - I (1.) (2.) (3.) Hopper full Maximum load from Railway Track Earth pressure without surcharge and subsoil water pressure Maximum load from steel columns for shed
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(5.) (6.) Maximum load from apron feeder Maximum load from coal tray.
(b.) Load Combination - II (1.) (2.) (3.) (4.) (5.) (6.) (c.) (1.) (2.) (3.) (4.) (5.) (6.) Hopper full Maximum load from Railway Track Earth pressure with surcharge and subsoil water pressure Maximum load from steel columns for shed Maximum load from apron feeder Maximum load from coal tray. Load Combination - III Hopper empty No load on Railway Track Earth pressure with surcharge and subsoil water pressure No load from steel columns for shed Dead load only from apron feeder Dead load only from coal tray.
Wagon tippler hopper shall be covered with removable grating made of minimum 25 thick MS flat (300 mm x 300 mm clear) resting on permanent structural framework. Spare storage room of minimum head room of 3.5m with complete ventilation, electrification etc shall be provided. 15.2 CRUSHER HOUSES
15.2.1 Crusher houses shall be of steel structure of framed / braced design. Crusher floors and roofs shall be RCC over structural steel beam as indicated in mechanical GA. Grade slab shall be of RCC. . Crusher as well as vibratory screens shall be mounted on the floor framing using vibration Isolation system consisting of springs and visco dampers. Crusher supporting floor shall be of RCC on steel beams. Handrail shall be provided around all

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big openings and kerb shall be provided around all small openings. For framing, cladding, roofing, waterproofing and other detail refer to Table-2 specified elsewhere. 15.2.2 Two staircases shall be provided one inside and one outside, both of structural steel. Elevator shall also be provided serving all the floors. Elevator pit shall be RCC. Machine (M/C) room floor and roof shall be of RCC. An RCC curb wall of 300 mm shall be given all round the floor. Main door to M/C room shall be of steel of flush welded construction. Adequate ventilation shall be given using glazed windows. Elevator pit wall shall be kept at least 500 mm above general grade level to prevent flooding. A sump shall be provided inside the pit to collect and pump out water. Sump shall be given with access ladder. Toilet shall be provided in the crusher houses. 15.2.3 Foundation of the building columns shall be of RCC. Foundation design criteria are given elsewhere. All the foundations / pile caps shall be connected together by the tie / plinth beams. Top of the pedestals for the columns shall be 150 mm above finished ground floor level. 15.2.4 Concrete floor provided with shear lugs can be considered to provide continuous lateral support to top flange of the supporting beams. At locations of large openings / cut outs in the floor slab suitable horizontal bracings shall be provided. In case of chequered plate floors, chequered plate shall not be considered to provide lateral support to top flange of beam. Spacing of floor supporting beams shall not be more than 2m. Loads from major equipment shall be directly transferred on to steel beam. Horizontal ties shall not be subjected to any vertical load. Minimum clear headroom of 5.5m below bottom of monorail shall be maintained. 15.3 JUNCTION HOUSES Construction details of Junction houses are similar to the crusher houses except that elevator and toilet may not be necessary unless otherwise specified in the Mechanical section of the document. Independent staircase shall be provided with landing facility at all floors. Clearance around drive unit/equipment shall not be less than 1200mm. Minimum clear head room of 3.2m shall be provided at all floors. If horizontal ties are subjected to vertical load, then the depth of the tie member shall be at least equal to the maximum depth of the vertical load carrying member connected to it. For framing, cladding, roofing, waterproofing and other detail refer to Table-2 specified elsewhere.
15.4
CONVEYOR GALLERIES AND TRESTLES
15.4.1 Overhead conveyors shall be housed in a suitably enclosed gallery of structural steel. Maximum span of gallery shall be limited to 24 m unless higher span is necessitated due to site constraints, which shall be subject to approval of OWNER. The overhead gallery shall consist of two vertical latticed

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girders having rigid jointed portal frame at both ends. Cross beams at floor level supporting conveyor stringer beams shall be made of single rolled steel beam or single channel section (ISMB or ISMC) or plate girder. Horizontal bracings are to be provided at top & bottom plan of the gallery (latticed girders shall be braced together in plan at the top and bottom). Common end portal frame shall not be used for adjacent conveyor spans. Roof truss shall be provided at upper node points of latticed girders to form an enclosure. The gallery should as far as possible be erected as a box section keeping all the vertical and horizontal bracing tied in proper position. The gallery should be checked for all erection stresses that are likely to develop during handling and erection and if required, temporary strengthening of gallery members during erection shall be made.
15.4.2 For double stream conveyor gallery one central and two side walkways shall be provided. For single conveyor, walkways shall be provided on either side. Width of the walkway and clear height of the gallery shall be as specified in Mechanical section of the document. Both sides of the central and side walkways shall be provided with pipe hand rails with curb plates using pipe type medium as per IS:1161 having 32 mm nominal size. Handrails shall not be connected to conveyor supporting stringer. Walkway shall be of chequered plate construction of minimum 8 mm thick with, anti skid arrangement. The anti - skid arrangement will consist of welding of 10 mm square steel bars at a maximum spacing of 500 mm along the length of the gallery. Where the slope of walkway is more than 12o, chequered plate steps with nosing and toe guard shall be provided. Floors of the conveyor gallery shall be provided with seal plates as specified in Mechanical section. 15.4.3 Conveyor gallery shall have permanently colour coated metal sheet on roof and both sides. Roof framing shall be given a slope of 1vertical : 4 horizontal. A continuous slot opening of 250 mm height shall be provided on both side walls just below the roof sheeting. These openings shall be covered with bird screens. Matching profiled translucent sheet (polycarbonate sheets) having thickness of 2 mm at the rate of 15 percent of floor area on the roof and 15 percent of the wall area shall be provided. Crossover shall be provided at approximately 100 metres interval along the conveyor preferably at 4 legged trestle locations. Stairs shall be provided at cross over locations. 15.4.4 In between transfer points, four legged trestles shall be given at a spacing of about 100 m. In between 4 legged trestles, two legged trestles may be provided. Four legged trestles shall be provided when height of trestles exceeds 20m .Trestles shall generally be provided using rolled sections only. 15.4.5 Sliding PTFE bearing support shall be provided at one end of the gallery for relieving forces due to temperature variation. Accordingly for the purpose of analysis one end of the gallery shall be treated as hinged and the other end on rollers.

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15.4.6 End of conveyor gallery, which will be supported over transfer tower, shall be so detailed that only vertical reaction is transferred from conveyor gallery. This side of the gallery shall therefore be supported on sliding PTFE support. For design criteria for foundation please refer part C. The top of pedestal for the foundations shall project 300 mm above the grade level. 15.4.7 Ground conveyor portals shall be provided at a maximum spacing of 3 m and the sides and roof covered with colour coated sheets and matching profiled translucent sheets. 15.4.8 While designing the structures of conveyor galleries and trestles, provisions of clause 8.14 of IS 11592 in addition to requirement of IS800 shall be followed. 15.4.9 The trestles shall be so designed that transverse deflection at places where conveyor galleries meet crusher/ junction house, should be equal to the respective transverse deflection of crusher/ junction house. 15.4.10 Suitable expansion joints shall be provided in the longitudinal direction. The maximum distance of the expansion joint shall be as per the provisions of IS: 800. Slotted holes shall not be assumed to act as expansion joint for relieving of stresses and suitable bearings shall be provided at the supports. 15.4.11Clear head room at road crossing shall be minimum 8.0m. 15.5 STACKER CUM RECLAIMER
15.5.1 Stacker cum reclaimer rail shall be supported on RCC foundations giving continuous support to the rails. The beams supporting the rails shall be given expansion joint preferably every 30 metres. Stacker / reclaimer conveyor support shall also be provided connecting the above two beams. Foundation system shall be rigid foundation resting on piles. Entire area shall be excavated to average 1600 mm depth. Excavated area shall be watered, rammed and compacted with 10 tonne roller. Minimum 800 mm thick river white sand cushion layer compacted in layers shall be placed over compacted sub grade with a layer of non woven geotextile on top. 500mm thick compacted gravel shall be placed on top of geotextile layer with consolidated 300mm thick compacted jhama bricks laid on top, joints filled with river sand. Longitudinal perforated HDPE pipe drains shall be laid in longitudinal direction along with jhamma brick bats wrapped in non woven geotextile to trap coal dust at regular intervals under the main geotextile layer to collect surface water for discharging into the mains surface drain. Retaining wall of 1m height shall be provided around the crushed coal pile to prevent spillage of coal. Drainage water shall be channelized to yard outfall sumps connected by R.C. hume pipes and collected to a common earthen collecting pond having two compartments lined with 750 micron LDPE membrane. Base of stockpile shall be prepared with minimum 300mm thick compacted crushed stone chips designed to withstand the surcharge load from the height of the stockpile. All around the stock piles longitudinal drains and cross drains will be provided to receive the coal pile runoff water and lead the same to a common

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header drain leading to a common collecting pond. This water mixed with coal (coal slurry) from all the drains shall be led to a common collecting pond. The header drain will be provided with a bifurcation at the discharge end i.e. at the inlet to the common collecting pond so that it gets divided in to two individual branch drains. Each individual branch drain will be provided with a gate suitable for operation in coal slurry at the inlet to individual section of the common collecting pond. Each of the two sections of the common collecting pond will be provided with provision for mounting a set of two (one working +one standby) sump pumps. The water from the main outlet header mixed with coal will be led to one of the two sections of the common collecting pond through one of the branch drains. The coal slurry containing coal and water shall enter the particular section of the common collecting pond. In this section of the common collecting pond, the clear water will float up allowing the coal to settle down. This clear water mixed with coal will be pumped off by one of the two sump pumps located at the particular section of common collecting pond to a clarifier located near the guard pond. The coal that settles at the bottom of the pond shall be removed manually. During the period of clearance of the coal from this particular section of the common collecting pond, the inlet gate on the other branch drain shall be opened and the coal slurry shall be led to the other section of the common collecting pond which would have been cleared of all the coal from the previous cycle of stock pile runoff water disposal to receive fresh slurry. The scheme of water and coal disposal from this section of the common collecting pond will be same as described earlier. RCC drains with removable precast RCC slotted cover shall be provided. RCC supports for dust suppression piping system shall also be provided. Beyond the stockpile area till the junction towers on either side, foundations for trestles and short supports will have to be given. The top of pedestal shall project minimum of 300 mm above the grade level. 15.6 RECLAIMER HOPPER PITS AND SHED
15.6.1 Hoppers shall be of RCC construction with 50mm thick guiniting. It shall be covered with removable grating made of minimum 25 thick MS flat (25 mm x 25 mm clear) resting on permanent structural framework. The pit shall accommodate the hoppers along with feeder and conveyors below. Minimum 3.0 m clear headroom shall be in between the floors. 50mm thick granolithic flooring with ironite topping shall be provided. The ramp approach shall be of RCC and minimum 100X100X10 edge angles shall be provided. 200mm wide X 12mm thick inserts @ 500mm c/c shall be provided to prevent damage to ramp due to inadvertent blade contact of the bulldozer. The hopper pit shall be of RCC construction and designed as Coal handling system substructure. During construction, proper provision shall be made to make the pit completely waterproof. Suitable sump shall be provided in the pit to affect surface water drainage. RCC access shaft shall be provided with staircase to the bottom of the pit. Monorail for taking machinery into the pit shall be provided in the access shaft projecting through two leaf steel sliding door. Plinth level of the pit shall be kept at least 500 mm above grade level with RCC sloped paving all round to enable bulldozer moveISSUE R0 TCE FORM 329 R5

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ment. Shed above hopper pit shall be of structural steel. The columns shall be raised from the four corners of the pit and shall be designed as free standing, supported only by roof framing, to facilitate dozer movement. Roof shall be provided with permanently colour coated galvanized sheeting. 15.7 TUNNELS, PENT HOUSES AND TRANSFER HOUSES
15.7.1 Tunnels shall be of RCC construction and designed as Coal handling system substructure. During construction proper provision shall be made to make the tunnel completely waterproof. A PCC screed shall be provided to direct the drainage on to one side of the tunnel. A small trench shall be provided on that side of the tunnel to lead the drainage to the nearest sump. The tunnel shall be provided with ventilation duct. Where the tunnel enters the ground level a pent house is provided of RCC construction. Pent house shall be provided with a lifting beam to lift equipments to the tunnel. Tunnel shall be provided with walkway on either side of the conveyor. Single pipe handrail shall be fixed to the tunnel wall to serve as handrail. Tunnel floor shall be provided with PCC steps in case of slope more than 120 to facilitate movement of operating / maintenance personnel. In the case of double conveyor such slope shall be provided in the centre also. Tunnel shall be box type and column free space shall be provided in the inside. Tunnel shall be wall-slab type configuration. All conveyor tunnels shall be designed to withstand the load due to movement of P & H Crane having self weight of 150MT at a speed of 5km per hour. 15.7.2 Where two tunnels meet, a Transfer house shall be provided. Transfer house is by and large a junction tower but the meeting of conveyors takes place below ground level. Transfer house shall be of RCC construction with RCC floors and roof, with RCC access shaft with staircase and monorail arrangement for carrying equipments down. Superstructure shall be generally of steel frame unless otherwise required due to system requirement. Proper drainage arrangement shall be provided in the bottom most floors. Handrails shall be provided around all openings. Around access shaft proper plinth protection shall be provided, with ramp towards the door. Access shaft should have one equipment entry, which shall be double leaf sliding door and a single leaf door for entry of personnel. Transfer house shall be designed, as Coal handling system substructure and provision shall be made during construction to ensure proper water proofing at after concreting is over. 15.7.3 Portion of the tunnel or transfer house over which railway line or road passes shall be appropriately designed to support the additional imposed load. Tell tale signs shall be provided above graded ground to identify the extent of the underground structure. 15.7.4 Drains of minimum 250mm depth shall be provided. Minimum slope of 1 in 450 shall be provided for efficient drainage. Drain shall be covered with minimum 40mm thick galvanized MS grating. Flat thickness shall be minimum 8 mm. Galvanization shall be minimum 610 grams/sqm.

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15.8 SWITCH GEAR ROOM / CONTROL ROOM
15.8.1 Number of switch gear room shall be decided based on the arrangement of various buildings and their electrical load requirement as discussed in the Electrical portion of this document. Switchgear room shall preferably be two storied RCC framed structure with cable vault on the ground floor and switch gears on the first floor. In the case of Switchgear cum control room, an additional floor shall be provided to accommodate the control room and offices above the switchgear room. Other constructional details shall be similar to ESP control room. Roof shall be given proper slope and parapet shall be provided. 15.8.2 Transformer yard, toilets, equipment hatch, staircase etc shall be as per Mechanical/Electrical requirements. 15.9 DUST SUPPRESSION, DUST EXTRACTION AND VENTILATION SYSTEM STRUCTURES
15.9.1 Civil works on account of the above system shall generally consists of pump houses, RCC reservoirs, slurry sumps, pump foundations, fan foundations etc., spread over the complete coal handling area. Location and details of these structures will depend on requirement based on system design. 15.10 DOZER SHED Dozer shed will be of structural framing and roofing system. It shall have suitable maintenance platform and lifting tools and tackle for carring out maintenance of dozers, wheel loader, excavators and dumpers. Brick wall with plastering shall be provided up to 3000 mm above finished floor level,. Above this level single skin non insulated permanent colour coated galvanised trough sheet cladding shall be provided and this will cover the brickwork also. It shall have maintenance and storage room, operation and maintenance staff rooms with toilets. Further suitable parking space shall be accommodated for stand by equipments/machines. Drinking water facility with water cooler and water filter to be provided. 15.11 DIESEL LOCOMOTIVE SHED. Diesel locomotive shed will be of structural framing and roofing system. It shall have suitable maintenance platform and lifting tools and tackle for carring out maintenance of diesel loco. Brick wall with plastering shall be provided up to 3000 mm above finished floor level, above this level single skin non insulated permanent colour coated galvanised trough sheet cladding shall be provided and this will cover the brickwork also. It shall have maintenance and storage room, operation and maintenance staff rooms with toilets. Drinking water facility with water cooler and water filter to be provided. 15.12 CHP OFFICE COMPLEX

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A double storey RCC framed office complex suitable to accommodate one Superintending Engineer, two Executive Engineers, eight Assistant Engineers and fifteen supporting staff of O&M shall be provided. The building will be cladded with brick wall. Drinking water facility with water cooler and water filter to be provided. The covered parking for about 20 vehicles shall be provided. 15.13 WORKSHOP BUILDING Workshop building will be of structural framing and roofing system. The dimension of the building shall be decided to suit the layout and maintenance requirement of the equipment. Main entry shall be through a rolling shutter permitting entry of truck with machinery. A minimum of two numbers single leaf steel flush doors shall be provided for movement of personnel. EOT cranes of adequate capacity as stated in mechanical section shall be provided. It shall have ware house, MCC room, tool room, office room, maintenance and supervisor`s office etc. Separate provision for WC and toilets shall be made. Office room, maintenance and supervisor`s office shall be provided with false ceiling. Brick wall with plastering shall be provided up to 3000 mm above finished floor level, above this level single skin non insulated permanent colour coated galvanised trough sheet cladding shall be provided and this will cover the brickwork also. For framing, cladding, roofing and other detail refer to Table-2 specified elsewhere. Roofs shall be properly sloped. Rain water down take pipes shall be galvanised pipes conforming to IS: 1239 class medium. Garland drains shall be provided around the building to carry the storm water to nearest plant drainage system. Plinth protection shall be given all round the building. Plinth protection shall be given on the side of the drain up to the brick wall. 15.14 SILO UTILITY BUILDING Silo utility building will be a single storied RCC framed structure with brick cladding. The building shall accommodate silo control room, silo MCC, dust conditioner water pumps, fluidising blower etc. Space for maintenance bay and toilet shall be provided. RCC Staircase shall be provided outside the building. Two numbers of rolling shutter shall be provided. The building size and height shall be decided by the bidder to suit his requirement of operation and maintenance. For framing, cladding, roofing and other detail refer to Table-2 specified elsewhere. 16.0 16.1 ASH HANDLING SYSTEM The superstructure of pump houses and compressor house shall be of RCC framed structure. The building shall support an EOT crane of adequate capacity. For framing, cladding, roofing, waterproofing and other detail refer to

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Table-2 specified elsewhere. Main entrance shall be of adequately sized rolling shutter. In addition minimum of two steel doors shall be provided. RCC foundations / pile cap shall be provided to support the structure based on soil condition. 16.2 Ash water tank may be above or below the ground level. The tanks shall be designed as a water retaining structure as per IS: 3370. RCC sumps for Ash Slurry Pump house shall be designed as per IS: 3370 duly considering water table as well as additional surcharge pressure. RCC staircase shall be provided for access to all the sumps. All basements shall be provided with handrails all round. MCC and Switch gear room shall be RCC framed structure with cable vault on ground floor and switchgear / control room on the first floor. Control room shall be air conditioned hence the same shall be given false ceiling and under deck insulation. Air washer room shall also be provided in the ground floor. Under deck insulation shall be provided for Air washer room also. Toilet shall be provided on the ground floor. Walls on the Transformer yard side shall be designed as per TAC regulations. For framing, cladding, roofing, waterproofing and other detail refer to Table-2 specified elsewhere. Roofs shall be properly sloped. Rain water down take pipes shall be galvanised pipes conforming to IS: 1239 class medium. Garland drains shall be provided around the building to carry the storm water to plant drainage system. Plinth protection shall be given all round the building.
16.3
16.4
16.6
Auxiliary transformer yard may be required near the Switchgear room. Transformer yard shall be provided with chain link fencing and gates along with fire wall, paving, soak pit, burnt oil pit etc. similar to ESP control room. Work shall include bottom ash hopper supports, bottom ash extraction equipment supports, pipeline supports and trenches from bottom ash hopper to ash slurry sump. Support for fly ash pipeline from ESP etc. to fly ash silo is also included in the slope of civil works. 16.8 Dry fly ash silo including development of the silo area including paving, boundary wall, access roads / drainage of the dry fly ash silo area are included in the scope. Drain around the edge of silo floor shall be connected with sump to drain off the water during day to day cleaning of the floor Fly ash silo shall be RCC construction. Roof above silo may be of structural steel construction.
16.7
16.9
Pipe line from ash slurry pump house to the final disposal area may run on RCC pedestals located near ground level with anchor blocks at all bends. The pipeline in cross country areas may run on pipe rack if so desired by the OWNER as described in Mechanical section of specification. In any case all Civil and Structural works shall be included in the scope. At all road / rail crossing pipe bridges are to be provided with bottom of the bridge at

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least 8 m above the road / rail level. If the OWNER permits at road crossings the pipes may be run inside box culverts also. 16.10 Dry fly ash storage area shall be provided with boundary wall and one gate and security hut for CISF. 16.11 The silos should be partially covered with PVC sheet at the bottom to reduce the spreading of ash in the atmosphere. Sprinkling system on the boundary wall with pressure jets facing upward to be provided all around the boundary of silo to act as water barrier to suppress the ash in the atmosphere . 17.0 17.1 FUEL OIL HANDLING SYSTEM Unloading pump houses to unload oil from road tankers or rail wagons shall be of RCC frame structure. A paved platform shall be provided between the pump house and the rail wagon / road tanker parking area with plain cement concrete over rubble soling, sloped towards a peripheral drain. The drain shall be led to a sump with oil water separator. No cable trenches shall be permitted in the pump house. Fuel oil pressurisation pump house shall house fuel oil pumps, heaters and MCCs. This shall also be of RCC framed structure. The pumps shall be located in an R.C.C basement. MCC shall be located at plinth level. Proper access shall be given to the basement. Basement shall be given proper drainage facility. The oil / water mixture collected in the sump shall be led to an oil water separator. The basement shall be designed as a water retaining structure. U/s crane or monorail facilities will have to be provided in all the pump houses as specified in the Mechanical section of the specification. For framing, cladding, roofing, waterproofing and other detail refer to Table-2 specified elsewhere. Fuel oil tanks shall be of structural steel designed as per IS: 803. Foundation of the fuel oil storage tank shall be provided with bitumen sand mixture laid over confined river sand bedding formed with RCC ring beam. The type of foundation to be adopted will depend on the soil condition. Where soil is very poor, tank may have to be founded on concrete pad resting on piles or the bearing capacity shall be improved using ground improvement technique. The storage tanks shall be surrounded by RCC wall to prevent the spread of fire or leakage of oil from a leaking tank to other areas. The height of the wall, centre to centre spacing of tanks as well as area provided within the concrete wall shall be decided based on the statutory requirements for the type and quantity of oil stored. The entire area outside the tank foundation, within the tank farm shall be paved. The paving shall slope towards RCC peripheral drains, which shall lead to an oil water separator. RCC crossovers shall be provided at appropriate locations for entry of personnel to the tank farm. Fuel oil storage area shall be protected by chain link fencing as in the case of Transformer yard. Extent of fencing shall be to satisfy statutory
17.2
17.3
17.4

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requirement. Foundations for trestles and pedestals for supporting the pipes, anchor blocks etc. shall be provided in RCC at appropriate locations. 18.0 18.1 D.M. PLANT Dimension and height of the building shall be decided based on equipment layout and height of the vessels accommodated inside. The DM plant building shall be of a structural steel framing to result in large column free space .For framing, cladding, roofing, waterproofing and other detail refer to Table2 specified elsewhere. Adjoining control room and laboratory shall be provided in an RCC framed building with brick cladding. Control room and switchgear room shall have a cable vault below. Control room and laboratory shall be air conditioned. False ceiling shall be provided in this area.Staircase in the Control room complex shall be extended to the roof also. Toilet shall be provided in the ground floor. In case a transformer yard is provided, the wall in front shall be designed to satisfy fire withstand capability as per TAC. Details of transformer yard shall be as discussed for ESP control room.
18.2
18.3 Neutralising pit shall be designed as a water retaining structure with external damp proofing. DM water storage tank outside the DM plant shall be supported on sand pad with RCC ring wall.
19.0 19.1
CONDENSER COOLING WATER SYSTEM RCC cooling water channel shall be of rectangular shape and designed as a water retaining structure. Depth of channel and width of channel shall match with the width and depth of the cooling water channel from cooling tower. These branch channels shall join together and form common channel to the forebay to the pump house. Dimension of the channel shall be decided on the basis of the quantity of water to be carried by the channel. Floor of the channel shall be given a mild slope to ensure necessary velocity of flow. The top of the channel shall be kept at least 500 mm above ground level with suitable galvanised MS pipe hand railing on either side. Expansion joint shall be given at a spacing of about 30 m. Pedestrian crossover shall be provided across the channel at approximately 300 m centres. The channel shall smoothly diverge and form the forebay in front of the pump house. It is suggested that the bottom of the forebay shall be kept flat and the difference in level between the channel and CW pump sump shall be made up in the channel stretch before joining the forebay, using a slope of 1 Vertical : 6 Horizontal. Depth of forebay shall generally match with the C.W. sump level, which shall be decided based on submergence requirement of the C.W. pumps at the lowest water level in the sump. Forebay shall be provided with cage ladder constructed of galvanised steel at four corners. Top of the forebay
19.2

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wall shall be kept at least 500 mm above grade level and handrail of galvanised M.S. pipes shall be given for the entire length. Water level indicator (float type) shall be provided in the forebay close to the pump sump on either side to observe the depth of water. 19.3 Dimension of the pump sumps shall be so selected as to prevent dead water areas, reverse currents, flow separation and eddies. Recommendations of British Hydromechanic Research Association (BHRA) and Hydraulic Institute Standards shall be followed. CONTRACTOR shall conduct Hydraulic Physical Model study to demonstrate trouble free operation of the pump sump and forebay for all possible alternatives / combination of pump operation. Pump sump shall be designed as water retaining structure. Each sump shall be provided with stainless steel groove for inserting coarse screen, fine screen and stop logs. Grooves for stop log shall be provided before and after the screens. The number of coarse screen and fine screen shall be the same as the number of pump sumps. The number of stop log shall be minimum of two. Top of the sump floor shall be kept same as of the top of forebay. This floor shall have openings for lowering and lifting of stop logs and screens. These openings shall be covered with galvanised mild steel gratings when the screens are not placed in position. Provision of handling of the screens and stop log shall be provided. Sufficient paved space shall be provided to keep the stop log when not in use and also for maintenance of screens. Galvanised MS handrails shall be provided on three sides of the pump floor (sump roof). Each individual pump sump shall also be provided with a drain sump to empty the sump for attending to maintenance of pump. 19.4 A thrust block shall be provided connecting the pump and motor floors to resist the pump thrust. RCC staircase shall be provided from the pump floor to motor floor. Motor floor shall be given handrail on the two sides. Pump maintenance area with truck access shall be provided on one side at the pump floor level with rolling shutter of adequate size to permit transport the pump. The pump house structure shall be of steel framed structure with EOT crane. For framing, cladding, roofing, waterproofing and other detail refer to Table-2 specified elsewhere. Ventilation and natural lighting shall be provided with glazed windows. Minimum of two doors shall be provided for movement of personal. While planning crane runway guiders, due care shall be taken to ensure that all the pumps can be erected and maintained using the crane. Maintenance bay of the pump house shall have R.C.C grade slab. Approach to roof shall be provided with steel cage ladder. An annex to the C.W. pump house shall be provided in RCC framed structure to accommodate Switchgear and Control room with cable vault below, Chlorinator room, Chlorine cylinder storage room and toilet block. Side cladding shall be of brickwork except Chlorine cylinder storage area where brick wall is provided only to a height of 1 m. All floors and roofs shall be of
19.5
19.6

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RCC. Roof shall be given proper slope and water proofing. Roofs shall be made accessible by MS cage ladder.
19.7
An auxiliary transformer yard may be required in front of the Switchgear room. Civil work similar to the transformer yard in front of ESP control room shall be included in the scope of work. Outside the pump house, support blocks for butterfly valves and pipes along with proper handling facility shall be provided. CW conduit from CW Pump house up to condensers and from condenser to cooling towers shall be steel pipe, conforming to IS: 3589. The pipes shall be formed of structural steel conforming to IS: 2062. CW piping shall be designed for pump shut-off pressure or 1.5 times the maximum pump head whichever is higher. Thickness of the pipe shall also be adequate to withstand full vacuum in the pipe. Also, the pipes shall be hydro-tested at a pressure of 1.5 times the design pressure. Thickness of the pipes shall be calculated as per requirement of AWWA M11. However, minimum thickness of CW pipes shall be not less than 20 mm at any location, including corrosion allowance of 1.5 mm and mil tolerance as per IS:3589. CW conduit shall be laid underground with minimum earth cushion of 1500 mm. A surcharge of 2 t/sq.m in addition to backfill shall also be considered. At road / rail crossings and path of extreme high load vehicular movement, the CW pipes shall be encased in reinforced cement concrete of minimum M20 grade. Also, if the water table is high, the pipe shall be encased in RCC to counter buoyancy. The minimum thickness of RCC encasement shall be 300 mm all-round up to 2200 mm dia pipe and 500 mm all-round for higher dia pipes. The encasement shall be designed adequately to withstand the additional imposed loads. Where pipes are not encased the pipe shall be given sand bedding conforming to requirements of IS: 5822. The minimum thickness of sand bed under bottom of pipe shall be 100 mm. The pipes shall be given an internal coating with epoxy paint 250 micron. Where pipes are not encased wrapping as per IS: 10221 shall be provided outside. At locations of the change of flow direction anchor blocks shall be provided as per requirement of hydraulic transient analysis. Manholes shall be provided along the length of pipe at about 50 m centers and near locations of bend in each pipe. Double kinetic type air-cum-vacuum valves shall be provided at each individual pump discharge lines, and other locations on CW supply and return header as per requirement of hydraulic transient analysis.
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The complete piping system shall be line tested before commissioning of the system. All site joints shall be inspected by radiography. 20.0 COOLING TOWER Refer part G of specification 21.0 Raw water pump house / Raw water reservoir Raw water pump houses both for WYC and STP shall be of RCC construction. Pump sumps shall be designed as a water retaining structure. Raw water pipe lines shall be routed on pedestals/pipe racks or culvert as required. Raw water storage reservoir with a storage capacity as indicated in mechanical section shall be provided. The reservoir shall be of earthen construction and provided with lining to prevent seepage. All measures to protect the liner from ground water table / pressure shall be provided. Necessary filter, rock toe, toe drain and turfing shall be provided for efficient functioning of the bund. Sand cushion of 150 mm thick shall be provided above and below the 750 micron HDPE lining on the base of the reservoir. In addition to the above, the inner sloped surface of raw water pond shall be lined with 750 micron LDPE liner overlaid with 50 thick precast concrete blocks as shown in the drawing. Minimum 4m wide road shall be provided on top of bund.
22.0 22.1
MISCELLANEOUS PLANT BUILDINGS AIR COMPRESSOR + DG + AIR WASHER BUILDING
22.1.1 Air washer, DG & compressor shall be housed in a two storied RCC framed, brick cladded single building. DG & compressors shall be in ground floor and air washer shall be on the first floor. Under slung crane/ monorail of adequate capacity as stated in mechanical section shall be provided. For framing, cladding, roofing, waterproofing and other detail refer to Table-2 specified elsewhere. 22.1.2 The dimension of the building will be decided by the BIDDER to suit equipment supplied. D.G set foundation shall be isolated from the floor. Proper care shall be taken to limit noise levels outside within limits specified. Acoustic doors as per requirement shall be provided. . Main door shall be rolling shutter of adequate size to allow entry of D.G set. Adequate ventilation and lighting shall be provided with glazed windows. Main door shall be adequately sized rolling shutter to permit entry of truck with compressor. Compressor foundation shall be isolated from the grade slab. Air receiver and Air drier can be supported from RCC grade slab. All trenches shall be of RCC. There shall be no entry of cables / pipes to these trenches below grade level from outside. All these trenches shall be

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covered with chequered plate over steel framing. Adequate number of sumps shall be provided to drain these trenches Water tank and RCC supporting structures for louvers, filter and foundation for equipment such as fans and pumps are also included in the scope. Proper drainage of the floor shall be provided. Doors shall be made airtight. Rolling shutter of adequate size should be provided for taking the equipment inside. 22.2 A C PLANT This shall be a single storey steel frame building. For framing, cladding, roofing, waterproofing and other detail refer to Table-2 specified elsewhere. The roof framing shall support an under slung crane of adequate capacity. The dimension of the building shall be decided to suit the layout and maintenance requirement of the equipment. Main entry shall be through a rolling shutter permitting entry of truck with machinery. A minimum of two numbers single leaf steel flush doors shall be provided for movement of personnel. 23.0 23.1 NON-PLANT BUILDINGS SERVICE BUILDING
23.1.1 Special attention shall be given to architecture of this building. This building shall be located close to the turbine building and shall be connected by a covered corridor to the turbine building at the operating floor level. 23.1.2 For framing, cladding, roofing, waterproofing and other detail refer to Table2 specified elsewhere. Building shall have a plan area of about 675 sq.m each floor with large column free area. Number of floors shall be decided by the BIDDER depending on the space requirement of various facilities proposed to be housed. Minimum five floors are recommended. 23.1.3 This building should provide office for the operating and maintenance staff, laboratory for Control & Instrumentation, relay testing and electrical testing, in addition to Conference room, archives, model room, change room with lockers for the operating and maintenance workmen, reception, telephone exchange, battery room, stores, pantry, air washer room and separate toilets for ladies as well as gents. The building shall be centrally air conditioned. Hence clear head room below beams shall be designed to run A/C ducts above false ceiling. Level of false ceiling may be kept at 2700 mm in the ground floor and 2500 in upper floor. Cabins for senior officers and conference rooms shall have attached toilet. 23.1.4 One elevator shall be provided at the entrance lobby. Entrance to lift shall be decorated with rose wood architrave and matching granite tile dado. Number of staircases provided shall be decided based on statutory regulations. For the staircases in the lobby the treads and dado shall match with

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the floor finish. Handrail shall also be of aesthetic appearance and made of stainless steel. At least one staircase shall lead to the roof. 23.1.5 Specially designed long RCC porch shall be given in front at the main entrance for receiving cars of VIPs. Length of the porch shall be at least 15 m. Special attention shall be given in front of service building in landscaping the area and developing garden with flowering plants. 23.1.6 For finishes reference may be made to clause Section VI of this document. 23.2 PARKING AREA
23.2.1 Parking area with RCC roof and plain concrete paving with ramps shall be provided near service building. 23.2.2 Near service building covered parking area may be provided for 20 cars / jeeps and about 50 two wheelers. The open parking area for 10 cars may also be provided.
24.0 24.1
EFFLUENT TREATMENT PLANT The BIDDER shall furnish a comprehensive proposal for treating the plant effluent to meet the requirement of the statutory authorities. All the treated effluent from D.M. plant building and other treatment areas shall be discharged to ash water tank or may be taken to guard pond. The treated effluent shall conform to the requirement of the Pollution Control Board. The treated water can be used for gardening / development of green belt. All sumps and pits in waste water treatment plant shall be of RCC construction with proper acid / alkali liners. Electrical / control panel shall be located in an RCC building with office space for operating personnel. PIPE AND CABLE RACKS All cable and pipe routing in and out lying area shall be clubbed and shall run over ground on structural steel pipe / cable racks at a height not less than 3000 mm above grade level. Where the pipes cross roads / railway clear headroom shall be 8000 mm. The racks can be multitiered. Cable shall normally be laid above the pipes. The racks are generally designed as a rigid frame in the transverse direction and braced in the longitudinal direction. Expansion provision shall be provided wherever there is a change in direction or where length of the rack exceeds 100 metres. Access ladder shall be provided at suitable location. Where so required chequered plate platforms shall be provided for maintenance purpose. Pipe rack columns shall be supported on RCC foundations with bottom of base plate about 300 mm above ground level.
24.2
25.0 25.1
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26.0 ASH DISPOSAL SYSTEM The scheme of disposal of ash in the existing and proposed ash disposal is described in the mechanical section of this document. Ash will be led to ash pond when the same cannot be stored in silos. Considering the area available for storage of ash in existing ash dyke, the height required for the bund around the ash pond will be very high to store the ash during the life of the project. Hence the bund of the existing ash pond shall be raised up to 14m from the initial height of 6.75m using pond ash or using locally available/ excavated earth laid to stable slope consistent with the properties of the soil. The bid drawing is indicating Scheme-I and Scheme-II for raising of ash bund. The top of the bund shall be kept 6 meter wide to accommodate a single lane WBM road. At the water side of the ponds, both the pond floor and side slopes, shall be lined with 750 micron thick HDPE membrane, to prevent ash water percolating into subsoil. On the sloping side the membrane shall be protected with PCC lining, minimum 50 mm thick. Culvert for entry of pipe into settling pond, energy dissipating arrangement at discharge point of ash slurry in the settling pond, overflow arrangement for decanted water from settling pond to stilling pond, and discharge shafts in stilling pond will be of RCC construction. Downstream slope of the bund will be protected with 75 thick sand bedding+750 micron thick GEO membrane (HDPE)+25 thick cement mortar+50 thick precast concrete block 500x250 size in cement mortar 1:5.,. A rock toe and peripheral drain shall be provided all round the downstream toe to protect the bund and lead away percolated rain water. 27.0 HORTICULTURE AND LANDSCAPING BIDDER shall hire professionally qualified landscaping agencies to develop the landscaping and horticulture in the plant area. Horticulture and landscaping should fullfil the requirement of MOEF. However Saplings will be planted in the pits at about 2.5 m interval to attain the tree density of about 1500 trees/hectare. Suggestive species and suggestive recommendations as given in the EIA, EMP report shall be followed. Special attention shall be given to development in front of Service building. Around the cooling towers and coal stockyard area fast growing tall trees shall be planted to reduce drift and dust, nuisance respectively. BIDDER shall include along with bid his broad proposal for horticulture and landscaping works. Development of green belt shall commence as soon as the boundary wall has been constructed.
Green Belt is to be raised by 100 m width, consisting of at least 3 tiers around the plant boundary with tree density not less than 2500 trees per hectare as per the TOR of MoEF.

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28.0 TOWNSHIP Township has been detailed in Part- J, Section VI.
30.0
RAIN WATER HARVESTING Rain water harvesting pond of adequate size may be provided for storage of rain water. The existing rain water harvesting scheme may be kept in view. The rain water shall be free from any pollutant and system shall be so created that no debris or any other material is discharged into the pond. The rain water harvesting scheme shall be got approved from central ground water board. Provision shall be made for diverting the overflow from the harvesting pond to drains. General guidelines for rain water harvesting are given in IS 14961. The contractor shall provide necessary piping, pumps, valves etc for utilization of rain water for irrigation of green belt, sprinkling on coal piles and toilet flushing.

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SECTION VI TECHNICAL SPECIFICATION PART A GENERAL REQUIREMENTS

1.0 1.1 GENERAL Design and construction of buildings, structures etc. shall take into account requirements for operation and maintenance of all equipment and its users. The buildings shall have good architectural features. The surrounding areas shall be properly micro levelled and graded. ARCHITECTURAL CONCEPT FOR BUILDINGS The architectural design concept of buildings shall be evolved considering the functional, technical and other requirements for efficient operation, ensuring comfortable working environment for personnel, satisfying the aesthetic requirements. Special care shall be taken to provide elegance and aesthetics, with effective use of appropriate treatment, materials, fittings and finishes. To achieve above objective CONTRACTOR shall employ a qualified architect/ architectural firm to carry out all designs and hold all other architectural responsibilities for the project. 1.3 The CONTRACTOR shall obtain and be conversant with all laws, by-laws and regulations of local and Statutory Bodies as applicable to the project. The architectural concept evolved should also take care of these requirements. The CONTRACTOR shall provide the drawings and documents for such statutory approvals. Before starting of design works, the contractor shall submit to the Owner for approval the project design manual containing the design data and the detailed design criteria for all civil structural and Architectural works. Design works shall commence only after approval of the project design manual by the Owner. ROOF ACCESS All roofs shall be provided with access through a staircase/ cage ladder. Minimum 1000 mm wide access path shall be provided with tiles to approach equipment on roof. 3.0 3.1 PLATFORMS AND WALKWAYS Platforms shall be provided to all major equipment, not directly accessible from the floors, for maintenance. Platforms and connecting walkways shall have a minimum clear width of 750 mm. Platforms in front of the entry shall be at least 900 mm clear wide. Platforms located close to each other shall be connected with walkways.
1.2
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3.2
All steel platforms above grade level shall be constructed with kick plates at edge of the platform to prevent tools or materials from falling off. It shall consist of 8 mm thick steel plate projecting 100 mm above the platform surface. Kick plate shall be painted with the same type of coating as the material to which it is attached. Generally continuous walkway, at least 800 mm clear wide shall be provided along the crane girder level with handrails on both sides of the building. Approach to walkway shall be ensured by Cage ladder / staircase. STAIRS AND LADDERS STEEL STAIRS All steel staircases shall normally have minimum clear width (back to back of stringer) of 1000 mm and maximum inclination with horizontal of 35.750. All stairs normally shall have not more than 13 risers in one flight. Channels (minimum MC200) shall be provided as stair stringers. Treads shall be minimum 250 mm wide of chequered plate/grating, with suitable nosing, and spaced equally so as to restrict the rise to maximum 180 mm. Effort shall be made to keep the riser height 150-160 mm.
3.3
4.0 4.1
4.2
STEEL LADDERS Ladders shall be provided to platforms, walkways, instruments and equipments which do not require frequent access. Ladders shall preferably be vertical and its angle with vertical shall not exceed 50. Ladders shall be of minimum 450 mm clear width with 20 mm diameter MS rungs spaced at 300 mm (maximum). Ladders shall be provided with a safety cage of minimum 750 diameters clear when the top of ladder is more than 4.5 m above the landing level. However safety cages shall start at 2.5 m above the lower landing level.
4.3
RCC STAIRS All stairs shall have maximum riser of 180 mm and a minimum tread of 250 mm. However, for public buildings riser shall be limited to 150 mm and tread width of 300 mm. Minimum width of stairs shall be 1200 mm generally. All stairs normally shall have not more than 13 risers in one flight. Aluminium angle nosing with minimum 50X25X3 angle shall be provided for edge protection of RCC stairs.
5.0 5.1
HANDRAILS Handrails shall be provided at appropriate places to ensure safety e.g. around all floors/roof openings, projections / balconies, walkways, platforms, steel stairs etc.

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5.2
Hand-railings shall conform to IS: 1239 (latest) (Medium) G.I pipe and flush welded construction, ground smooth using 32 mm nominal bore pipe. Handrails for platforms, walkways and projections shall be a two-rail system with the top rail 1065 mm above the walkway surface and the intermediate rail 535 mm below the top rail. Toe guard made of M.S. Flat (Min.100x6mm) shall be provided for structural flooring. For concrete floor an integral concrete kerb to be provided. Handrail post spacing shall be limited to 1500 mm as far as possible but can be proportioned to the length of the protected horizontal opening. In such a case spacing shall not exceed 1850 mm centre to centre of posts. Handrails shall be shop fabricated for specific locations and field welded or bolted to the erected structural steel. For platforms at elevation more than 30 m, three rail systems with top rail at 1500 mm shall be adopted with toe guard. For RCC stairs, handrails with 20 mm square MS bar balustrade with suitable MS flat & aluminium / Teakwood handrail shall be provided, unless specifically mentioned otherwise. EDGE PROTECTION Wherever possible around floor openings an RCC kerb of 100 mm wide 150 mm high shall be provided. All concrete edges, where breakage of concrete corner is expected, shall be provided with angles at least L 50x50x6 with lugs for edge protection e.g. all round the cut-outs/openings in floor slab, edges of drains supporting grating covers, edges of RCC cable/pipe trenches supporting covers, edges of manholes supporting covers and supporting edges of precast covers etc.
5.3
6.0
7.0 7.1
ANCHOR BOLTS AND INSERT PLATES Anchor bolts shall be designed for working stress, in tension and shear, for embedded length of the anchor bolts and pipe sleeves. Shear and crushing strength of concrete shall also be checked. Increase in allowable stress for loading including seismic and wind loads shall not be permitted in design of anchor bolts. Insert plates shall be designed/ checked for shear and bending moment. All lugs shall be checked for tension. Bond strength of concrete shall also be checked. Lugs using steel flats min 25x6mm shall preferably be fillet welded to the plate to transfer full strength of the lug. VERTICAL HEADROOM All accessible areas shall be provided with minimum clear headroom mentioned as follows, unless otherwise specified: Finished floors to soffit of beams
7.2
8.0 8.1

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(buildings) Doors, Walkways, Platforms, Stairs etc. False ceiling of office areas False ceiling walkway Safety cage for ladders Access for forklift trucks Main roads/Railway crossings & crane access Other plant roads and truck access Cable & Pipe rack (except Road/Rail crossings) Cable spreader floor 9.0
: : : : : : : : : :
3000 mm 2100 mm 2500mm 1000 mm 2500 mm 2800 mm 8000 mm 5000 mm 3000 mm 2400 mm
CONSTRUCTION, EXPANSION AND CONTRACTION JOINTS
9.1
Construction joints The number of construction joints should be kept as low as possible consistent with reasonable precautions against shrinkage. Concreting should be carried out continuously up to construction joints. Where it is necessary to introduce construction joints, careful consideration should be given to their exact location, which should be indicated on the drawings. Alternatively, the location of joints should be subject to agreement between the Engineer and the Contractor before any work commences. Construction joints should be at right angles to the general direction of the member and should take due account of shear and other stresses. Joint lines should be so arranged that they coincide with features of the finished work. If a kicker (i.e. a starter stub) is used it should be at least 70 mm high and carefully constructed. The kicker must be incorporated with the previous concrete. Where possible, the formwork should be designed to facilitate the preparation of the joint surface, as the optimum time for treatment is usually two to four hours after placing. The maximum horizontal length of wall to be poured in one operation in any one direction is 7.5 metres. A period of 7 days to be allowed between adjacent pours except where water stops are provided when this can be reduced with Engineers approval. Alternatively a gap of 600 mm wide shall be left between adjacent pours and filled after 7 days from the date of formation subject to Engineers approval. Immediately prior to recommencement of concreting on a joint, the surface of the concrete against which new concrete will be cast should be free from laitance and should be roughened to the extent that the largest aggregate is exposed but not disturbed. Care should be taken that the joint surface is clean immediately before the fresh concrete is placed against it. Particular

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care should be taken in the placing of the new concrete close to the joint. This concrete should be particularly well compacted and if possible a vibrator should be used. Where the Engineer considers that special preparation is necessary, i.e. for an in-situ structural connection, preparation should be carried out preferably when the concrete has set but not hardened, by spraying with a fine spray of water or brushing with a stiff brush, which is sufficient to remove the outer mortar skin and expose the larger aggregate. Where this treatment is impracticable, sand blasting or a needle gun should be used to remove the surface skin and laitance. Hacking of hardened surfaces should be avoided. A record shall be kept on site of the time and date of placing the concrete in each section of the work. 9.2 Expansion and contraction joints The expansion joints, contraction joints and other permanent structure joints shall be provided in positions as shown in the drawings. Joints shall be straight and vertical, except where other specified and concrete surfaces on both sides of the joint shall be flush. Where necessary, waterstops of a type approved by the Engineer shall be embedded in the concrete. The waterstop should be made of high quality material which must obtain its resilience through the service live of the structure for the double function of movement and sealing. The surface of waterstops should be carefully rounded to ensure tightness of the joint even under heavy water pressure. To ensure a good tightness with or without movement of the joints the waterstop should be provided with anchor parts. The cross-section of the waterstops should be determined in accordance with the presumed maximum water pressure and joint movements. The complete works of fixed and welded connections must be carried out strictly in accordance with the manufacturers instructions. All joints between structural steel and concrete parts shall be sealed by a suitable permanent flexible compound.
10.0 10.1
BRICK/STONE/CONCRETE BLOCK MASONRY AND PARAPET WALL All masonry works shall be designed in accordance with IS:1597, IS:1905,IS:2185 (part-1) IS:2212, IS:4326 and other relevant IS codes as applicable. Structural design of load bearing and non-load bearing walls constructed with solid or perforated burnt clay bricks or concrete blocks shall be in accordance with criteria specified by Section 4 of National Building Code of India Part VI. All walls shall be non load bearing infill panel walls. External walls of all buildings shall be at least one brick thick (230mm). All internal walls shall be
10.2

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at least one brick thick except for internal partition walls for office area, canteen, change rooms, first aid rooms and toilets which may be half brick thick (115mm). Internal walls between toilet/kitchen/ pantry and office area will also be 230mm thick. 10.3 10.4 50 mm thick DPC (1:1.5:3) with water proofing admixture shall be provided at plinth level before starting masonry work. Minimum 75 kg/sq.cm compressive strength of Class Designation 7.5 brick shall be used for non load bearing super structure work. Cement sand mortar 1:6 for one brick thick wall and 1:4 for half brick thick wall shall be used.RCC transoms and mullions shall be provided to reinforce the wall where required. Wall panels shall be designed and sized suitably satisfying IS: 1905 in steel framed building. Type, thickness and height of external wall, facing the transformer yard to take care of fire accidents in transformer yard shall be according to the requirements of Tariff Advisory Committee. Even where metal cladding is specified, for initial 3 m height from the ground level, minimum one brick thick masonry wall (230mm) shall be provided. All upstands and parapet walls (minimum thickness 125 mm) on roof shall be of RCC construction, minimum height of parapet walls for non accessible roof shall be 750 mm and 1050mm for accessible roof. DRAINAGE FLOOR DRAINAGE
10.5
10.6
10.7
11.0 11.1
11.1.1 For all buildings and areas, suitable arrangement for draining out water collected from equipment blow downs, leakage, floor washing, fire fighting, etc. shall be provided on each floor. Gully traps, inspection pits, collecting pits etc. shall be located suitably and designed considering flow volume, easy access, maintenance and safety. 11.1.2 All drains inside the building shall have minimum 40 mm thick grating covers. In areas where heavy equipment loads would be coming, precast RCC covers (min thick 100 mm) shall be provided in place of steel grating. These drains shall lead the water to drain sump or suitable outfall. 11.1.3 Garland drains shall be provided around all buildings to receive the drainage water from roof and floor and lead them to the plant storm water drainage system. 11.2 ROOF DRAINAGE

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11.2.1 Roof drainage system shall be provided for quick and efficient draining of rainwater from roof to avoid seepage and damage to roof. The runoff gradient for the roof shall not be less than 1 in 100. Roof drainage system shall consist of roof drain heads, rainwater down take pipes and fixtures. System shall be designed to handle design requirements for the specific site and shall be in accordance to stipulations of IS: 742 and IS: 2527. Roof drains shall conduct water to storm drains through down take pipes. 11.2.2 Rain water down take pipes shall be M.S. pipe type medium conforming to IS: 1239. M.S. Gutter shall be of minimum thickness 4 mm and galvanised. 11.3 SUMPS In case of underground structures, sumps with pumping arrangement shall be provided at suitable location to collect and pump out any incidental water collection to nearest storm water drains. 12.0 12.1 WATERPROOFING OF UNDERGROUND STRUCTURES All underground structures (other than Coal handling system) like basements, pump house sumps, liquid retaining/conveying structures etc. shall have plasticiser cum waterproofing cement additives conforming to IS:9103. In addition, limits on permeability as given in IS: 2545 shall also be met with. The concrete surface of these structures in contact with soil shall be provided with minimum two coats of bituminous painting of grade 85/25 conforming to IS:702 mixed with 1% antistripping compound as per IS: 642. Bitumen shall be applied @ 1.7 kg/sq.m (minimum) for water / damp proofing. Also provision shall be made on the inner surface of walls and base slab, so that water proofing grouting can be injected later in case of leakage. All liquid retaining/ conveying structures including sumps of Pump House shall be tested for water tightness as per IS: 3370 & 6494 and in case of soakage, leakage, seepage the same shall be rectified by chemical injection grouting as specified. Bidder shall submit a comprehensive scheme for water proofing treatment based on above or any other alternative scheme, internationally accepted for OWNERs approval prior to commencement of work.
12.2
Underground structures of Coal handling system shall be provided with following waterproofing treatment: Water proofing of underground portion of Wagon tippler, tunnels, and underground portion of transfer houses shall be done by providing the following treatments: (a) Chemical injection grouting for inner faces (details as specified elsewhere).

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(b) Polymer modified cementitious coating on earth side face as per the following : (1) On the outer surface of walls, frames and roof slabs coming in contact with earth, polymer modified cementitious coating in two layers as specified and as per manufacturers specifications shall be provided directly on the concrete surface. (2) 50 mm thick P. C. C. (1 : 2 : 4 with 10 mm nominal size stone aggregates) shall be provided under the raft i.e. over the lean concrete, followed by polymer modified cementitious coating in two layers ( slurry mix application ) as per manufacturers specification. 50 mm thick P. C. C. (1: 2: 4) with 10 mm nominal size stone aggregates shall then be laid over the polymer modified cementitious coating before laying the raft. The Contractor shall furnish a Performance Guarantee of minimum 10 years for the treatment. This guarantee shall commence from the date of completion of work or handing over, whichever is later. Format of Performance Guarantee shall be furnished by the Contractor for approval by the Owner/ Owners consultant. 12.3 CHEMICAL INJECTION GROUTING Minimum, 12 mm dia. ( NB ) threaded nozzle of suitable length, shall be provided over the surface and along the construction joint line in a grid pattern at a spacing not exceeding 1.5 m c / c before concreting operation. Adequate precaution shall be taken to keep the nozzles plugged at both ends to prevent them from getting closed by concrete. For fixing of any nozzle in set concrete suitable size hole shall be drilled, preferably by using repercussive hammer drill electrically operated, in grid pattern and grouting nozzle shall be fixed in these holes. After the nozzles are fully set, neat cement slurry admixed with water soluble non - shrink polymer / monomer based chemical shall be injected through the net - work of nozzles with low pressure grout pumps at a pressure of about 2.0 Kgs. / cm2. Cement slurry shall be prepared by mixing cement with non-shrink polymer/monomer @ 500 gm/50 kg bag of cement and water, ensuring that Water: Cement ratio does not exceed 2 (by weight). Wetter the structure, lesser should be the water cement ratio. The property of the polymer/monomer should be such that when it is mixed with water @0.5% by weight of water, the viscosity of the resultant solution (water and polymer/monomer) should not be more than 1.2 centipoises. Plasticizing agent shall be added wherever required. The grouting shall be started at very low pressure and increased gradually to a required pressure. The grouting shall continue, till the hole refuses to take any further grout, even at

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an increased pressure. Applied pressure shall not be more than the designed strength of the concrete. After completion of grouting operation, the nozzles shall be sealed properly to the satisfaction of the Engineer. Material shall be of M/s SIKA, CICO, FOSROC or approved equivalent. 12.4 POLYMER MODIFIED CEMENTITIOUS COATING
12.4.1 Materials Modified liquid polymer blend shall be a dispersion containing 100 % acrylic based polymer solids. Polymers shall be mixed in the ratio of 1 cement: 0.5 polymers (for minimum solid content of polymer 30%). Portland cement based dry powder. Clean, fine specially prepared quartz sand approximately 0.6 mm size. Material shall be of M/s SIKA, CICO, FOSROC or approved equivalent. 12.4.2 Mixing The liquid polymer shall be stirred well and cement based powder shall then be added slowly to make a Slurry Mix. For preparation of Brush Topping Mix, quartz sand shall be added slowly and mixed well till a homogeneous mixture is obtained. The mix shall be used within half an hour of the preparation. Addition of quartz sand may not be necessary, in case dry power contains the same. 12.4.3 Properties of Coating It must adhere to wet surface. It should develop adequate bond strength, with the concrete surface, not less than 2 N / Sq. mm. Co - efficient of permeability shall be about 5x10-10 Cm / Sec. Water absorption after continuous soaking shall not be more than 1 %. The materials shall be permeable under water vapour. The material shall be resistant to acids and alkalis present in the soil and underground water with normal pH value between 4 and 14. The co - efficient of thermal expansion of the material shall be close to that of concrete. 12.4.4 Application The concrete surface shall be cleaned and made free from grease, oils or loosely adhered particles. The surface shall be damp without any free water. For exterior underground part, application (b) pertaining to Brush topping Mix shall be followed.

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(a)
For Slurry Mix
A minimum of 2 coats shall be applied on the surface. The first coat being applied, when the surface is still damp and left to harden for 4 to 6 hours. After 4 to 6 hours of the application of second coat, it shall be finished by rubbing down with a soft dry sponge. The coverage shall not be less than 1 : 1 Kgs. / m2 in the 2 coats. A lap of 75 mm shall be provided at the joints. The coating shall be air dried for 4 to 6 hours and, thereafter, cured for 7 days after the application of last coat. (b) For Brush Topping Mix
This shall be applied in two coats. A primary coat of slurry mix can also be first applied on the surface as first coat. After the coating has dried up, a coat of Brush Topping Mix shall be applied over it with a push broom or any other similar brush. It shall be left in broom finished condition. The nominal thickness shall be 1.5 mm and minimum thickness shall be 1.0 mm. A lap of 75 mm shall be provided at the joints. It shall be ensured that no pinhole exists and rebrushing shall be done to cover the pinholes, if any. The Coating shall be air dried for 4 to 6 hours and thereafter cured for 7 days after the application of last coat. Rate of application of coating shall be established to achieve the required thickness.
13.0
ANTI TERMITE TREATMENT Pre-constructional anti termite treatment shall be given to all vulnerable areas and shall include column pits, wall trenches, foundations, filling below the floors etc. as per IS: 6313 and other relevant Indian Standards. If the area of construction or it`s adjoining area is even slightly affected due to termites, anti-termite treatment has to be done for all the building. The Contractor shall furnish a Performance Guarantee of minimum 5 years for the treatment. This guarantee shall commence from the date of completion of work or handing over, whichever is later. Format of Performance Guarantee shall be furnished by the Contractor for approval by the Owner/ Owners consultant.
14.0 14.1
PLINTH LEVEL Finished ground floor level (plinth level) of all buildings and pump houses shall be minimum 500 mm above the formation level/grade level.

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14.2 14.3 15.0 15.1
All cable vaults shall be located above ground level i.e. cable vaults shall not be provided as basements in the buildings. Finished floor levels of Boiler area / transformer area yard paving shall be kept 200 mm lower than the finished floor level of turbine building. STATUTORY REQUIREMENTS All the applicable statutory rules pertaining to Indian Factories act, Factory rules of state government, Fire safety rules of Tariff Advisory Committee, Water act of Pollution Control Boards, Explosives act etc. and stipulations of other relevant statutory authorities shall be taken into consideration at the time of design. Provisions of safety, health and welfare according to Factories act shall be complied with. These shall include provision of continuous walkway in general of at least 800 mm width (minimum 500 mm wide at column location) along crane-girder at crane girder level on both sides of the building, comfortable approach to EOT crane cabin, railings, fire escape, locker room for workmen, pantry, toilets, rest room etc. Adequate number of fire escapes shall be provided in a building. Fire proof doors, number of staircases, fire separation walls, lath plastering on structural steel member (in fire prone areas) shall be made according to the recommendation of TAC. For fire safety requirements of buildings IS: 1641 and IS: 1642 shall be followed in addition to TAC requirements. All masonry firewalls shall be minimum 345 mm thick and RCC firewall shall be minimum 200 mm thick. SETTLEMENT MEASUREMENTS Levelling bolts shall be installed by the contractor immediately after construction of foundation slabs and shall be protected by a suitable cover from damage. For the levelling bolts, the requirements of IS: 8009 are to be met. In all buildings and major foundations at least one levelling bolt shall be installed at 1.00 m above floor surface; for important parts of buildings however, a minimum of 4 levelling bolts shall be provided, depending upon the importance of the installations. The position and thus the total number of surveying points shall be decided by the Engineer in co-operation with the contractor, on the basis of the settlement report. The civil engineering contractor shall mark the position of all settlement bolts on his shuttering drawings and shall ensure that these surveying points are not built in as construction proceeds.
15.2
15.3
16.0

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In order to keep the number of points which are to be levelled to a minimum, settlement bolts shall be installed on a specific grid. For all measurements, the requirements of IS: 8009 are to be met. Measurements of all levelling bolts are to be executed:i) immediately after setting of the bolt ii) prior to the erection of mechanical equipment iii) several times during the erection period of the mechanical equipment iv) After completion of the buildings/structures and erection of all equipment once before the plant is handed over to the Employer. 17.0 TOLERANCES IN CONSTRUCTION WORKS The following tolerances for buildings and structures are binding: a) For setting-out and as-built measurements, the position must be within the following limits: i) Buildings ii) Pipes and channels iii) Underground lines, offshore structures b) For elevations, the following limits must be observed: i) ii) iii) iv) Floors : + 1 cm Concrete ducts : + 2 cm Underground lines, cables, offshore structures, etc : + 5 cm Drainage systems : In accordance with gradient : + 1 cm : + 2 cm : + 10 cm
c) Tolerances on concrete lines, shapes and dimensions of structures shall be as follows: i) Deviation from specified dimensions of cross-section of columns & beams : +12 mm : -6 mm
ii) Deviation from dimensions of footing: 1) Dimensions in plan : +50 mm - 12 mm
2) Eccentricity : 0.02 times the width of the footing in the direction of devia tion but not more than 50 mm

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3) Thickness : + 0.05 times the specified thickness. d) For settlement measurements: i) For each settlement measurement, the levelling instrument shall be checked by levelling from the centre and adjusting as required. The results shall be recorded in a Surveyors Field Book. ii) The so called base measurement shall in all cases be carried out twice completely independently. The base measurement shall not have any point obtained by an intermediate slighting. The closing error for all levelling operations shall not exceed 3 mm and the heights of the individual points obtained from 2 levelling operations shall not differ from each other by more than 2 mm after distribution of the errors. e) In the settlement measurements, one measurement is sufficient provided the following requirement is satisfied: i) check of the starting point ii) from the starting point, levelling out and back to the next settlement bolt, maximum difference 2 mm from the settlement bolt for which the height has been determined, a loop levelling (without intermediate sighting) back to the starting point, with a closing error of less than 3 mm. f) The values stated here are minimum requirements. In the case of structures which are especially sensitive to settlement or for built-in items of plant, tighter tolerances may be necessary.

SPEC.NO. TCE.6417A-H-500-001
1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA TECHNICAL SPECIFICATION PART B SECTION VI TECHNICAL REQUIREMENTS PART B LOADS AND LOAD COMBINATIONS
SHEET 69 of 267
1.0
GENERAL All structures shall be designed for the most critical combinations of dead loads, imposed loads, equipment loads, crane loads, steam piping (static & dynamic) and other piping loads, wind loads, seismic loads, temperature loads, forces developed due to differential settlement and any other loading conditions which can occur during the design life of the facility.
2.0 2.1
DEAD LOADS Dead loads consist of the weights of the complete structure with finishes, fixtures, partitions, wall panels and all equipment of semi-permanent nature including tanks, silos, bins, partitions, roofing, piping, cable trays, bus ducts etc. The content of tanks, silo, bins and hoppers etc. shall be measured at full capacity for this purpose. The piping loads, cable tray loads and the contents of the tanks, silos, bins and hoppers shall be listed separately so that they can be excluded from dead load when dead loads are acting as stabilising load for uplift, overturning and sliding. The following unit weight of material shall be considered for computation of loads. Loads given in IS: 875 (part-I) shall be made use of for material not listed below. Materials Plain cement concrete Reinforced cement concrete Structural steel Brick work Cement plaster Roof Treatment (7 course bituminous) Roof Treatment (9 course bituminous) Floor Finish Coal Fly Ash Bottom Ash : : : : : : : : : : : : Unit weight 2.40 t/cum 2.50 t/cum 7.85 t/cum 2.0 t/cum 2.1 t/cum 30 kg/sqm. 0.04 40 kg/sqm. 2.4 t/cum 1.20 t/cum 1.60 t/cum 1.60 t/cum
2.2
2.3

SPEC.NO. TCE.6417A-H-500-001
1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA TECHNICAL SPECIFICATION PART B
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3.0
3.1
IMPOSED LOADS Imposed loads in different areas shall include live loads, dust loads, minor equipment loads, cable trays, small pipe racks / hangers, erection loads, operation/ maintenance loads, etc. The loads considered shall not be less than that specified in IS: 875 (Part II). The loads listed hereunder are the minimum loads for the areas involved. Special use areas shall be investigated and loads revised upward as necessary. Floors and supporting members which may be subjected to heavy equipment live loads shall be designed on the basis of the weight of equipment or specifically defined live loads, whichever is greater. The specific minimum floor live loads are listed below
3.2
3.2.1
Roofs: a) Flat Accessible Roof
: 1.5 kN/sqm + 0.5KN/sqm (dust load) + Hung Loads, if any b) Flat Non-Accessible Roof : 0.75 kN/sqm + 0.5KN/sqm (dust load) + Hung Loads, if any c) Flat Accessible Roof with : 5.0 kN/sqm + 0.5KN/sqm (dust load) Equipment etc + Hung Loads, if any b) Sloped Roof : As per IS: 875 (Part II) 3.2.2 Turbine Building a) Ground Floor : General area 50 kN/ sqm : Unloading area 50 KN/sqm : 15kN/sqm plus hung loads : Rotor removal Area 30 kN/sqm plus hung loads. Rotor removal area beams shall also be checked for half the rotor load at the centre of the beam. : Equipment Lay- down Area 30kN/sqm plus hung loads. :Other areas in Turbine Hall 25 kN/sqm plus hung loads. : All other areas except Turbine Hall 15 kN/sqm plus hung loads. : 15 kN/sqm plus hung loads. : 7.5kN/sqm plus hung loads. : 10kN/sqm plus hung loads. : 12 kN/sqm : 20kN/sqm
b) Mezzanine Floors c) Operating Floor
d) Heater bay floor e) Cable spreader room f) Deaerator platform g) Precast conc. covers h) Feed water tank floor

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Equipment loads like heater load, valve loads, deareator loads etc shall be considered in addition to the above minimum loads. Hung loads if any shall also be considered over and above the loads indicated. 3.3 BOILER / BUNKER AREA a) Floor at (+/-) 0.00 : 25 kN/sq.m (under operation) or actual loads specified by Boiler manufacturer : 20 kN/sqm (Beams however shall be checked for feeder / tripper load /short supports load +10kN/sqm imposed load) : 5 kN/sq.m in addition to equipment load
b) Feeder / Tripper floor
c) Tripper house roof
Dust load and Hung loads if any shall also be considered over and above the loads indicated. 3.4 MAIN CONTROL ROOM/ ELECTRICAL BUILDINGS a) b) c) d) e) f) g) 3.5 Control Room Floor MCC Room Cable vault Floor Battery Rooms AHU, AC & ventilation plant floors Switchgear room PLCC, relay room : 15 kN/sqm : 15 kN/sqm : 7.5 kN/sqm : 15 kN/sqm : 15 kN/sqm : 15 KN/sqm : 15 KN/sqm
PUMP HOUSES Operating floor slab : 15 KN/sqm +equipment load or as required by equipment supplier whichever higher : 10 KN/sqm
3.6 3.7
WORKSHOP Other Areas a) RCC Floors
b) Stairs and Platforms c) Chequered plate/gratings d) Walkways e) Toilet rooms
: 5KN/sqm for offices, laboratories, conference rooms and general floors : 5 KN/sqm : 5 KN/sqm : 5 KN/sqm : 2 KN/sqm
ISSUE R0
TCE FORM 329 R5

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3.8 3.9
Design of roads shall be in accordance with Indian Road Congress standard IRC37. Railway supporting structures such as bridges, culverts etc. shall be designed as per Railway bridge rules. Road Culverts and allied structures including RCC pipes crossings and road crossing of trenches shall be designed for Class A loading and checked for Class A loading as per IRC standards for two lane road and above. Covers for trenches & channels, which are not exposed to vehicular traffic, shall be designed for live load of adjoining area or 2t/sqm whichever is higher. Where channels are likely to be exposed to vehicular traffic, the requirements of code of practice for road bridges shall be adhered to. Piping anchor and restraint forces of major piping shall be obtained from piping analysis results and shall be considered as additional live load in the structure design. In addition to the live loads, a minimum of 2.50 kN/sqm shall be considered as Hung loads for electrical, ventilation & air conditioning. Load of 1.0 kN/sqm shall be considered as Hung loads for piping unless otherwise mentioned. Live load reduction shall be in accordance with the provisions of IS: 1893 in case of seismic analysis. Foundations and fixing arrangements for items of equipment, which generates vibration, will be designed to prevent transfer of such vibrations to the adjoining structures. EARTH PRESSURE LOADS Earth pressure for all underground structures shall be calculated using coefficients of earth pressure at rest, coefficient of active or passive earth pressure (whichever is applicable). However, for design of substructure of pump house, cold water basin of cooling tower, underground liquid storage tanks and Coal Handling System substructures earth pressure at rest shall be considered in the design. In addition to earth pressure and ground water pressure, etc. a minimum surcharge load of 2.0 t/sqm shall also be considered for the design of all underground structures including channels, sumps, cable and pipe trenches, etc. to take into account the vehicular traffic in the vicinity of the structure. WIND LOAD
3.10
3.11
3.12
3.13
3.14
3.15
4.0 4.1
4.2
5.0

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5.1
Wind load on structures shall be calculated as per provisions of IS: 875 (part 3). The wind shall be assumed to blow in any direction and most unfavourable condition shall be considered for design. Basic wind speed shall be 47m/sec. Risk coefficient (K1) as 1.07 and Terrain category 2 shall be considered for all structures. In design of structures, wind force on equipments supported on frame including all fixtures, piping, staircases, ladders, handrails, etc. shall also be considered. SEISMIC LOADS Criteria for design shall be as governed by Part-1 and part-4 of IS: 1893. All the structures fall under category 2 and 3 as per Table-5 of IS: 1893 Part4,and the project is located in seismic Zone IV. Importance factor for all structures shall be taken as per IS : 1893 Part-4. Seismic analysis shall be carried out by Response Spectrum Method and Base shear to be increased if Base shear is more than static method of analysis. TEMPERATURE LOAD Expansion and contraction due to changes of temperatures of materials of a structure shall be considered and adequate provisions shall be made for the effects produced (as per provision in relevant IS codes). Suitable expansion joints shall be provided in the longitudinal direction wherever necessary with provision of twin columns. The maximum distance of the expansion joint shall be as per the provisions of IS: 800 and IS: 456 for steel and concrete structures respectively. Analysis shall be carried out for ambient temperature variation. The temperature variation shall be considered as 2/3 of average maximum annual variation in temperature. The average maximum annual variation in temperature for this purpose shall be taken as the difference between the mean of the daily minimum temperature during the coldest month of the year and mean of daily maximum temperature during the hottest month of the year. The structure shall be designed to withstand thermal stresses due to 50% of the temperature variation. Coefficient of thermal expansion of steel shall be taken as per IS: 800. Coefficient for thermal expansion for concrete shall be taken as per IS: 456 EQUIPMENT LOADS Static and dynamic loads of major equipments such as deaerator, heaters, etc. shall be based on the manufacturers data of the specified equipments and shall be considered in design in addition to the live load. However,
5.2
6.0 6.1 6.2
6.3 6.4
7.0 7.1
7.2
7.3 8.0 8.1
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where the uniform floor live load adequately accounts for the equipment moving weight, the weight of such equipment as a dead load shall not be considered e.g. switchgear and control room floors are usually designed for a live load that includes the equipment weight. 8.2 All equipments, tanks and piping design loading shall include hydraulic test loading. Weight of equipments, ducts, tanks, pipes, conduits, etc. supported by structure shall include maximum possible loading conditions i.e. flooded conditions and associated impacts, test loading, anchorages and constraint effects. Air and gas duct loads shall include weight of insulation, duct attachments, dust accumulation loads, seismic, wind and other loads applicable.
8.3
9.0 9.1
CRANE, MONORAIL & ELEVATOR LOADS Crane girders and supporting columns shall be designed for vertical and horizontal forces (including impact forces) as per crane vendors data. All lifting beams and monorails shall have their design loads increased for impact factor as mentioned hereinafter. IMPACT FACTOR Loads for cranes, hoists and elevators shall be taken as per IS: 875. The minimum impact factor to be used in design shall be as follows:
9.2
9.2.1
Crane Loads a) For vertical force, an impact factor of 25% of the maximum crane wheel load. A lateral crane surge of 10% of the weight of the trolley plus lifted load applied at the top of each rail divided in proportion to the relative lateral stiffness of the rail support system. A horizontal surge of 5% of the maximum static wheel loads of the crane applied at the top of the rail in the longitudinal direction.
b)
c)
9.2.2
Monorail Loads a) Impact factor of 10% of lifted load of hoist for monorail and support design b) Impact factor of 25% of the lifted load for electrical pulley and support design.
9.2.3
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100% of the lifted load including elevator live load plus the cab weight for the elevator support beams. 9.2.4 10.0 10.1 Pedestals supporting gravity take ups for conveyors and pedestals in elevator pits shall be designed assuming 100% impact factor. OTHER LOADS Stresses imparted to structures due to differential settlements, variation of water table, erection and maintenance loads, creep and shrinkage shall also be considered in design of all structures. In order to allow for unusual loading during steel member erection or during the construction period, all beams on major column lines acting as column struts or ties shall be designed to withstand an axial force of 45t in combination with the dead load of the beam. End connections on these beams are designed to transfer its axial load. Minimum of 12mm thick connection angle shall be provided unless thicker angles are required by design. Roof girders / trusses in the service / maintenance bay of Turbine building shall be designed for crane erection loads. Columns in turbine building near transformer yard shall also be designed to support tension due to strung conductors and shield wire, if the conductors are connected to the Turbine building columns. All structures situated in the vicinity of railway lines shall be designed conforming to the Indian Railway Standard Specification. BASIC LOAD CASES The following basic load cases shall be considered for the analysis: i) ii) iii) iv) v) vi) vii) Dead load Self Weight of permanent equipment Live load on floor/walkway Live load on roof Crane load with lift Crane load without lift Wind load : : : : : : : : : : : D EL L LR CR1 CR2 WL SL SP SCL HP
10.2
10.3
10.4
10.5
11.0
viii) Seismic load ix) x) xi) Load due to soil pressure Load due to surcharge Load due to hydrostatic pressure

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xii)
Load due to temperature
: :
TL SPL
xiii) Special loads
12.0
12.1
LOAD COMBINATIONS The individual members of the frame shall be designed for worst combination of forces such as bending moment, axial force, shear force and torsion. Permissible stresses for different load combinations shall be taken as per IS: 875 (Part-V) and other relevant IS codes. Wind and seismic forces shall not be considered to act simultaneously. Criticality of erection / maintenance loads shall also be checked separately in combination with other simultaneously occurring loads for possible design loading. For design of main plant structures during seismic conditions, the deareator feed water tank shall be considered full, up to operating level. However for other load combinations flooded condition shall be assumed. Lifted load of crane shall not be considered during seismic condition. In case more than one crane is provided and Tandem operation is not envisaged, the load shall be taken as one crane fully loaded and second crane without lifted load but standing idle adjacent to first crane. 50% of lifted load shall be considered during Wind load condition. LOAD COMBINATIONS FOR UNDERGROUND STRUCTURES Following loading conditions shall be considered in addition to the loading from super structure for the design of sub structure of pump house, channels, sumps, tanks, reservoirs, trenches and other underground structures.
12.2
12.3
12.4 12.5
12.6 13.0
13.1
Only liquid pressure from inside and no earth pressure and ground water pressure and surcharge pressure from outside (applicable only to the structures which are liable to be filled with water or any other liquid). Earth pressure, surcharge pressure and ground water pressure from outside and no water pressure from inside. Base slab of the pump house shall be designed for the condition of different combinations of pump sumps being empty during maintenance stages with maximum ground water table. Intermediate dividing piers of pump sumps and partition walls in channel shall be designed considering water on one side only and the other side being empty for maintenance.
13.2
13.3

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13.4
Design shall also be checked against buoyancy due to ground water during construction and operation stage. Minimum factor of safety as per IS: 3370 against buoyancy shall be ensured considering empty condition ignoring superimposed loads. Ground water table shall be considered at finished ground level for design. SPECIAL STRUCTURES For the following structures additional loading criteria as mentioned below in addition to the criteria discussed above: COAL BUNKERS
14.0
14.1
14.1.1 The following densities shall be considered for design of coal bunkers a) For volume calculations : 800 kg/cum b) For structural design : 1200 kg/cum 14.1.2 The coal bunker shall be designed as per criteria outlined in IS: 9178 (Part I&II). 14.2 ASH SILOS
14.2.1 The following densities shall be considered for the design of concrete ash silos a) b) c) For volume calculation of bottom ash silo For volume calculation of fly ash silo For load calculation of both types of silos : 650 kg/cum : 750 kg/cum : 1600 kg/cum
14.2.2 The concrete ash silo shall be designed generally as per the criteria laid down in IS: 4995 (Part I & II). The static pressure calculated at rest shall be multiplied by an over pressure factor of 1.35 for the top 1/3 rd portion and by a factor of 1.75 for the bottom 2/3 rd portion. Special attention shall be given in assessing the effect of hot temperature of ash on the concrete wall. Temperature of ash shall be taken as 1500C 14.3 SWITCHYARD STRUCTURES
14.3.1 The loading for the design of switchyard structures shall be as per IS: 802 Part 1/Sec 1: Following loads shall be considered a) Dead load due to equipment and structure. b) Wind load on towers, conductors, ground wires and insulator strings calculated as per Clause 8 and 9 of IS: 802. c) Temperature effects consisting of effect of temperature variation and sag tension as per clause 10 of IS: 802. d) Climatic loads as per clause 11.2 of IS: 802. e) Anti cascading loads as per clause 11.3.1 of IS: 802.

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f) Torsional and longitudinal loads caused by breakage of conductor as per clause 11.3.2 and 16 of IS: 802. g) Construction and maintenance loads h) Seismic loads as per IS: 1893. i) Short circuit forces including snap effect in the case of bundled conductors. 14.3.2 Switchyard structure shall be designed for the worst combination of above loads. The factor of safety for design of members shall be considered as 2 for normal & broken wire conditions and 1.5 for combined short circuit and broken wire conditions. Short circuit forces and wind forces shall not be considered simultaneously. 14.3.3 Foundation shall be designed for a factor of safety 2.2 for normal and broken wire condition and 1.65 for combined short circuit and broken wire conditions. Design of foundation shall be carried out as per IS: 4091. 14.4 COAL HANDLING SYSTEM In addition to the loads specified elsewhere, following additional loads shall be considered for design of various structures. a) Flat roof - accessible - non accessible b) c) Inclined roof Building floors : 1.5kN/sqm IL + 1kN/sqm dust load : 0.75kN/sqm + 1kN/sqm dust load : As per IS 875 +0.50KN/sqm dust load : 5kN/sqm IL or equipment load whichever is higher +1kN/sqm spillage load (Equipment and IL need not be considered at the same location) : 5Kn/sqm+spillage load of 1.0 Kn/sqm : 10 kN/sqm : 5kN/sqm
d) e) f)
Walk ways of conveyor galleries MCC floors Service platform, cross over, maintenance platforms Grating in wagon tippler
g)
: 1m high coal and load due to Dozer movement (min 35T)
h)
Dynamic factor for belt, material on belt, idlers and other mov-
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ing/rotating parts
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i)
Spillage load i) ii) Gallery walk way Seal plate : 1kN/sqm : 1kN/sqm : 1.50
j)
Impact factor for drive machines
14.5
BOILER / ESP SUPPORTING STRUCTURES
14.5.1 The supporting structure shall be designed for the following: i) ii) iii) Live / imposed loads. Dead loads. Static and dynamic loads of piping, movable equipment and maintenance parts. iv) Cantilever loads of not less than 20 kN/metre at a distance of 1200 mm from the external face of the columns, on both sides of the ESP, for cable trays and walkways. v) Cantilever loads of not less than 5 kN/metre at a distance of 1200 mm from the external face of the columns, on both sides of the boiler, for cable trays and walkways. vi) Dry ash piping supported from the main columns of ESP structure. vii) Ash water piping supported on the outermost row of boiler column. viii) All ESP hoppers filled up with ash up to the top of the hoppers or the bottom of the electrodes (whichever is more) using a bulk density of not less than 1350 kg/cum for the ash, along with additional ash buildup from the end of the third field up to the inlet duct bottom level at a natural repose angle (not less than 30 degree to horizontal in any case). ix) Seismic or wind loads as specified elsewhere in the specification. x) Temperature variation of +/- 250 C for atmospheric temperature variations. xi) Temperature variations under ESP operating condition. xii) The loads listed above indicate the minimum requirements. 14.5.2 Boiler supporting structures shall be so configured that the temperature of steel does not exceed 600 C unless specified otherwise. Brackets shall be provided on both sides of the outermost row of columns of both the boiler and ESP for supporting cable trays and walkways at a height not exceeding 10 m. The exact levels shall however be decided during detail engineering.
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Each ESP hopper shall be supported at four corners by providing four columns from the ground. 14.5.3 Dry ash transportation pipes and supply air pipes shall be supported on the structural members of the ESP. 14.5.4 The bracings in the boiler structure shall be provided such that under no circumstance normal/convenient access to all points in the boiler is blocked or obstructed. 14.5.5 The ESP hopper outlet flanges shall be terminated at a height of 3.5 m above ground level. 14.5.6 Boiler and ESP supporting structures shall be checked for differential settlement of foundations, which shall be restricted to 1 in 1000 of span or 8 mm whichever is less. 14.5.7 In design of boiler / ESP supporting structures dynamic piping loads need not be considered acting simultaneously with wind or seismic loads. Increase in permissible stresses shall be allowed in load combinations where dynamic piping loads are considered and shall be as permitted under seismic load conditions. Design Criteria for foundations and some other facilities / areas are covered separately in this specification.
14.5.8
14.6
R.C.C CHIMNEY Refer section H
14.7
NATURAL DRAFT COOLING TOWERS Refer section G

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PART C - REINFORCED CONCRETE STRUCTURES AND FOUNDATIONS

1.0 GENERAL All structures, building foundations, machines / equipment foundation, water retaining structures, trenches, pits, etc. shall be designed as per latest relevant IS codes in general. Construction in general shall follow provisions of IS: 456 and IS: 3370 for normal and water retaining structures. 2.0 2.1 2.1.1 DESIGN METHODOLOGY GENERAL All designs of RCC structures shall be carried out by limit state method as per IS: 456 unless use of working stress method is specifically mentioned. Design strength of materials and design loads shall be calculated using appropriate partial safety factors over characteristic strength and characteristic loads as per IS: 456. RCC silos shall be designed as per IS: 4995 (Part 1 & 2). IS: 11384 shall be followed for design of steel concrete composite beam. For reinforcement detailing IS: 13920 and SP: 34 shall be followed. The walls shall be provided with reinforcement on both faces for sections 150 mm or more, even if not required from design consideration. FOUNDATION AND UNDERGROUND STRUCTURES General
2.1.2
2.1.3 2.1.4
2.2 2.2.1
2.2.1.1 Type of foundation system, i.e. isolated, strip, raft or pile shall be decided based on the loading arrangement, load intensity and soil strata. Design of foundations at various levels shall be dependent upon the soil bearing capacity and settlement at that level. 2.2.1.2 Foundation system adopted shall ensure that settlement / relative settlement is as per provision of IS: 1904 and other Indian Standards. However, the settlement shall be restricted to a lower value, if necessary as per the system requirement. 2.2.1.3 All foundation including machine / equipment foundations shall be of RCC construction. All foundations shall be designed in accordance with relevant parts of the latest revisions of Indian standards IS: 2974 and IS: 456. Raft foundations shall be designed as per IS: 2950.

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2.2.1.4 For design of underground structures, subsoil water level shall be assumed at finished grade level (FGL) unless a more stringent value is indicated in soil report. Effects of uplift and reduction in bearing capacity due to underground water table shall also be considered. *2.2.2 Void *2.2.3 Void *2.2.4 Foundation system shall be decided based on the recommendation in the detail geo technical investigation to be conducted by the Bidder and as approved by the OWNER. *2.2.5 Void 2.2.6 Liquid Retaining Structures
2.2.6.1 RCC water retaining structure like storage tanks, reservoirs, cooling tower basin, etc. shall be leak proof and designed as un-cracked section in accordance with IS:3370 (Part 1 to IV) by working stress method. 2.2.6.2 Water channels, Forebays and substructure of pump houses shall be designed as cracked section with steel stresses as per IS: 3370 (Part 1 to IV) by working stress method and limiting crack width to 0.1mm. 2.2.6.3 All water retaining / storage structures shall be designed assuming liquid up to the height of wall irrespective of provision of any over flow arrangement. No pressure relieving devices shall be permitted in underground structures. 2.2.6.4 In all liquid retaining structures, PVC water bar shall be provided at each construction / expansion joint. The sequence of construction shall also be specified on drawings showing construction joints. All structures shall be tested for water tightness as per the provisions of IS: 3370 and IS: 6494. 2.2.7 Coal handling system substructures
2.2.7.1 Wagon Tippler pit, Reclaim Hopper pit, Tunnel, Underground Transfer houses shall be designed by limit state method as per stipulations of IS: 456 with limited crack width of 0.2 mm. 2.2.8 Pile Foundations
2.2.8.1 In case piles are adopted, following shall be adhered to: a) The pile foundations shall be RCC bored cast-in-situ piles and piling shall be as per IS: 2911 (relevant part). Boring shall be done by using conventional or rotary hydraulic rig. Flushing of pile bore shall be enISSUE R0 TCE FORM 329 R5

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sured by air lift technique duly approved by OWNER. The construction methodology to be adopted shall be suitable to ensure proper termination of pile in the strata and to ensure pile bore free from spoils. b) c) Only RCC piles shall be provided. Diameters of pile shall be 450mm, 600 mm,,750mm and 1000mm. The allowable load capacity of the 450mm, 600 mm and 750mm diameter piles in vertical compression shall be limited to 65T, 125T,185T and 350T respectively. The uplift and lateral load capacities shall be restricted to 20% and 5% respectively of the allowable load capacity in vertical compression. Minimum shaft length is envisaged as 22m from pile cut off level. However, the pile capacities to be adopted shall be the least of the estimated design values based on geotechnical investigation report and that obtained from the pile load tests. The allowable load capacity in no case shall exceed the values as specified in below table. For piles of dia. 600mm and above pile cut-off level shall generally be 4.5m to 6.5m below FFL of TG building. For piles of dia. 450mm, pile cut-off level shall be 2.5m to 3.0m below FFL of TG building. Dia. of pile (in mm) 450 600 750 1000 Allowable capacity ( in MT) Vertical Uplift Lateral compression shear 65 13 3.25 125 25 6.25 185 37 9.25 350 70 17.5 Pile cut-off level below FFL (in m) 2.5 3.0 4.5 6.5 Do Do Minimum shaft length (in m) 22 22 22 22
d)
Only vertical piles shall be used.
e)
CONTRACTOR shall furnish the design of piles (in terms of rated ca-
pacity, length, diameter, termination strata and criterion to locate the founding level for construction of pile, reinforcement for job as well as test piles etc.), construction methodology/ specifications for construction of piles and scheme and locations of initial pile load tests in vertical, lateral and uplift, and the details of equipment for OWNERs approval. f) Regular QA checks for density of circulation mud, contaminated mud and samples from pile bore bottom, slump of concrete, pile concrete integrity test on all piles etc. shall be done by the CONTRACTOR. Pile Load Tests
g)

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CONTRACTOR shall install all types of piles for initial pile load test.
Minimum number of initial load tests to be performed for each diameter and rated capacity of pile shall be as under: i) Vertical (Compression) 2 ii) Lateral (Horizontal) 2 iii) Uplift (Tension) 1 The initial pile load test shall be conducted with test load up to two times the estimated pile capacity. In case of compression test, the method of loading shall by cyclic as per IS: 2911 (relevant part). Contractor shall ensure that all the measuring equipment and instruments are properly calibrated at a reputed laboratory / institute prior to their use. Settlement / movement of the pile top shall be made by Linear Variable Differential Transducers (LVDT) or dial gauge having a least count of 0.01mm. Safe load interpretation from pile load test shall be as per IS: 2911 (Part-IV). Number of routine pile load tests to be performed for each diameter/ allowable capacity of pile shall be as under. i) Vertical - 0.5% of the total number of piles provided subject to a minimum of one. ii) Lateral - 0.25% of the total number of piles provided subject to a minimum of one. The routine test on piles shall be conducted up to test load of one and half times the allowable pile capacity by direct loading method. The test load on initial test piles shall be applied by means of reaction from kentledge. i) A report on the pile load tests shall be submitted for OWNERs approval. In case, routine pile load test shows that the pile has not achieved the desired capacity or pile (s) have been rejected due to any other reason, then contractor shall install additional pile (s) as required and accordingly, pile cap design should be reviewed and modified if required at no extra cost to the owner. Low Strain Pile Integrity test shall be conducted on all test piles and selected job piles. This test shall be used to identify the routine load test and not intended to replace the use of static load test. This test is limited to assess the imperfection of the pile shaft and shall be undertaken by an independent specialist agency. The test equipment shall be of TNO or PDI make or equivalent. The process shall conform to ASTM and it shall be pulse eco method. k) Minimum dia. of main reinforcement shall be 16mm. 2.2.8.2 Other Requirements i) Cement type - As specified elsewhere in the specification.
j)

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ii)
Concrete grade - Minimum grade of concrete shall be as specified elsewhere. Concrete shall be dense and durable. Minimum cement content for piles shall be 400 kg/cum of concrete. Reinforcement steel type - As specified elsewhere. Cover to reinforcement - As per IS: 456, subject to minimum of 50 mm for foundation. For excavations comprehensive dewatering arrangement shall be provided to maintain the foundation pits dry during the construction period. Backfilling, around foundations and bottom of pipes, thrust blocks, etc. shall be compacted to 95% standard proctor density for cohesive soil and to 75% of relative density for non-cohesive soils.
iii) iv) v) vi)
vii)
2.3
MACHINE FOUNDATIONS The design of machine / equipment foundation shall be as per IS: 456 and IS: 2974. The provisions of DIN 4024 shall also be followed for machine foundations.
2.3.1
All machine / equipment foundations and structures subject to vibrations shall be suitably proportioned so that amplitude and frequency of the foundation / structures are within permissible limits. All block foundations resting on soil shall be designed using the elastic half space theory/ Barkans method. All block foundations resting on pile, Novaks formulation to compute the dynamic stiffness of soil-pile system shall be adopted (Refer: Design of structures and foundations for vibrating Machines by Arya.S., ONeill.M., Pincus.G). The mass of the RCC block shall not be less than three times mass of the machine. Dynamic analysis shall be carried out to calculate natural frequencies in all modes including coupled modes and to calculate vibration amplitudes. Frequency and amplitude criteria as laid down by the relevant codes or machine manufacturers shall be satisfied. Minimum reinforcement shall be governed by IS: 2974 and IS: 456. For the foundations supporting minor equipment weighing less than one ton or if the mass of the rotating parts is less than one hundredth of the mass of the foundation, no dynamic analysis is necessary. However, if such minor equipment is to be supported on building structures, floors, etc. suitable vibration isolation shall be provided by means of springs, neoprene pads, etc. and such vibration isolation system shall be designed suitably. Where so stipulated in the mechanical section of this specification, foundations for equipment such as, Steam turbine generators, Boilers Feed Pumps, FD Fans, ID Fans, PA fans, Crushers, Vibratory screens and Mills shall be supported on vibration isolation system. The vibration isolation sysISSUE R0 TCE FORM 329 R5
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2.3.3
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tem shall consist of helical spring units and viscous dampers supporting the RCC inertia block which support the machine. The spring units shall conform to DIN 2089 and DIN 2096. 2.3.5 2.3.6 Void. All dynamic foundations shall be separated from adjoining part of building and other foundations. A clear gap of 50 mm shall be provided all round the foundation deck from the adjoining floor slab of the building. Joints at Ground floor / slab shall be suitably sealed with PJF and joint sealing compound. All appendages to such foundations shall be reinforced suitable to ensure integral action. Special foundation should be provided for rotating equipment. INCREASE IN STRESSES Where stresses due to wind (or seismic) and temperature are combined with those due to other loads, the allowable stresses in concrete and reinforcement steel shall be increased by 33.33% in case of working stress design. Bearing capacity of the soil/ pile shall be allowed to be increased by 25 % under seismic/ wind load condition except in case of wind dominated structures. STABILITY OF STRUCTURES Design shall be checked against buoyancy due to the ground water during construction and maintenance stages for structures like underground storage tanks, pits, trenches, basements, etc. Minimum factor of safety of 1.2 against buoyancy shall be ensured considering empty condition inside and ignoring the superimposed loading. For purpose of calculating downward load due to any overburden, only the mass located vertically above the projected area of the base slab shall be taken in to consideration. All building sub-structures including pump houses shall be checked for sliding and overturning stability during both construction and operating conditions for various combination of loads. Factor of safety for these cases shall be taken as mentioned in IS: 456 and other latest relevant IS codes. However following minimum factor of safety shall be followed: a) b) c) Factor of safety against overturning due to wind, seismic or other lateral load shall be 1.5 minimum Factor of safety against sliding shall be 1.5 minimum Factor of safety against uplift due to hydrostatic forces shall be 1.2 and due to any other loads shall be 1.5.
2.4 2.4.1
2.4.2
3.0 3.1
3.2

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3.3
3.4
Stability of the structure shall also be investigated for loading conditions during construction, repair or other temporary measures. Lower factor of safety may be used for such loading conditions as per relevant IS codes. In cases where dead load provides the restoring force, only 0.90 times characteristic dead load shall be considered. Imposed loads shall not be considered as restoring force. MINIMUM THICKNESS OF CONCRETE STRUCTURAL ELEMENTS The following minimum thickness shall be followed: a) b) c) d) e) f) g) h) i) j) k) l) m) o) Walkways /canopy slabs, etc. Suspended floor / slab /Ground floor slab (non-suspended) Water Retaining slabs / walls Cable/pipe trenches/underground pits/ Launder walls and base slab All footings (including raft foundations) Parapets Sunshades Precast louvers / fins Precast trench cover slabs / floor slabs / louvers RCC paving Pile cap Basement walls and base slab Silo / bin walls Underground reservoir Below ground water table Above ground water table : : : : 125mm 150mm 200mm 125mm
4.0 4.1
: 300mm : 125mm : 75mm at edge : 50mm : 75mm : 150mm : 500mm : 200mm : 150mm : : 200mm 150mm
4.3
From fire resistance point of view minimum thickness of reinforced concrete members shall be as per fig.1 /or Table 16A of IS: 456. R.C.C grade slab of grade M25, minimum 150 mm thick with minimum reinforcement of 10 dia HYSD bars 200 c/c both ways at top and bottom shall be provided. MINIMUM HEIGHTS FOR PEDESTALS OF STEEL COLUMNS Pedestals to Steel Columns for building structures: Top of RCC foundations (pedestals) shall normally be kept at a lower level so that the column base plates together with gussets and stiffeners remain below finished floor level (FFL) unless specified otherwise. Foundation levISSUE R0 TCE FORM 329 R5
4.4
5.0 5.1

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els for columns shall be decided to accommodate underground services, pits, trenches, etc. 5.2 Stair and ladder pedestal shall be kept 200 mm above the finished floor level. Pedestals to Steel Columns for Equipment structures: Top of RCC pedestals shall be kept above FFL as stated below; a) Equipment in open area : as required (300mm min) b) Equipment in covered area : as required (150mm min) c) Structures and equipment : as per vendors data subject to supplied by vendor minimum as specified above. MINIMUM HEIGHTS FOR ENCASEMENT OF STEEL COLUMNS In case the top of pedestal is kept at a lower level so that the column base plate together with gussets and stiffeners remain below finished floor level (FFL) the column bases as well as the column sections shall be encased in concrete above FFL as per following: a) b) 7.0 7.1 Open area : 300mm above paved level Covered area : 150mm above FFL
5.2.1
6.0
CONCRETE MIX Ordinary Portland cement 43/53 grade conforming to IS: 8112 and, IS: 12269 shall be used for all structural work and special structure and for foundation. Portland pozzolana cement conforming to (IS: 1489, part-1) shall be used for plastering work, fill concrete and PCC. Sulphate resistant cement, conforming to IS-12330, shall be used in concrete mixes when concrete is exposed to aggressive soil/water conditions. Cement manufacturer shall be approved by the Owner.
7.2
The minimum concrete grade for different structures shall be as follows. M7.5 M10 M15 M20 : : : : Fill concrete Blinding layer below foundations, trenches and underground structures. Pavement around buildings including plinth protection work, damp proof course below brick masonry work etc. Base plate encasement, encasement of structural steel work, block area paving, screed concrete, Drains, Manholes, Trench/ Pit cover slabs, grade slab etc. Super structure and foundations, Piles & pile caps, precast covers.
M25

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M30 M35
: :
Water retaining structures, Chimney shell, Cooling tower and substructure of spring supported machine foundation Major dynamic foundations like TG foundations, mills, and BFP and fan foundations.
Minimum cement content, maximum water cement ratio for different exposures shall be as per Table 5 and 6 of IS: 456. For structures below ground level which are exposed to sulphate attack, requirement of cement shall be as per Table 4 of IS: 456. 7.4 Inter mixing of different grade of concrete in the same structure shall not be allowed normally. However in the case of structures like RCC chimney, natural draft cooling towers, etc. different mix will be permitted at different levels. REINFORCEMENTS Reinforcement bars shall be as per the following: High Yield Strength Deformed bars of minimum grade Fe 500 conforming to IS: 1786 either of SAIL, TATA STEEL, and RINL. Mild steel bars conforming to : Grade I of IS: 432 of either of SAIL, TATA STEEL, and RINL Welded wire fabric conforming to IS: 1566 Hard drawn steel wire shall conform to grade-1 of IS: 432(part-2) Binding wire for general use shall be 1.6 mm dia galvanized annealed wire. All reinforcement shall be clean, free from pitting, oil, grease, paint, loose mill scales, rust, dirty, dust, or any other substance that will destroy or re duce bond. 8.2 Intermixing of different grades of rebars of different material composition in same structure shall not be allowed. GROUTING Ordinary grout shall be provided for miscellaneous structure base plates viz. operating platforms (not supporting equipment), pipe supports up to 2.5 m height (above concrete top), cross-over, staircases and ladders. The proportions of grout shall be such as to produce a flowable mixture consistent with minimum water content and shrinkage. Based on requirement for obtaining non-shrink grout, aluminium powder may be used as an
7.3
8.0 8.1
9.0 9.1

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admixture. The grout proportions shall be limited as follows:Use Fluid mix General Grout thickness Under 25 mm Mix proportions W/C ratio 0.44 0.53
One part Portland cement to one part of sand 25 mm and over One part Portland cement but less than to 2 parts of sand 50mm
a) Sand shall be such as to produce a flowable grout without any tendency to segregate. b) Sand for general grouting purposes, shall be graded within the following limits:i) Passing IS 2.36 mm sieve : 95 to 100% ii) Passing IS 1.18 mm sieve : 65 to 95% iii) Passing IS 300 micron sieve : 10 to 30% iv) Passing IS 150 micron sieve : 3 to 10% c) Sand for fluid grouts, shall have the fine material passing the 300 and 150 micron sieves at the upper limits specified above. a) Surfaces to be grouted shall be thoroughly roughened and cleaned of all foreign matter and laitance. b) Anchor bolts, anchor bolt holes and the bottom of equipment and column base plates shall be cleaned of all oil, grease, dirt and loose material. The use of hot, strong caustic solution for this purpose will be permitted. a) Prior to grouting, the hardened concrete surfaces to be grouted shall be saturated with water. b) Water in anchor bolt holes shall be removed before grouting is started. Forms around base plates shall be reasonably tight to prevent leakage of the grout. Adequate clearance shall be provided between forms and base plate to permit grout to be worked properly into place. Grouting, once started, shall be done quickly and continuously to prevent segregation, bleeding and breakdown of initial set. Grout shall be worked from one side of one end to the other to prevent entrapment of air. To distribute the grout and to ensure more complete contact between base plate and foundation and to help release entrapped air link chains can be used to work the grout into place. Grouting through holes in base plates shall be by pressure grouting. 9.2 NON-SHRINKING GROUTING FOR COLUMN BASES Special grout shall be provided in strict accordance with the manufacturers instructions/specifications. Pre-mixed Grout Conbextra GP-2 of FOSROC make or equivalent of crushing strength 650 kg/cm for major equipment foundations and Conbextra GP-1 having crushing strength of 450 kg/cm for other foundations where concrete grade M25 or higher is provided. Forms and shims used to obtain adequate clearance shall not be removed and the anchor bolts shall not be tightened for at least three days after placISSUE R0 TCE FORM 329 R5

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ing the grout. After the removal of forms and shims, area occupied by shims shall be filled and the area between the base and edge of the foundation shall be finished smooth to allow drainage away from the base. Attachment of interconnecting piping of machinery and complete load transfer of machinery shall not be done before the bolts are tightened. During this period, grouting work shall be properly cured using rags/gunny bags. In view of extremely small proportion (about 0.01% by weight of cement) of the aluminium powder required, it is necessary to take all precautions to ensure thorough mixing. It is advisable to mix the blend of aluminium powder thoroughly with sand and cement before water is added because aluminium powder has a tendency to float on water. 9.3 Proprietary material of approved manufacture used as an admixture to obtain non-shrinking grout shall be mixed in the proportion of 1:1:1 (1 cement : 1 admixture : 1 sand), or as per manufacturers instructions. Pre -mixed nonshrinking grout shall be used all as per manufacturers instructions and without any additional materials/admixtures such as cement, sand and aggregates etc.Nominal thickness of grouting shall be at least 50mm for building columns and pedestals of major equipment. For secondary posts, stair and ladder base, etc. grouting shall not be less than 25mm thick. MINIMUM COVER TO FOUNDATION BOLTS Minimum distance from the centre line of foundation / anchor bolt to edge of pedestal shall be the maximum of the following: a) Clear distance from the edge of base plate / base frames to the outer edge of the pedestal shall be minimum 50mm. b) Clear distance from the face of pocket to the outer edge of pedestal shall be 75mm. c) Clear distance from the edge of sleeve or anchor plate to the edge of pedestal shall be 75mm.
10.
11.0
11.1
MISCELLANEOUS REQUIREMENT Fillets at the junction of roof and vertical walls shall be provided with cast in situ cement concrete 1:2:4 (nominal mix) followed by 12mm thick 1:4 cement mortar. A screed layer not less than 100 mm thick of cast in situ concrete of nominal mix 1:3:6 shall be provided below all water retaining structures. A sliding layer of craft paper or bitumen paper shall be provided over the screed layer to destroy the bond between screed and base slab. All underground structures such as conveyor tunnels, wagon tippler pits, reclaim hopper pits, slurry pump house, etc. shall be designed as leak proof structure. In case of leakage in the above structures injection grouting
11.2
11.3

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method shall be applied to repair the structure according to the requirement of IS: 6494. 11.4 For switchyard foundations anchor bolt with mechanical anchorage shall be provided along with foundation concrete. Bolts in pocket shall not be adopted. Foundation for all switchyard towers shall be designed on per IS: 4091. Contact between foundation and the soil strata shall be ensured for all conditions and combinations of loading. Plywood formwork shall be used for all water retaining / conveying structures and for all over ground concrete works. For other areas steel / plywood formwork shall be used. Unless specified 20 mm and downgraded aggregates shall be used for all structural concrete works. However 40 mm and downgraded aggregates may also be used under special conditions for foundation. Tolerance for formed and concrete dimension shall be as per IS: 456. Dewatering during construction This division applies to the methods and techniques of ground water control. Prior to the decision for the method and technique to be applied, a comprehensive knowledge of the soil and ground water conditions have to be obtained from the results of the soil investigation and/or information given in writing by the Engineer. All costs for the ground water control for keeping the construction pits dry shall be included in the relevant excavation items of the lump sum except otherwise indicated. The method and technique shall be based on the IS: 3764. The scope and supply includes the installation of all equipment, plants, pipes, machinery, etc and its removal after completion including operation & maintenance of the equipment during the construction period. Where necessary, cofferdams, sheet piles, pump sumps, equipment and channels, troughs, inlet gutters, pipes and any other works required for the water control and discharge shall be considered. The dewatering system shall be designed and installed in such a way that all alternations and extensions can be made at any time throughout the operating time, if necessary. Reserve units shall be kept ready for service when failure of any of the installed units occurs. The contractor has to consider the possibility of a temporary failure of any pump, diesel engine and/or the electric power service and shall install emergency power units with sufficient capacity to feed the necessary power to be installed unit at the moment of failure. The contractor shall submit to the Engineer, the detailed method of the envisaged pumping system for dewatering, the pump capacity and the standby reserve units. The contractor shall adjust the system if required by the Engineer.
11.5
11.6
11.7 11.8

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The contractor must ensure that the dewatering works will not cause any interference to his own work and to those of other contractors working elsewhere on site or at structures under construction. Any damage occurring during the above mentioned period shall then be made good by the contractor at his own expense. During the foundation works, the excavated works, the excavated areas, foundation levels, pits are to be kept free of water down to at least 0.50m below the foundation level. 12.0 MAJOR EQUIPMENT FOUNDATIONS Special requirements for concreting of major equipment foundations shall be as given below: 12.1 COARSE AGGREGATES Sound and durable crushed stone aggregates shall be used. All aggregates shall be tested for alkali aggregate reaction. Materials, which contain high percentage of reactive silica, shall not be used. In exceptional cases of high percentage of reactive silica content, aggregate may be allowed where low alkali cement shall be used. Lime stone aggregate shall not generally be used for foundations which are subjected to high temperature and repeated temperature cycles (like in the case of all machine foundations). 12.2 TEMPERATURE CONTROL OF CONCRETE The temperature of fresh concrete shall not exceed 230 C when placed. For maintaining the temperature of 230 C in the top deck of machine foundations, crushed ice shall be used in mixing water. 12.3 ADMIXTURE Plasticizer cum retarder type admixture shall generally be added to the concrete for promoting workability in addition to retarding setting time for mass concreting work. The slump of concrete shall generally be in the range given below: TG Top deck BFP, ID/PA/FD Fan and Mill deck Block foundation Column 12.4 FORM WORK Plywood formwork of adequate thickness shall be used for the top deck of all machine foundations and also for columns of TG foundation. Forms shall
: 150mm to 200mm : 100mm to 150mm : 100mm to 150mm : 100mm to 150mm

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be constructed from steel or from sound timber well seasoned and free from shakes. Only steel scaffoldings shall be used. 12.5 SCHEME FOR CONCRETING Weigh batching plants shall be mobilized for all RCC works. Concrete pump shall be mobilized for all RCC works. Arrangements for stand-by Plant and Equipments shall also be made.
12.6
PLACING OF CONCRETE Base mat as well as top deck of machine Foundations shall be cast in a single pour. In case of break down, the decision of ENGINEER In- Charge is final.
12.7
ULTRASONIC TESTING Ultrasonic pulse velocity test shall be carried out for the top deck of all machine foundations and TG substructure to ascertain the homogeneity and integrity of concrete. UPV test shall also be carried out for Chimney and NDCT on the bottom portion to a height of 30metre from top of foundation and shall be conducted immediately after the construction up to 30m. In addition, additional cubes (at the rate of one cube per 150 cum of concrete subject to a minimum of six cubes) shall be taken to carry out Ultrasonic Pulse velocity (UPV) testing on the cubes to serve as reference UPV values. Testing shall be done as per IS: 13311 (Part-1). In case of any defects, the CONTRACTOR shall rectify the defects suitably using cement / epoxy grout etc.
13.0
CONCRETING IN HIGH AMBIENT TEMPARATURE IS:7861 (Part 1) concreting in hot weather shall apply. The temperature of the mixed concrete at the time of placement shall not exceed 40 C except for TG top deck and other deck type vibratory foundations, where it shall be limited to 23 degree C. The contractor shall take special measures in the mixing, placing and curing of concrete. These measures shall include the shading of aggregates, spraying of aggregates with water, cooling of the mix constituents (introduction of ice to the mixing water) and reduction of transportation time to the minimum. During placing suitable measures shall be provided to prevent premature setting of concrete placed in contact with hot surfaces. All concreting areas, formwork and reinforcement shall be shielded from the direct rays of the sun and sprayed with water when necessary. All joints between structural steel and concrete parts shall be sealed by a suitable permanent flexible compound.
14.0
CONCRETING AT NIGHT

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When approval is given to carry out concreting operations (under control of the Engineer) at night or in places where daylight is excluded, the contractor has to provide adequate lighting at all points of mixing, transportation and placing of concrete.
15.0
PROTECTIVE MEASURES OF CONCRETE In general, the cover of rebars shall be as per IS:456 taking into account the site conditions. However, the minimum concrete cover shall not be less than: a) b) c) d) e) Concrete parts above ground (external surface) : 40 mm Concrete exposed to underground & groundwater : 50 mm Slabs : 20 mm Beams : 25 mm Columns : 40 mm
Immediately after the compaction of the concrete has been finished, the contractor shall ensure adequate protection from the weather. Excessive drying can lead to crack formation as a result of plastic contraction. The concrete surface shall be covered with a layer of sacking, canvas, straw mats or similar absorbent material, special protection sprays kept constant moist Curing compounds or other methods of preventing evaporation may be used if approved by the Engineer. Where formwork cannot be removed within 24 hours after placing the concrete, the formwork shall be kept shaded from the direct rays of the sun and shall be sprayed with water. Engineers approval to the use of a particular curing compound and to the method of application will only be given after the contractor has completed satisfactory site trials and a sample panel has stood for at least 28 days. 16.0 CONCRETING UNDER WATER Underwater concreting shall be done as per IS: 456. Underwater concrete must comply with the following characteristics:a) The quantity of cement must be not less than 350 kg/m when using 3 aggregate mixes with a maximum particle size of 40 mm. b) The water-cement ratio must not exceed 0.6. c) Preferred aggregates are those with continuous grading curves lying approximately in the middle of the favourable range. d) Slump shall be as per clause 7.1 of IS: 456. Underwater concrete is to be placed continuously without interruption. For water depths up to 1 m the concrete may be placed without tremie. In the case of water depths exceeding 1 m, the concrete is to be placed in such a

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way that it does not fall freely through the water. The tremies must at all time dip sufficiently far into the freshly placed concrete to ensure that the concrete emerging from the tremie does not come into contact with the water. All work connected with the placing of concrete underwater shall be designed, directed and inspected with due regard to local circumstances and purposes. Work shall not proceed until all phases and methods to be used in the placing operations have been approved by the Engineer. 17.0 CONCRETING WITH HIGH WEARING RESISTANCE Concrete which is exposed to severe mechanical action, e.g., due to inten sive traffic, sliding of bulk materials, frequent impact blows or movements of heavy objects, or due to fast-flowing water carrying solids, or other causes, should possess high wearing resistance and correspond at least to grade 30. The aggregate up to 4 mm size should consist predominantly of quartz or materials of at least equal hardness; the coarser particles should consist of stone or artificial materials possessing high abrasion resistance. In the case of particularly severe mechanical action, it will be necessary to use special hard materials. The particles of all types of aggregate should have a moderately rough surface and be of compact shape. The combined aggregate should be as coarsely graded as possible. Furthermore, the concrete should be as stiff as possible, in order that there will be no concentration of cement slurry or water in the top layer. The concrete should be kept moist for at least 7 days after placing. 18.0 FINISHING OF FORMED SURFACES Fins and other surface projections shall be removed from all formed surfaces except exterior surfaces that shall be covered with earth backfill. Exterior surfaces that shall be exposed above grade and all interior surfaces, except those not usually exposed to view, shall be cleaned and rubbed. Rubbing shall produce a smooth, uniform surface free of marks, voids, surface glaze, and discolorations. Rubbing shall be done by hand with a carborundum stone using only the mortar produced by the rubbing action and the application of water. Projecting ends of all form ties shall be removed. The resulting recesses shall be cleaned, wetted, and filled with patching mortar. Patches on rubbed surfaces shall match the texture of the adjacent concrete. 19.0 FINISHING OF UNFORMED SURFACES No surface treatment shall be required for buried or permanently submerged concrete. As a minimum, unformed surfaces shall be finished by screeding and floating. Surfaces requiring a trowelled finish shall be finished by screeding, floating, and trowelling. Float finished and screeded surfaces shall be finished to provide a flat proISSUE R0 TCE FORM 329 R5

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file within a 6 mm deviation as measured from a 3 meter straightedge. Trowel finished surfaces shall be finished to form a flat plane. The surface profile shall not deviate more than 3 mm when measured from a 3 meter straightedge. 19.1 SCREEDING Screeding Concrete shall be of grade M 15 minimum and shall be 50 mm minimum thick. FLOATING The surfaces shall be screeded and given an initial float finish as soon as the concrete has stiffened sufficiently to work. Coarse aggregate disturbed by the float or causing a surface irregularity shall be removed and replaced with mortar. Initial floating shall produce a surface of uniform texture and appearance. Initial floating shall be followed by a second floating at the time of initial set. The second floating shall produce a smooth float finish of uniform texture and colour. Floating shall be performed with hand floats or suitable mechanical compactor floats. The exposed portions of the tops of equipment bases, tops of interior curbs, and the surfaces of interior slabs not receiving a separate finish shall receive a steel trowel finish. Trowelling shall be performed after the second floating when the surface has hardened sufficiently to prevent excess cement from being drawn to the surface. Trowelling shall produce a dense, smooth, uniform surface free from blemishes and trowel marks. Surfaces to be covered with neoprene-hypalon coatings shall be lightly trowelled but not burnished. 19.3 BROOMING Brooming shall follow the float finish for exterior surfaces where a nonslip surface is required. Brooming shall be done with an acceptable steel or fiber broom not less than 450 mm wide. Brooming ridges shall be transverse to the normal traffic direction and shall be between 1.5 mm and 3 mm deep. Adjacent strokes of the broom shall overlap slightly. Broomed surfaces shall be free of porous spots, irregularities, depressions, and small pockets or rough spots. 19.4 AGGREGATE EXPOSURE Surface mortar shall be removed and the aggregate exposed from surfaces that shall be covered with mortar, concrete, or grout at a later time. 19.5 EDGING Unless specified to be bevelled, exposed edges of floated or troweled surfaces shall be edged with a tool having a 6 mm corner radius.
19.2

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19.6
FINISHING MORTAR Finishing mortar shall be added if there is not sufficient mortar available from the concrete mix. The proportions for this finishing mortar shall be 102 kilograms of concrete sand to one sack of Portland cement, mixed with enough water for proper application. Slump for finishing mortar shall not exceed 50 mm.
20.0
FLOOR FINISHES Floor finish to be provided as specified in finish schedule. Base slab surfaces shall be ground or filled until each surface is within the specified tolerances. Low areas shall be filled. High spots shall be ground slightly lower than required and then filled and smoothed to the proper elevation and surface. Surfaces that receive epoxy set quarry tile and resilient tile shall be flat with a profile that shall not deviate more than 3 mm from a 3 meter straightedge placed on any part of the surface. These surfaces shall be either trowel finished concrete at the elevation indicated on the drawings or a float finished surface set 3 mm low and levelled with trowel finished fill material. Surfaces that receive a mortar set quarry tile, ceramic tile, or terrazzo finish shall be given a smooth, tight, and uniform float finish with a profile tolerance of 6 mm as measured from a 3 meter straightedge.
21.0 21.1
FORMWORK DESIGN AND CONSTRUCTION For stability and type of formwork and support framing used, IS: 14687 is to be observed. The formwork and the supporting structure are to be so dimensioned as to be able to withstand all vertical and horizontal forces safely. Supporting structures shall be sufficiently rigid to maintain the forms in their correct position and to be true to shape and dimensions so that the final concrete is within the limits of the dimensional tolerances specified in IS Codes/ Specifications. The contractor shall submit in sufficient time in advance for the approval of the Engineer the calculations, designs and details of the methods adopted and materials proposed for the formwork. Particular attention must be paid to the formwork supports and braces to avoid any slip when the concrete is poured.
21.2
MATERIAL OF FORMWORK Forms shall be constructed from steel or from sound timber well seasoned and free from shakes. Plywood lining for forms shall be of timber which is resin-bonded and water repellent. Formwork surfaces in contact with concrete shall be free from adhering

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grout, projecting nails, splits or other defects. Joints shall be sufficiently tight to prevent the leakage of cement grout. Connections shall be constructed to permit easy removal of the shuttering and shall be either nailed, screwed, bolted, or otherwise secured so as to be strong enough to retain the correct shape during consolidation of the concrete. Where a slope exceeds 1 V : 2 H formwork shall be provided for the top of the concrete faces and anchored to prevent flotation. The details of fair faced concrete facades have to be to the satisfaction of the Engineer. The concrete surface for facades has to be absolutely stainless and all efforts have to be taken to achieve this. 21.3 GRADING OF FORMWORM AND OF FINISHED CONCRETE SURFACES Quality of formwork, materials to be used and treatments of surface are graded according to the finish of the concrete surface as given in IS:14687. The type and treatment of the formwork lining (plywood, metal, plastics, etc) should be appropriate to the grade of concrete finish required. 21.4 PREPARATION AND INSPECTION OF FORMWORK Before concrete is placed, all formwork shall be inspected to see if it is built according to the approved plans and to see if it has been cleaned and is free from sawdust, shavings, dust, mud, earth or other contamination and properly oiled. Contact surfaces of panels shall be treated with a suitable release agent (e.g. non-staining mineral oil) where applicable. Surfaces which are not oiled shall be wetted thoroughly to prevent warping. 21.5 ERECTION AND PLACING OF FORMWORK All formwork shall be erected and placed in accordance with the construction drawings approved by the Engineer. Shuttering shall be true to line and braced and strutted to prevent deformation under weight and pressure of the wet concrete, live-loads, wind and other forces. The deflections shall not exceed 3mm. The formwork for beams and slabs shall be erected so that the form on the sides of the beams and of the soffits of slabs can be removed without disturbing the beam soffit. If the formwork for columns is erected to the full height of the columns, one side shall be provided with openings for concreting in order to guarantee a proper compaction of the poured concrete. Formwork for walls and elsewhere shall be arranged for a maximum concreting height of 2.5 m in a single pour. Where necessary panel openings are to be provided in the forms for cleaning, inspection, access of vibrators, etc. Before placing of concrete, bolts, ties and fixings shall be positioned and all devices used for forming openings, holes, pockets, chases, recesses, etc shall be fixed to the formwork carefully. Panels shall be put together to ensure a perfect fit at the joint and fixed in both directions. Where concrete surfaces will be exposed to view (permanently exposed

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surfaces) the formwork shall be such as to produce a completely true, smooth surface, free from perceptible irregularities or to show clearly the desired texture. Such formwork shall be marked on the drawings as Fair faced Formwork. Where concrete surfaces will be covered (non-exposed surfaces), the formwork shall be referred to and marked as Sawn Formwork. Internal spacers and ties, if any, shall be so arranged that after removing of the forms no holes shall extend through the concrete, in the case of watertight concrete or to be closed by plastic plugs and epoxy mortar in all other cases. All formwork will be inspected and approved by the Engineer before concrete placing commences but this shall not relieve the contractor of any of his responsibilities under the contract. 21.6 STRIKING OF FORMWORK Formwork shall not be removed until the concrete has sufficient strength to carry its own weight plus any constructional or designed loads likely to be applied with a normal factor of safety. It shall be removed in such a manner that no shock or injury shall result to the concrete. Before removal of the formwork, the concrete shall be examined and removal shall proceed only on the instructions and under the supervision of a competent person. In accordance with IS: 456 clause 11.3.1, the striking period for cast in-situ concrete under certain conditions may be taken as follows:Type of Formwork Minimum period before striking formwork 16 to 24 hours 3 days
(a) (b)
(c)
(d) (1) (2) (e) (1) (2)
Vertical formwork to columns, walls, beams Soffit formwork to slabs (props to be refixed immediately after removal of formwork Soffit formwork to beams (props to be refixed immediately after removal of formwork Props to slabs: Spanning up to 4.5 m Spanning over 4.5 m Props to beams and arches: Spanning up to 6 m Spanning over 6 m
7 days
7 days 14 days 14 days 21 days
Special care is necessary in the case of components which have to carry nearly the full calculated load as soon as the formwork is struck. Columns, piers and walls are to be struck before the beams and slabs supported by them. Scaffolds, formwork supports and self-supporting floor

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formwork are to be carefully lowered by releasing the devices. Extreme care shall be taken to avoid chipping of corners during removal of formwork. To keep deflections through creep and shrinkage to a small amount, auxiliary supports should be left in place or immediately repositioned after striking. 22.0 STOCK OF REINFORCING STEEL In order to ensure due progress of the works, the contractor shall at all times maintain on the site a stock of reinforcing steel sufficient for the following months work. No reinforcing steel shall be used upon the works until it has been accepted as satisfactory by the Engineer. 23.0 REJECTION The Engineer at his discretion may order random testing of the reinforcement steel and in the event of any failed test reject the entire lot notwithstanding the manufacturers or coating applicators certificates. The contractor shall remove all rejected reinforcing steel from the site without delay at his own expense. 24.0 CURING Concrete shall be protected from loss of moisture for not less than 7 days after the concrete is placed. Trowelled surfaces, except those that receive a separate finish or coating, shall be cured with a membrane curing compound. Float finished surfaces, except those that receive a separate finish, may be cured with either a membrane curing compound or with water. Only water curing shall be used if the surface receives a separate finish. 24.1 WATER CURING Water saturation of concrete surfaces shall begin as quickly as possible after initial set of the concrete. Water curing shall begin within 12 hours in dry weather and within 24 hours in damp weather. The rate of water application shall be regulated to provide complete surface coverage with a minimum of runoff. The application of water may be interrupted for surface rubbing. The concrete surface shall not be permitted to dry. After the rubbing has been completed, rubbed surfaces shall be covered with burlap and kept saturated for the remainder of the curing period. 24.2 MEMBRANE CURING Membrane curing compound shall be applied within 30 minutes after final finishing of the surface or as soon as possible after finishing without causing damage to the surface. Membrane curing compound shall be spray applied at a coverage of not more than 7.4 square meters per litre. Membrane curISSUE R0 TCE FORM 329 R5

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ing shall not be used on surfaces that shall be covered at a later date with mortar, concrete, damp-proofing, tile, or any coating. Membrane curing shall not be used on cast-in-place concrete bases for field erected tanks. 25.0 FLOOR SEALER All concrete floors shall be given two coats of clear floor sealer in addition to that applied as membrane curing compound. The first coat shall be applied at the end of the curing period before any traffic is permitted on the floor. The second coat shall be applied after the floor has been cleaned in preparation for the final inspection. Floor sealer shall be applied in strict accordance with the manufacturer's recommendations. 26.0 REPAIRING OF DAMAGED AND DEFECTIVE CONCRETE Concrete which has completed its final setting shall be inspected by the Engineer and any cracks, honeycomb areas, segregations, etc shall be marked. No repairs shall be carried out until direction by the Engineer. Surface defects in formed concrete shall be repaired to the satisfaction of the Construction Manager within 24 hours. Concrete that is porous, honeycombed, or otherwise defective to a depth in excess of 25 mm shall be cut out and removed to sound concrete. Edges shall be square cut to avoid feathering. Cut surfaces shall be coated with epoxy bonding compound before the concrete is placed. Defective concrete shall be replaced within 48 hours after the forms have been removed. Concrete repair work shall not interfere with the curing of surrounding concrete. Mortar and concrete used in repair work shall be adequately cured and shall be finished to match adjacent surfaces 27.0 PERMISSIBLE TOLERANCES The dimensions of concrete as cast when compared with those on the drawings shall be within the tolerances given below in mm. a) Cast in situ concrete works Permissible deviation in mm (max)
Description of item/structural element Faces of concrete in foundations And structural members against Which backfill are placed Location of footing (for RCC Framed structures only) Eccentricity of footing
+25 +25
-10 -25
2% of footing width in direction of misplacement but limiting to 50mm
Top surfaces of slabs and of


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Concrete to receive base plates Shall be grouted Alignment of beams, lintels, Columns, walls, slabs, and Similar structural elements Cross sectional dimensions of Walls, slabs and similar Structural elements Deviation from specified Dimensions of cross section Of columns and beams Alignment of holding down Bolts without sleeves Alignment of holding down Bolts with sleeves Level of holding down Bolt assemblies Embedded parts (in any direction) Centres of pockets or holes With greatest lateral dimension Not exceeding 150mm Variation in steps: Riser Tread Plumb
+5
-5
+5
-5
+5
-5
+12
-6
+1.5
-1.5
+5
-5
+10 +5
-10 -5
+10
-10
+1.5 -1.5 +3.0 -3.0 3mm for every metre Subject to maximum Of 10mm
b)
Form work +6 mm 3mm for every metre Subject to maximum Of 10mm +3 mm

Levels and heights Plumb
Unevenness of any surfaces

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Length or breadth Diagonals
+12 mm +15 mm
In case of inclined surfaces like folded plates etc, the deviation in the alignment of inclined surfaces, shall not exceed 3 mm with reference to the theoretical alignment, for a length of 1000 mm measured vertically, subject to maximum of 10mm. c) Masonry
All masonry shall be built true and plumb within the tolerances prescribed as below. Care shall be taken to keep the prepends properly aligned. Deviation in verticality in total height of wall of a building more than one storey in height shall not exceed +/- 12.5mm. Deviation from vertical within a storey shall not exceed +/- 6mm per 3.0m height. Deviation from the position shown on the plan of any brickwork more than one storey in height shall not exceed 12.5mm. Relative displacement between load bearing walls in adjacent storeys intended to be in vertical alignment shall not exceed 6 mm. Deviation of bed joint from horizontal in any length up to 12m shall not exceed 6 mm, and in any length over 12m it shall not exceed 12.5 mm total. Deviation from the specified thickness of bed joints, cross joints or prepends shall not exceed +/- 3 mm. d) Plastering work
The finished plastered surface shall not show any deviation more than 4 mm when checked with a straight edge of 2 metre length placed against the surface. The thickness of the plaster shall be measured exclusive of the thickness of key i.e. grooves or open joints in brickwork. The average thickness of plaster shall not be less than the specified thickness. The minimum thickness over any portion of the surface shall not be less than the specified thickness by more than 3 mm for plaster thickness above 12mm and 1 mm for ceiling plaster. Extra thickness required in dubbing behind round of the corner at junctions of wall or in plastering of masonry cornices etc. shall be ignored. e) Pre-cast concrete work
Length : +/-0.1 percent subject to minimum of -5 mm and maximum of +10 mm. Cross sectional dimensions: +/- 3 mm or +/- 0.1 percent whichever is greater.

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Straightness of bow : 1/750 of the length subject to minimum of 5 mm and maximum of +10 mm. Squareness : When considering the squareness of corner, the length of the two adjacent sides being checked shall be taken as the base line. The shorter side shall not vary in length from the perpendicular by more than 5mm. Flatness: The maximum deviation from a 1.5m straight edge placed in any position on a nominal plane surface shall not exceed 5mm. f) Reinforcement work Permissible deviation in mm (max)
Description of item/structural element Placing of reinforcement: For effective depth 200mm or less For effective depth more than 200mm Cover to reinforcement Cutting of reinforcement When minimum length specified When maximum length specified When maximum or minimum length not specified
+10 +15 -
-5 -10 -5
+75 +75 +75
-50 -25
g)
Tolerances in erected CW liners/pipes, if applicable 25mm in position and level 50mm in position and level 6mm in position and level Connections and the plane of the flanges shall be within 3 mm of the required plane measured across any diameter. 6mm in position and level and the plane of the flange shall be within 0.3% of the diameter or 1mm whichever is greater of the required plane measured across any diameter.
At setting out points Between setting out point Flanges for condenser
Other terminal points

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h) Maximum deviation of finished pile from vertical 1 in 75 and other tolerance shall be as per IS: 2911 (part-1).

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1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA TECHNICAL SPECIFICATION PART D
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SECTION VI TECHNICAL SPECIFICATION PART D - STEEL STRUCTURES

1.0 1.1 GENERAL Design of structural steel work shall include generally but not be limited to the steel constructions listed below: i) Steel building structure and open structures: This shall include beams, columns, bracings, supporting structures for floors, roof slabs, cladding etc. ii) Crane, gantry girder, monorails etc. iii) Coal bunkers iv) Coal conveyor galleries and trestles v) Large diameter oil tanks vi) Large diameter pipe line for cooling water vii) Single steel flue for R.C.C. Chimney viii) Galvanised latticed structures for switchyard ix) Pipe and cable racks x) Platforms and walkways xi) Ladders, staircases, handrails etc. 2.0 2.1 FRAMING All steel framed structures shall be either rigid frameor simple space frames or a combination of the two. Lateral forces shall be resisted by stiff jointed moment connections in rigid frame design in transverse direction and braced frame in longitudinal direction. The column bases shall generally be fixed to concrete foundation pedestal by providing moment resistant base detail. Simple space frame design utilises single-span beam systems, vertical diagonal bracing at main column lines and horizontal bracing at the roof and major floor levels. The turbine building design shall be a combination of rigid frame in transverse direction and braced frame in longitudinal direction. Pipe rack shall consist of rigid main frame/braced frame in transverse direction spaced longitudinally as required. In longitudinal direction, pipe rack shall be divided into sections of suitable length with an anchor bay. The main transverse frames shall be connected with longitudinal beams, which
2.1.1
2.1.2
2.2
2.3

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will transmit horizontal forces to braced anchor bays. The pipe and cable rack bridge structure shall be adequately rigid to carry the forces from pipelines at anchor points without undue deflection so that pipelines are really anchored at the anchor points. 2.4 Concrete floors shall be considered to provide continuous lateral support to the top (compression) flange of the support beams. However where large cut outs are provided in the floor slabs horizontal floor bracing shall be provided. Grating / chequered plate floor shall neither be considered to provide lateral support to the top flange of supporting beams nor to provide a shear diaphragm. Adequate lateral support and horizontal bracing shall be provided as required in such cases. Floors for vibrating machines of all kind together with supporting framework shall be adequately braced in both horizontal and vertical planes. Floors or structure supporting mechanical equipment shall be designed to minimise vibration, avoid resonance and maintain alignment and level. Columns shall be designed to support the load combination, which produces the maximum interaction ratio. Columns shall also be designed to resist moments caused by discontinuous vertical bracing or non-concentric bracing work points. MATERIALS Structural steel shall conform to Grade E250 (Fe410W), quality A (semi killed) of IS: 2062 for rolled steel members and plates up to and including 20 mm thickness. For plates above 20mm thickness and welded construction, steel conforming to Grade E250 (Fe410W) quality B (Killed and normalised) of IS: 2062 shall be used except for crane girders where steel conforming to quality C (Killed and normalised) shall be used. Chequered plates shall conform to Grade A of IS: 2062 and IS: 3502. All plates of 25 mm thick and above in crane girder and similar dynamically loaded structure shall be UT category. All gratings shall be pressure locked type (preferably electro-forged) manufactured in accordance with applicable Indian Standard Codes. Minimum thickness of the grating shall be 40 mm for indoor installation and 32 mm for outdoor installation. The opening size shall not be more than 30 mm x 100 mm. All gratings shall be hot dip galvanized with coating thickness of 610 grams. per sq.m. . Crane rails shall conform to IS: 3443. Structural steel shall be of SAIL, RINL, TATA STEEL, or make JINDAL CONNECTIONS Welding shall be used for shop fabrication and joints. For site connections, welding or high strength friction grip (HSFG) type bolts shall be used, exISSUE R0 TCE FORM 329 R5
2.5
2.6
3.0 3.1
3.2
3.3 4.0 4.1

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cept in few cases for shear connections of lighter members where bolted (class 4.6) joints may be adopted e.g. purlins, side girts etc. All removable type connections shall be with bearing type HT bolts of grade 8.8 (minimum). 4.2 4.3 IS: 816 and IS: 9595 shall be followed for welding of structures. For high strength friction grip bolt connections IS: 4000 shall be followed. High strength friction grip bolts shall be of property class 8.8 or 10.9 and shall conform to IS: 3757 and shall not be less than 20 mm in diameter unless designated otherwise. All bolted connections shall have bolts of minimum 16 mm diameter. The connections of stairs shall be made with 20 mm diameter threaded fasteners conforming to IS: 1363. Erection bolts shall be black bolts of minimum 16 mm diameter. All bolts and nuts shall have property class compatible to each other. For bolts carrying dynamic or fluctuating loads and those in direct tension shall be provided with an additional double coil helical spring washer conforming to IS: 6755. The threaded portion of the bolt shall project through the nut at least by one thread. All bolts, nuts and washers shall be procured from the manufacturers as approved by ENGINEER In-Charge. Where a steel beam or member is to be connected on RCC structure, it shall be connected using an insert plate and preferably through shear connection. For all built-up members, welding between web and flange plates shall be carried out by submerged arc welding process. Full penetration of weld between web plate and top flange shall be ensured. Welding across tension flange of crane girders will not be permitted. Bearing stiffener edges of crane girders shall be machined. Where practical, the working point of the bracing connection shall be the centre of column and girder to which it connects. The connections of gusset plates to column and girders shall be made to include provisions for eccentricity in connection. Horizontal bracings shall be of angle / tee section located near the compression flange of framing beams. Horizontal bracing shall be arranged to avoid framing into the beams at column locations. Connection of vertical bracings with connecting members and diagonal truss members shall be designed for full tensile capacity of the bracings. Size of fillet weld for flange to web connection for built up section will be as follows: a) Full shear capacity or actual shear for box section.
4.4
4.5
4.6
4.7
4.8
4.9
4.10 4.11

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4.12
4.13 4.14 4.15 4.16
4.17
b) 80% of full shear capacity or actual shear (if indicated in drawings) or 0.5 times of the web thickness whichever is more for I section. Weld shall be double fillet. Shear connections shall be designed for 75% of section strength for rolled sections and 80% of section strength for built up section or rolled section with cover plates. Design shear force shall be more than actual shear. Moment connections between beam and column shall be designed for 100% of moment capacity of the beam section. All butt welds shall be full penetration butt welds. Connection of base plate & gusset members with the columns shall be done considering that total load gets transferred through weld. All splicing work shall be of full strength. Field splicing shall be done with web/flange cover plates. For exceptional cases, the field splicing shall be designed for 50% of load carried by the cover plates and remaining load through full penetration butt-weld. Shop splicing for all sections other than rolled sections shall be carried out by full penetration butt welds. Shop splicing of all rolled sections shall be carried out using web and flange cover plate. Following connections will be provided during erection : a) Welded Connection Connection of secondary beam to main beam Connection of bracing to column Connection of bracing to longitudinal tie beam Connection of longitudinal tie beam to column Connection of spandrel beam to column Connection of other secondary structures b) Welded / HSFG Connection (Grade 8.8 and 10.9 bolts) Splicing of column/transverse frame beam/ longitudinal tie beam Connection of frame beam to column Connection of Crane Girder to column Connection between crane girders Other major connections c) M.S. bolts ( Grade 4.6 ) Purlins, stairs, wall beams
4.18
Minimum size of fillet weld shall be 8 mm. Main structural elements shall be welded continuously. Intermittent weld shall be used only on secondary members, which are not exposed to weather or other corrosive influence. Efficiency of site welds to be considered shall be as follows: a) b) Butt weld above 25 m from ground Others --- 50% --- 80%
4.19
4.20
All electrodes, flux, bare wire etc shall be procured by the contractor only from approved manufacturers. The bare wire electrodes for submerged are

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welding shall conform to IS: 7280 (latest). The combination of wire and flux for submerged arc welding shall be as follows: Filler wire shall be of classification AWS-A-5.17-EH14 and flux shall be of agglomerated type of classification AWS-A-5.17F7 A2-EH14. Low hydrogen electrodes as approved by the Engineer shall invariably be used in the following cases:a) For welding of all important joints such as butt-joints in columns (flange or web), butt-joints in main frame beams (flange or web) etc. b) For welding the steel having thickness more than 20 mm. In case of fillet weld between two components, the thickness of the thicker part shall be considered as the limit for (ii). Minimum preheat & interpass temperature for welding over 40 mm to 63 mm (thickness of the thicker part at the point of welding) shall be 66 C and for over 63 mm, it shall be 110 C. However, higher preheat & interpass temperature may be required due to joint restraint etc and shall be followed as per approved welding procedure. 4.21 All structural steel members for switchyard structures and gratings at power house shall be hot dip galvanized in accordance with IS: 4759 or equivalent. The fasteners shall also be galvanized in terms of IS: 5358. Galvanising of steel structure shall be done after all fabrication work is completed. However, fasteners may be tapped or re-run after galvanizing. Threads of bolts & nuts shall be capable of developing the full strength of the bolt. The spring washers shall be electro-galvanised as per IS: 1573. All galvanizing shall be uniform and of standard quality and shall withstand test in accordance with IS: 2633.
5.0
5.1
DESIGN METHODOLOGY The Design of steel structures shall be done by Limit State method, in accordance with the provisions of IS: 800- 2007. and other relevant IS codes as applicable to specific structures. All buildings / structures shall be framed structure. Basic consideration for structural framing shall be stability, rigidity, building usage, ease of fabrication / erection and overall economy. Additional bracings / moment connections shall be used to assure stability of structures. Structure shall be designed such that the surfaces of all parts shall be accessible for inspection, cleaning, painting and maintenance. Crane gantry girders shall be single web plate girders of welded construction with bearing and intermediate stiffeners. Crane girder shall be designed as simply supported and of single span length. Chequered plate shall be used for gantry girder walkway flooring. For lifting / monorails beams ISMB sections shall be preferred and the bottom flange of all beams shall be checked separately for distortion and reinforced suitably if required.
5.2
5.3

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5.4
For design which requires the use of the minimum column load, (such as, uplift on anchor bolts, column axial tension, etc.) the following criteria shall be used in determining minimum load. Use 90% of the column dead load, No live load is to be used, Uplift forces from vertical bracing are included where applicable and Wind uplift on the roof is included where applicable. Base plates shall be placed on foundation pedestal with grouting. For large base plates necessary grout holes shall be provided. All anchor bolts for fastening steel columns on foundation shall be embedded in foundation during concreting itself. No anchor pockets in foundation shall be allowed. Design of base plates shall be based on design pressure on foundation which shall not exceed the following for working loads: Pedestal in concrete grade M25 Pedestal in concrete grade M30 6.25 N / sq.mm 7.5 N / sq.mm
5.5
5.6
The total horizontal shear force at the base of column is transferred to the column pedestals through friction between the base plate and the grout. A coefficient of friction of 0.30 shall be used in conjunction with the minimum column load as defined above. If the horizontal shear force exceeds the frictional resistance force or if the column is subjected to a net uplift load, the total force shall then be transmitted through shear bars / shear keys welded to the base plate. Anchor bolts are not assumed to resist any horizontal shear force. Necessary recesses shall be kept in the foundation concrete for shear key. PERMISSIBLE DEFLECTIONS The permissible deflections of various steel members under normal loading conditions shall be as per IS: 800 2007 and as specified below. For calculation of deflections in structures and individual members dynamic effects shall not be considered, unless specified otherwise. Vertical Deflection: a) b) c) d) e) For beams supporting dynamic equipment For beams supporting floors / masonry For beams supporting pipes (pipe racks) For roofing and cladding components For gratings and chequered plates : : : : : Span / 500 Span / 300 Span / 400 Span / 240 Span / 200 subject to a maximum of 6 mm : Span / 450
6.0 6.1
6.1.1
f) Coal conveyor gallery bridges 6.1.2
For crane gantries or any member subjected to working loads, the maximum deflection under dead load and live load excluding impact shall not exceed the following values:

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a)
b)
For manually operated cranes and monorails : Span / 500 For electric overhead cranes i) up to 50 t capacity : Span / 750 ii) over 50 t capacity : Span / 1000
6.2
Horizontal deflections The permissible horizontal deflections shall be as per IS: 800 2007 and as specified otherwise: a) Single storey building (without crane load) b) Multi storied building: Height / 500; : Height / 300 inter storey drift within storey height/300 : Height / 200 : Height / 200 : Span/400, relative displace -ments between the rails 10 mm : Height / 400,
c) Pipe rack columns d) Open Structures e) Crane gantry girder due to crane + wind f) Building main columns at crane rail level due to crane + wind relative displacement between h) Coal handling trestles (transverse direction) i) Coal handling galleries k) Transverse deflection of Transfer points, Crusher House, Bunker building ( at floor level meeting the conveyor gallery)
rails 10 mm. : Height / 1000 : As per IS:11592
: Height / 1000
6.3
Provisions of IS: 800-2007 and relevant latest IS Codes shall be followed for limiting deflections of structural elements not listed above. MINIMUM THICKNESS AND SIZES OF STEEL ELEMENTS MINIMUM THICKNESS The minimum thickness of various components of a structure and hot rolled sections shall be as follows. The minimum thickness of rolled shapes shall mean flange thickness regardless of web thickness.
7.0
7.1

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a) b) c) d) e) f) g) h)
Trusses, purlins, girts and bracing : 6 mm Columns and beams : 8 mm Gussets : 8 mm Stiffeners : 8 mm Base plates : 12 mm & above Chequered plates : 6 mm o/p & above Grating flats : 5 mm Minimum thickness of structural members other than gratings and chequered plate directly exposed to weather and inaccessible for painting and maintenance shall be 8 mm.
7.2
MINIMUM SIZES The flange width of purlins supporting light weight concrete slab shall not be less than 65 mm and for those supporting roof sheeting and wall cladding it shall not be less than 50 mm. Width of steel rolled section connected to other member shall be at least 50 mm. The depth of beams for platform of all structures shall not be less than 125 mm.
8.0 8.1 8.2
SLENDERNESS AND DEPTH RATIO The slenderness ratio of main members in tension, compression or bending shall be in accordance with IS: 800. The following limiting ratios of depth to span shall be considered as a general guide. a) Truss b) Rolled beams and girders for Ordinary floors and rafters c) Supporting floor beams for vibrating Machines / equipments d) Roof purlins and girts e) Gable columns 1 / 10 1 / 24 1 / 15 1 / 45 1 / 30
9.0
9.1
FABRICATION AND ERECTION CONTRACTOR shall prepare detailed fabrication drawings and erection scheme based on the design drawings approved by OWNER. Fabrication drawings are not to be submitted to OWNER for approval as the responsibility for correct detailing rests exclusively on the CONTRACTOR. However these drawings shall be furnished to OWNER for their reference to effect payment. Fabrication shall commence only on the basis of the fabrication drawings approved by the CONTRACTORS Consultant.

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(a) Fabrication shall in general follow the provisions of IS: 800, and good engineering practice where provisions of IS: 800 are not clear. (b) Tolerance in fabricated steel work shall be as per IS: 7215. (c) Erection of fabricated steel components shall be as per erection drawings prepared by CONTRACTOR and approved by his CONSULTANT. (d) Tolerance for erected steel structures shall be as per IS: 12843. 9.2 INSPECTION OF WELDING The extent of quality control in respect of welds for structural elements shall be as follows. 9.3 9.3.1 VISUAL EXAMINATION All welds shall be 100% visually inspected to check the following: i) Presence of undercuts ii) Surface cracks in both welds and base metals. iii) Unfilled craters iv) Improper weld profile and size v) Excessive reinforcement in weld vi) Surface porosity 9.3.2 Before inspection, the surface of weld metal shall be cleaned of all slag, spatter matter, scales etc. by using wire brush or chisel. DYE PENETRATION TEST (DPT) This test shall be carried out for all important fillet welds and groove welds to check the following: i) Surface cracks ii) Surface porosities
9.4 9.4.1
9.4.2 Dye Penetration Test shall be carried out in accordance with IS: 3658 or equivalent American National Standard ASTME165. 9.4.3 5% of the total length, dye-penetration test shall be carried out to the root and final run for fillet welds. 9.4.4 10% of the total length, dye-penetration test shall be carried out to the root run after back gouging for butt welds. 9.5 ULTRASONIC TESTING

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9.5.1
All butt weld shall be tested for 100% length by ultrasonic test to detect the following: i) Cracks ii) Lack of fusion iii) Slag inclusions iv) Gas porosity
9.5.2
Ultrasonic testing shall be carried out in accordance with IS: 3664, IS: 4904 or equivalent American National Standard ANSI / AWS D1-92 Chapter 6: Part C. Before Ultrasonic test is carried out, any surface irregularity like undercuts, sharp ridges etc. shall be rectified. Material surface to be used for scanning by probes must allow free movement of probes. For this purpose, surface shall be prepared to make it suitable for carrying out ultrasonic examination. All butt-welds in beams, girders & columns will be of full penetration. Butt welds shall be radiographically or ultrasonically tested as per IS: 822 and standard practice. Plates above 25 mm thickness shall be subject to ultrasonic test as per ASTM-A435 or equivalent to check the presence of lamination
9.5.3
9.5.4
9.5.5
9.6 9.6.1
RADIOGRAPHIC TESTING(X RAY AND GAMMA RAY EXAMINATION) Generally, splicing shall not be provided in tension flange of bunker girder. For structures supporting bunkers and deaerator, 100% length of all butt welds shall be tested. For other structures, this test shall be limited to 2% of length of welds of each element of butt joints for welds made by manual or semi-automatic welding and 1% of length of weld if made by automatic welding machines. The location and extent of weld to be tested by this method shall be decided by OWNER to detect the following defects: i) ii) iii) iv) v) gas porosity slag inclusions lack of penetration lack of fusion cracks
When radiograph is not possible due to inaccessibility to the satisfaction of ENGINEER In-Charge, ultrasonic test shall be carried out after grinding the surface as per cl. 9.5 above... 9.6.2 Radiographic testing shall be conducted in accordance with IS 1182, IS 2595, IS 3657 or equivalent American National Standard ANSI / AWSD1.192.

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9.6.3
Any surface irregularity like undercuts, craters, pits, etc. shall be removed before conducting radiographic test. The length of weld to be tested shall not be more than 0.75 x focal distance. The width of the radiographic film shall be width of the welded joint plus 20 mm on either side of the weld. CONTRACTOR shall provide testing equipment for conducting nondestructive tests for confirming the integrity of welding wherever necessary as directed by the OWNER. ACCEPTABLE LIMITS OF DEFECTS OF WELD Limits of Acceptability of welding defects shall be as follows. i) Visual inspection and Dye Penetration Test
9.7
9.8 9.8.1
The limits of acceptability of defects detected during visual inspection and Dye Penetration Test shall be in accordance with clauses 8.15.1 and clauses 9.25.3 of American National Standard ANSI / AWS D1.1-92 respectively, for statically and dynamically loaded structures. ii) Ultrasonic Testing
The limits of acceptability of defects detected during ultrasonic testing shall be in accordance with clause 8.15.4 and clause 9.25.3 of American National Standard ANSI / AWS D1-92 respectively, for statically and dynamically loaded structures. iii) Radiographic Testing:
The limits of acceptability of defects detected during Radiographic testing shall be in accordance with clause 8.15.3 and 9.25.2 of American National Standard ANSI / AWS D1.1-92 respectively for statically and dynamically loaded structures. 9.9 9.9.1 RECTIFICATION OF DEFECTS IN WELDS In case of detection of defects in welds, the rectification of the same shall be done as follows: i) All craters in the weld and breaks in the weld run shall be thoroughly filled with weld ii) Undercuts, beyond acceptable limits, shall be repaired with dressing so as to provide smooth transition of weld to parent metal. iii) Welds with cracks and also welds with incomplete penetration, porosity, slag inclusion etc. exceeding permissible limits shall be rectified by removing the length of weld at the location of such defects plus 10 mm from both ends of defective weld and shall be re-welded. Defective weld shall be

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removed by chipping hammer gouging torch or grinding wheel. Care shall be taken not to damage the adjacent material. 10.0 10.1 PAINTING All steel members of buildings and structures shall be provided with suitable protective coating. The CONTRACTOR shall guarantee the quality of their coating works for the period of minimum 10 years. First coat of primer shall be given in shop after fabrication, (after surface preparation) but before dispatch to erect at site as described below. The second coat of primer shall be applied after erection and final alignment of the erected structures. Topcoats shall also be applied after erection. CONTRACTOR shall submit QA/QC activities for approval. The guarantee period starts from the date of acceptance of COCTRACTORs paint work. Steel surface, which is to be painted, shall be cleaned of dust and grease and the heavier layers of rust shall be removed by chipping prior to actual surface preparation.. Primer paint shall be applied over blast cleaned surface to near white metal conforming to Sa2 finishes on all exterior and interior surfaces Finish paint shall be as follows Structure Prime coat Intermediate Top coat (Mi- Total Dft (Micron) coat (Mi- cron) (Micron) cron) Inorganic HB epoxy 150 zinc silicate polyamide 1x75 (pigmented) 1x75
10.2
10.3
Station building, Boiler structure, Mill & bunker bay structure, ESP structure, Misc Covered structure DM plant Inorganic zinc silicate 1x75 Coal han- Inorganic dling and ash zinc silicate handling 1x75 structures Pipe and ca- Inorganic ble rack and zinc silicate misc open 1x75 structure
HB MIO Aromatic polyEpoxy 1x75 urethane acid resistant 1x50 HB MIO HB epoxy Epoxy 1x75 polyamide (pigmented) 1x75 Aliphatic polyurethane (UV resistant) 1x50
200
225
125

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10.4
Joints to be site welded shall have no paint applied within 100 mm of welding zone. Similarly where friction grip fasteners are to be used no painting shall be provided. On completion of the joint the surfaces shall receive the paint as specified. Surfaces inaccessible after assembly shall receive two coats of primer prior to assembly. Surfaces inaccessible after erection including top surfaces of floor beams supporting gratings or chequered plate shall receive one additional coat of finish paint over and above number of coats specified before erection. Portion of steel member embedded / to be encased in concrete shall not be painted. Tolerances in structural steel work Tolerances on dimensions for fabrication of steel structures shall be according to IS: 7215. Tolerances on dimensions for erection of steel structures shall be according to IS: 12843. Dimension and weight tolerance of rolled steel shapes shall be as per IS: 1852.
10.5
10.6
11.0 11.1
REQUIREMENTS FOR SPECIFIC STRUCTURES COAL HANDLING SYSTEM STRUCTURES
11.1.1 Toe guards shall be provided on sides of conveyor gallery, toe guard shall have a minimum size of 65 x 6 mm. 11.1.2 In case the inclination of the conveyor is more than 10, walkway shall be given with steps. 1.1.1.3 For the design of conveyor gallery, load due to cables, light fittings and pipes as well as effect of gravity take up loads shall also be considered, in addition to dead load, wind load and imposed load. 11.1.4 Lattice girders supporting the conveyor shall be suitably braced at top and bottom chord levels to transmit the wind load to the end portals connected to trestles. Roof purlins and walkway runners shall also be suitably braced at both ends. 11.1.5 In the case of galleries, temperature expansion joint shall be introduced at intervals as per IS: 800 to divide the galleries into blocks. In each block four legged rigid support guaranteeing stability of structure in the longitudinal direction shall be provided. This shall also to take care of all longitudinal

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forces in the given block. Effect of wind load acting on 2-legged trestle shall also be considered while designing the 4-legged trestle. 11.1.6 Base plates for trestles shall be designed as gusseted base with shear lugs to transfer horizontal forces. Anchor bolts shall be designed only for uplift forces. 11.1.7 Conveyor galleries and trestles having two conveyors belt shall be designed for both conveyors working together. 11.1.8 Chute loads on floors of houses shall be considered plugged with material for the entire height of the chute. 11.1.9 In case chequered plates are used as floor covering the thickness of plate o/p shall be 8 mm. Suitable plan bracings shall be provided 75 mm from top of steel to transfer all the horizontal forces. 11.1.10 Anchor fasteners shall not be used for supporting equipment imparting dynamic forces. 11.1.11 Bracing patterns and locations shall be so planned such that they do not hinder movement of personnel and movement of equipment during maintenance. When floor beam forms part of vertical bracing system, additional loads from the floor beams transferred to the bracing shall be taken into account. 11.1.12 Angle section shall not be used as flexural members except for purlins, side girts and walkway runners. Minimum angle size used shall be L50x50x6. 11.1.13 All foundation bolts shall be provided with double nuts. 11.1.14 End connection for rolled beams and channels shall be designed for a minimum of 75% of their shear capacity and built up beams for 80% of their shear capacity in addition to axial load. 11.1.15 Dynamic analysis shall be carried out for beams supporting screens, vibrating feeder, rotating equipment and conveyor supporting beam in conveyor gallery. 11.1.16 To admit proper light into the conveyor gallery polycarbonate sheet shall be provided as per specification specified elsewhere in the document. 11.2 SWITCHYARD STRUCTURES
11.2.1 All switchyard structures comprising of towers, gantries, lightning masts, lighting towers, equipment structures etc. shall be galvanised steel with bolted site connection.

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11.2.2 Three dimensional analysis shall be carried out for structures like towers and gantries whereas two dimensional approach may be followed for equipment support structures. 11.2.3 All structural steel shall be of tested quality and shall conform to IS: 2062. Steel tubes where used for equipment support structures shall conform to IS: 1161. 11.2.4 All bolts and nuts shall be galvanised. In addition to heavy washers conforming to IS: 6610, spring washers conforming to IS:3063 shall be provided at all bolted connections. Bolts shall conform to IS: 12427. 11.2.5 Fabrication and erection shall in generally be as per IS: 802 and IS: 800; wherever there is a contradiction between two codes the provision in IS: 802 shall govern. 11.2.6 Galvanising 11.2.6.1 Galvanising of the towers shall be as per IS:4759 and IS: 2633 and as given in the following paras. 11.2.6.2 Before galvanising, the steel shall be thoroughly cleaned of any paint, grease, rust, scale, acid or alkali or such other foreign matters as are likely to interfere with the galvanising process. 11.2.6.3 The acceptable values of the coating of zinc on the steel materials shall be in accordance with Table below: KIND OF MATERIAL COATING Minimum value 610 gm/sq.m 500 gm/sq.m
Average value Structural steel members Over 750 gm/sq.m except bolts, nuts and washers For bolts, nuts and washers Over 550 gm/sq.m
11.2.6.4 The galvanised surface shall consist of a continuous and uniformly thick coating of zinc, firmly adhering to the surface of steel. The finished surface shall be clean and smooth, and shall be free from defects like discoloured patches, bare spots, globules, spiky deposits, blistered surface, flaking or peeling off, etc. The presence of any of these defects noticed on visual or microscopic inspection shall render the material liable to rejection. 11.2.6.5 There shall be no flaking or loosening when struck squarely with a chisel faced hammer. The galvanised steel member shall withstand minimum four number of one minute successive dips in copper sulphate solution as per IS: 2633 unless specified otherwise.

SPEC.NO. TCE.6417A-H-500-001
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11.2.6.6 All galvanised members shall be treated with sodium dichromate solution or an approved equivalent after galvanising, so as to prevent white storage stains. 11.2.6.7 Wherever galvanised bolts, nuts, washers, accessories, etc. are specified these shall be hot-dip galvanised. Spring washers shall be electrogalvanised. Readily available GI nuts, bolts and washers conforming to galvanising requirements may also be used. 11.2.6.8 CONTRACTOR shall ensure that galvanising is not damaged in transit. In the event of occurrence of any damage, CONTRACTOR shall at his own cost adopt scrapping and regalvanising the member to satisfy the specific requirements. 12.0 12.1 LARGE DIAMETER OIL TANKS Design, fabrication and erection of the cylindrical welded storage tank shall follow the provisions of IS: 803. The stresses in the tank shall be computed on the assumption that tank is filled with water. Tension in each course shall be computed at 30 cm above the centreline of lower horizontal joint of the course under consideration. Wind and internal vacuum loads shall be considered together to stability of tank. check the
12.2
12.3
Joint efficiency factor shall be taken as 0.85 for butt joints to determine the minimum thickness of shell plates provided all the vertical and horizontal butt welds are spot radiographed. Where welds are not inspected by radiography joint efficiency factor of 0.7 shall be used. However it is recommended that all butt welded joints shall be radiographed. Minimum thickness of shell plate shall be as given in clause 6.3.3.2 of IS: 803 to which corrosion allowance shall be added. Maximum thickness of shell plate shall not exceed 40 mm. Width of shell plate shall not be less than 1500 mm. Bottom plate uniformly resting on the substructure shall have a minimum thickness of 6 mm for tank up to 10 m in diameter and 8 mm for higher diameter. Bottom plate shall project at least 25 mm all round beyond the outer edge of weld attaching the bottom to the shell plate. For large diameter oil tanks supported cone roof shall be provided. Arrangement of columns and rafters shall in general be as per fig 9 and 10 of IS: 803. Roof plates shall have a minimum thickness of 6 mm and shall not be attached to the supporting member. A curb angle shall be provided at the top of the shell in line with clause 6.3.6.2 of IS: 803. Roof plates shall be atISSUE R0 TCE FORM 329 R5
12.4
12.5
12.6

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SHEET 123 of 267
tached to the curb angle with a continuous fillet weld on the top side only. Minimum slope of roof shall be 1 in 16. 12.7 Rafter clips for the outer row of rafters shall be welded to the shell. Columns shall not be rigidly attached to the bottom plates guide. Clips shall be welded to the tank bottom to prevent lateral movement. Roof supporting columns shall be made from structural shapes or pipe or built up section. Suitable base frames or reinforcing pads shall be provided at the column base to distribute loads coming on the tank bottom. Appurtenances and mountings covered under section 7 of IS:803 shall be provided in addition to any other appurtenance which the BIDDER considers essential for the safe and smooth operation of the fuel oil storage and oil handling system.
12.8
12.9
12.10 After erection and inspection of the tank, the tanks shall be tested as per clause 12 of IS: 803. Leakage, if any noticed shall be repaired to the satisfaction of the OWNER and the tank retested to satisfy acceptance criteria. 13.0 LARGE DIAMETER STEEL PIPES Design, installation and testing of the pipe shall be, in general, conforming to latest edition of Steel pipe - A guide for design and installation AWWA Manual M11 published by American Water Works Association. Pipes shall be as per IS: 3589, fabricated from steel plates conforming to IS: 2062. Piping shall be designed for pump shut-off pressure or 1.5 times the maximum pump head whichever is higher. Thickness of the pipe shall also be adequate to withstand full vacuum in the pipe. Also, the pipes shall be hydrotested at a pressure of 1.5 times the design pressure. Thickness of the pipes shall be calculated as per requirement of AWWA M11 and / or ASME B31.1. Underground large diameter piping shall be laid with minimum earth cushion of 1500 mm. A surcharge of 2 t/sq.m in addition to backfill shall also be considered. The pipes shall be given an internal coating with epoxy paint 250 micron. Where pipes are not encased wrapping as per IS: 10221 shall be provided outside. Underground large diameter piping shall be given sand bedding conforming to requirements of IS: 5822. The minimum thickness of sand bed under bottom of pipe shall be 100 mm. At locations of the change of flow direction thrust blocks shall be provided as per requirement of hydraulic transient analysis. Double kinetic type air-cum-vacuum valves shall be provided at locations as per requirement of hydraulic transient analysis. The complete piping system shall be line tested before commissioning of the system. All site joints shall be inspected by radiography 14.0 CIRCULAR COAL BUNKERS Design of the bunkers shall be as per IS: 9178. Plates shall be cut to the maximum width to reduce the number of horizontal joints. Vertical joints

SPEC.NO. TCE.6417A-H-500-001
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shall be staggered. All vertical joints above bunker supporting zones and both vertical and horizontal joint below the zone shall be inspected by radiography to ensure quality. Trial assembly of the bunker including hopper shall be made at least for one bunker before commencing regular fabrication of the bunkers. Stainless steel liner of 5.14mm thickness conforming to AISI 304, finish grade 2B (cold rolled, annealed & pickled and skin passed) on M.S plate for inside surface of hopper and mouth of hopper of bunker shall be provided. For inside vertical surface of bunker stainless steel liner of 3.14mm thickness conforming to AISI 304, finish grade 2B (cold rolled, annealed & pickled and skin passed) on M.S plate shall be provided. 15.0 STEEL FLUE FOR RCC CHIMNEY Refer part H

SPEC.NO. TCE.6417A-H-500-001
1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA TECHNICAL SPECIFICATION PART E
SHEET 125 of 267
SECTION VI - TECHNICAL SPECIFICATION PART E - OUTDOOR CIVIL WORKS
1.0
DRAINAGE AND SEWERAGE All drainage lines for storm water, sewage and waste drainage etc. shall preferably be laid in service aisles close to the road. Separate network shall be provided for lines of storm water, sewage, and waste drainage.
1.1 1.1.1
SURFACE DRAINAGE All the paved and unpaved areas shall be adequately drained. The surface drainage system shall be designed for surface washings and / or rain / fire water as the case may be. Unpaved open areas shall be drained through RCC drains and connected to main storm drains. The paved area shall be sloped towards the drains with a minimum slope of 1 in 100. The maximum drainage travel extent shall be limited to 10 metres. The surface drainage from uncontaminated area shall be connected to the nearest open storm water drains through rectangular drains. Contaminated area surface drainage shall be collected through separate network. The interconnecting pipes and rectangular drains shall be sized for carrying the design discharge when running full. The rectangular drains shall be minimum 300 mm wide of RCC construction. The pipes for water drainage system shall be of RCC class NP2 conforming to IS: 458 with minimum size of 150 mm NB. However for road crossings etc. pipe of class NP3 shall be provided. For rail crossings, pipes conforming to railway loading standards shall be provided. If sufficient clearance cannot be provided between the top of the pipe and road top, the pipes shall be encased in RCC. The maximum velocity for pipe drains and open drains shall be limited to 2.4 m/sec and 1.8 m/sec respectively. However minimum velocity for self cleansing of 0.6 m/sec shall be ensured. Slope of drain shall not be milder than 1 in 1000. Minimum cover of 450 mm shall be provided over drainage pipes in paved areas. Garland drains, minimum 300 mm wide shall be provided all round the building to lead away roof drainage to plant drainage system. Plinth protection as
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.7
1.1.8

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specified elsewhere in specification shall be provided between brick wall and drain with appropriate slope. 1.2 STORM WATER DRAINAGE SYSTEM The storm water drainage should be designed keeping in view the existing storm water drainage system. The following should be reviewed and kept in view:
1.2.1
The plant storm water drainage system shall take into account the topography of the plant area, area drainage patterns and intensity of rainfall etc. The drainage system shall be designed for precipitation intensity equal to hourly rainfall. All storm water drainage shall preferably be conveyed through open storm water drains provided on both sides of the roads and shall be designed to drain the appropriate catchment area including road surface, open and covered area etc. The drains shall be minimum 300 mm wide at the base. Not used All open drains rectangular in cross section shall be in RCC of grade M 20. The thickness of side and bottom shall be mini mum 100mm or as per design considerations whichever is higher. Drains in paved areas shall be covered with perforated pre-cast RCC slabs ( minimum grade M25) of minimum 50 mm thickness with provision of openable galvanized steel grating covers at about 4.0 m intervals. In areas where vehicular loads would be coming, pre-cast RCC covers of suitable thickness without perforations and designed for the vehicular loading shall be provided. RCC box/pre-cast RCC pipe culverts shall be provided for road and rail crossing. RCC guard posts shall be provided @ 1500mm distance in case of open drains where width or depth exceeds 900 mm due to safety reasons.
1.2.2
1.2.3 1.2.4
1.2.5
The pipes as required for water drainage system shall be of concrete of class NP2 conforming to IS: 458. However for road crossings etc. higher strength pipe of class NP3 shall be provided. Diameter of pipes used for drainage / culverts shall be between 300 mm to 600 mm. Beyond 600 mm, R.C.C box culverts shall be provided. Surface drains shall normally have a bed slope not milder than 1 in 1000 along longitudinal direction and RCC pipes shall have such slopes so as to have effective discharge. The maximum velocity for pipe drains and open drains shall be limited to 2.4 m/sec and 1.8 m/sec respectively. Suitable manholes shall be provided to pipe drainage lines at every 30 m intervals, at junctions and at change of gradient, alignment and diameter of
1.2.6
1.2.7

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pipe and shall be of RCC construction. Minimum size of manholes shall be 1.0m x 1.0m. All manholes shall be designed considering maintenance, inspection and cleaning of pipes. Easy accessibility and safety shall also be given due consideration. 1.2.8 The cushion over the pipes for storm culverts shall be minimum 600 mm. Where fewer cushions are available, pipe shall be encased in RCC M 25. Suitable RCC or masonry structures shall be provided at drops / falls to prevent scouring or damage to surface. Invert of drainage pipe / drain shall be decided in such a way that the water can easily be discharged above the high water level in water course outside the plant boundary to which the storm water is to be led. The drainage system shall be designed for a maximum hourly rainfall of 75mm. Run off coefficient for paved and unpaved areas shall be taken as 0.9 and 0.6 respectively. Storm water drainage system shall be designed in two parts. (a) Main drains (b) Auxiliary drains Main drains shall be designed as a network covering total plant area and shall ultimately be led to the existing storm water holding pond via existing drain network. Proposed plant area drains shall be connected to the existing drain network at suitable locations based on available drain size and capacity. Modifications of existing drains if required shall be in the scope of the CONTRACTOR. Auxiliary / branch drains shall collect discharge from plant buildings and shall connect to main drain at suitable locations. At places where covered drainage system is required, channels with removable cover shall be preferred to piping system, as piped system tends to get blocked. Underground storm water piping shall be restricted strictly to areas where surface drains are not desirable or practicable from functional point of view. Drainage shall be provided where necessary to prevent pending and ground erosion and to carry surface water away from building, structures and other works including roads, building or equipment foundations. 1.3 PLANT EFFLUENT DRAINAGE (OILY WASTE / PROCESS WASTER DRAINAGE) The oily / process waste shall be drained / collected through a separate sewer system consisting of underground (over ground if required) concrete / cast iron pipes. Catch pits shall be provided at the source location and they shall be interconnected by buried pipes. No bends and branches shall be
1.2.9
1.2.10
1.2.11
1.3.1

SPEC.NO. TCE.6417A-H-500-001
SHEET 128 of 267
provided in the pipe line. Manholes shall be provided at all junctions of pipes. Catchpits shall have a minimum internal dimension of 600 mm x 600 mm. They shall be of RCC construction and provided with CI grills. 1.3.2 The main and branch connection pipes shall be sized for the expected maximum discharge subject to a minimum of 250 mm NB and 100 mm NB respectively. The pipes shall be adequately sloped for drainage and shall carry flow to neutralisation pit / ETP / Oil water separator as required. SEWAGE SYSTEM Cement concrete pipes shall be used below ground level for sewage disposal. Pipes connecting toilet facilities to manholes shall be minimum 100 mm diameter NB. Pipes connecting various manholes shall be minimum 150 mm diameter NB. However salt glazed stoneware pipes of diameter not exceeding 150 mm can be used in localised areas not subject to any traffic loads. For main power block below paved area, cast iron spun pipe of Class LA conforming to IS: 1536 shall be used. Sewers shall have such slopes so as to have effective discharge. Sewers shall be designed for a minimum self cleansing velocity of 0.75 m/sec for peak flow condition (assumed as 3 times the average flow) and pipes flowing half full. The maximum velocity shall not exceed 2.4 m/sec. Suitable manholes shall be provided to pipe sewage lines at every 30 m intervals, at junctions and at change of gradient, alignment and diameter of pipe and shall be of RCC construction. Details of manholes shall be as per IS: 4111 (Part-I). Minimum size of manholes shall be 1.0m x 1.0 m. All manholes shall be designed considering maintenance, inspection and cleaning of pipes. Easy accessibility and safety shall also be given due consideration. The sewage will be led to Sewage Treatment Plant. The treated effluent shall meet the requirement of the state pollution board. INTER PLANT TRENCHES All cable and pipe trenches shall be of RCC with minimum M25 grade. Trenches located outside the buildings shall project at least 150 mm above finished formation level to avoid entry of storm water into the trenches. The bottom of trench shall be provided with suitable slope for draining out collected water into a sump pit. Trenches shall be covered using precast RCC cover of minimum M25 grade, each not weighing more than 65 kg and shall be provided with a lifting hooks. As far as possible trenches in the open area shall be avoided for running cables especially in areas where the water table is high. Instead cable racks running above ground shall be provided.
1.4 1.4.1
1.4.2
1.4.3
1.4.4 2.0 2.1
2.2
2.3

SPEC.NO. TCE.6417A-H-500-001
SHEET 129 of 267
3.0
ROADS AND PARKING AREA Roads from main gate to power block and roads in power block (from transformer yard to chimney) shall be of rigid pavement type and shall be designed in accordance with the provision of the relevant IRC Codes of Practices. All other roads shall be flexible pavement. Top level of parking area shall be flushed with crown of the connecting roads with a cross slope.
3.1
All roads shall be designed for class E of traffic i.e. traffic intensity of 4501500 per day (heavy vehicles exceeding 3 tonnes laden weight) as per IRC 37 1984 Guidelines for the design of flexible pavements. and IRC-58 Guidelines for the design of rigid pavement for highways. The rigid pavement shall be designed for 30 years of life and considering a minimum traffic growth of 1%. The flexible pavements shall be designed for 15 years of life for the same traffic growth as stated above. However, the inspection and maintenance roads shall be designed for a vehicular traffic of 0-15 nos. of vehicles per day. California Bearing Ratio (CBR) method shall be adopted for the design of flexible pavements.
3.2
3.3
Sub-base shall be of granular material i.e. laterites, moorum, natural sand, gravel, crushed stone (grading-1) or combination thereof laid over well compacted subgrade. Granular base shall be of wet mix macadam course (WMM) construction as per IRC: 109. The wearing coarse shall be bituminous macadam binder course with close graded 20 mm thick premix carpet laid over it. Shoulder provided on either sides shall be in moorum construction of 150 mm compacted thickness. Kerbs of PCC or stone shall be provided to distinguish carriage way. The geometric design of roads shall be done in accordance with IRC-73. Road widths, curves and parking areas shall have adequate space for manoeuvring of vehicles. The ruling gradient for roads in longitudinal direction shall be 1 in 30. Normally the roads shall have much flatter gradient. Transverse camber of 1 in 60 shall be provided for the RCC pavement and a slope of at least 1 in 40 shall be provided on other pavement and shoulders. Finished top (crest) of roads shall be 250 mm above the surrounding grade level. Minimum radius of curvature along the inner side of the carriageway shall generally be 15m. However for minor roads this may be reduced suitably as per layout requirements and site conditions. Road width and turning radii shall also be checked for to take largest foreseeable vehicles and equipment, which can reasonably be expected. All service and utility lines crossing under roads shall be taken through concrete pipes / ducts and designed for imposed loading. Number of such crossings shall however be kept to a minimum.
3.4
3.5

SPEC.NO. TCE.6417A-H-500-001
SHEET 130 of 267
3.6
The road shall be designed to cater to the load and needs of construction and maintenance of heavy trucks carrying machinery and heavy cranes. All roads providing access to buildings / structures / systems requiring maintenance by vehicles shall be 10m wide. All other major roads shall be 7.0m and minor roads shall be 4.5 m wide. 1.5m and 0.75m wide road shoulder shall be provided on either side of 10m/7.0 m and 4.5m wide roads respectively with appropriate topping. Wet mix Macadam (WMM) roads with bituminous topping shall be provided for access roads and vehicular parking areas. Bituminous topping of all plant roads and parking areas shall be taken up after construction of the plant is completed. On either side of the roads open drains shall be provided. Drainage lines and other underground services shall be located at least 1 m clear from the edge of the road. All service and utility lines crossing the roads shall be taken up through NP3 class RCC pipe designed for impact loading. Culvert shall be as specified in the relevant clause of Storm water drainage system.
3.6.1
3.6.2 Signs shall be provided for vehicular management and shall meet Indian standards. All signs shall be dual worded in both English and the local Indian language. 4.0 FENCING (Please refer clause 2.3 of Section V) 5.0 5.1 5.1.1 PAVING RCC PAVING R.C.C paving of grade M25, minimum 150 mm thick laid to a slope of 1 in 100 towards the nearest drain, with nominal reinforcement of 10 dia HYSD bars 200 c/c both ways at top and bottom placed 50 mm from the top surface, shall be provided in the following areas. (i) Entire backside of the main turbine building up to the farther edge of chimney. The paving shall extend to a minimum of 5 m on either side from the outer most face of equipment structures in the other direction. Ash silo area extending at least 10 m on all sides from outer periphery of the silos. 5 m wide corridor all along the entire width of TG and Deareator bay at both gable ends. Complete Transformer Yard, covering area between A-row of the turbine building up to the fencing of the Transformer yard. Fuel oil decantation platforms. NDCT area
(ii) (iii) (iv) (v) (vi)

SPEC.NO. TCE.6417A-H-500-001
SHEET 131 of 267
5.1.2
The underbed shall consist of well compacted ground supporting dry rubble soling of compacted thickness 225 mm with interstices properly filled with grits, followed by a layer of PCC of M 10, 75 mm thick. PCC PAVING PCC paving of nominal mix of grade M20, 100 mm that laid over 150 mm thick compacted rubble soling shall be provided in the following area. i) Plinth protection around all building to a width of 1500 mm or the distance between the brick wall to the garland drain, whichever is more.
5.2 5.2.1
5.2.2
PCC paving of M20, min. 100 mm thick shall be provided as paving inside fuel oil tank farm; the paving shall be laid over well compacted ground and laid to slope towards peripheral drain. STONE AGGREGATE PAVING
5.3
5.3.1
Entire switchyard area shall be provided with 75 mm paving of 40 mm size stone aggregate on top and 75 mm paving of 20 mm stone aggregate below. Each layer shall be compacted by using tonne roller with 4-5 passes & suitable water sprinkling. Before laying the paving, the ground surface shall be treated with anti weed chemicals as per manufacturer recommendations. Specifications, test certificates for anti weed treatment chemicals to be submitted for OWNER`s approval. Any modification, if required in the proposed materials, shall have to be done by the contractor at no extra cost to the OWNER. For auxiliary transformer yard, paving of stone aggregate of 75 mm thick using 20 mm size aggregate shall be provided after compacting the under bed and treating with anti-weed chemicals.
5.3.2

SPEC.NO. TCE.6417A-H-500-001
1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA TECHNICAL SPECIFICATION PART F
SHEET 132 of 267
SECTION VI - TECHNICAL SPECIFICATIONS PART F - FINISHING WORKS The minimum quality of finishes used for various building areas are furnished in this section. The bidder is at liberty to use superior finishes provided all specific requirements for the finish specified herein below are satisfied, without any extra cost to the owner. The type of finish to be adopted are given below. 1.0 FLOORING The nominal total thickness of floor finish shall be 50 mm including under bed and topping. The flooring shall be laid on already matured concrete base. The under bed for floors shall consist of cement concrete 1:2:4 with stone chips 12.5 mm downgraded as coarse aggregates. The under bed shall be provided appropriate slope towards catch pit for floor drainage. 1.1 FALSE FLOORING SYSTEM Removable type false flooring system shall be provided in computer rooms and control rooms as required. RCC floor slab will be sunk to a depth of about 800 mm (or depth necessary to lay the cables). Top of false floor shall be at same level with the adjacent finished floor level. The flooring shall consist of fire resistant phenol formaldehyde bonded particle board panels 600x600x35 mm size, backed by aluminium sheet, mounted on steel pedestals of adjustable height and supporting steel grid system to provide under floor space. The entire assembly shall be shall be constructed in such a way as to allow conductivity of electrostatic charges and shall be connected to the earthing system. 2 mm thick flexible anti-static PVC topping on top and PVC strip edging on sides of each panel shall be provided. 1.2 PVC FLOOR FINISH Two mm thick PVC as per IS: 3462 and laid as per IS: 5318 shall be provided over particle board false floor panels in areas as specified in finish schedule (clause no. 12.9). PVC tiles shall ensure anti static surface. 1.3 1.4 Not used. GRANOLITHIC FLOORING Granolithic flooring with non-metallic floor hardener topping 12 mm thick with a total thickness of 50 mm shall be provided in areas as described in finish schedule (clause no. 12.9) where heavy duty flooring is required. HEAVY DUTY CERAMIC TILES
1.5

SPEC.NO. TCE.6417A-H-500-001
SHEET 133 of 267
Heavy duty ceramic tiles with matt finish shall be used in toilets, pantry, locker rooms etc. The tiles shall be 300 x 300 x 7 mm of approved shade brand and colour. Tiles shall be of first class quality, uniform size, even surface, sharp, parallel, non-crumbling edges, free from soluble salt, and other detrimental constituents; free from cracks and blisters, serrated edges, chipped corners and other imperfections or flaws affecting their quality, appearance and strength; rear and side surface capable of bonding effectively for placing, laying and jointing. All ceramic tiles shall be of approved make and bear the identification mark of the manufacturer on the lower face in either positive or negative embossment. 1.6 ACID / ALKALI RESISTING TILES Battery rooms and other areas coming into contact with acid / alkali vapours or fumes shall be given acid / alkali resistant tiles 25 mm thick, jointed with acid / alkali resistant cement slurry. Bedding shall comprise of potassium silicate mortar conforming to IS: 4832 (Part-I) and resin based mortar like epoxy for jointing. Total thickness of flooring shall be 50 mm. Ceramic unglazed vitreous tiles conforming to IS: 4457 with minimum thickness of 20 mm may also be used as acid / alkali resistant tile. The above specifications do not apply to D.M. Plant. 1.7 INTEGRAL FLOOR FINISH For cable trenches floor finish integral to the concrete base shall be provided as per IS: 2571. 1.8 1.8.1 ACID / ALKALI RESISTANT TILING / BRICK LINING IN D.M PLANT Bitumen primer followed by 12 mm thick bitumastic, 6 mm thick potassium silicate mortar bedding and 38 mm thick alkali / acid resistant bricks as per IS: 4860 shall be provided for CPU regeneration area, Chemical house floor, effluent drains, floors around equipment and chemical handling vessels, chemical storage area for the floor, curbs and sumps, all as per the acid / alkali proofing specialist Contractors requirement. For floor of neutralising pit, the finish shall be as follows. Bitumen primer followed by 18 mm thick bitumastic, 6 mm thick potassium silicate mortar bedding and 75 mm thick acid / alkali resistant brick as per IS: 4860. For walls of neutralizing pit, the same specification as 1.10.2 shall apply except that thickness of the brickwork shall be 115 mm with suitable pilasters at 2000 mm c/c. Special instruction to be followed for acid resistant lining in neutralizing pit shall be as follows. i) The structures shall be tested for water tightness.
1.8.2
1.8.3
1.8.4

SPEC.NO. TCE.6417A-H-500-001
SHEET 134 of 267
ii) iii)
Surface on which lining is to be applied shall be prepared as IS: 2395.
per
Joints between acid resistant bricks / tiles shall be filled with resin type mortar conforming to IS: 4832 (Part II). Seal coat of readymade epoxy paint shall be provided at the joints to cover up any porosity. Acid resistant bricks shall be laid with 6 mm wide and 20 mm deep pointing. Pointing shall be with epoxy / furnace / CNSL as per the requirement of the agency guaranteeing the performance of lining. Under side of all precast slabs / steel covers over effluent drains shall be given two coats of epoxy coating, each coat of 150 microns thick. Acid / alkali resistant treatment shall extend at least 1 metre on all sides from the outermost periphery of pedestals / saddles for indoor installations and 2 metres all round for outdoor installations.
iv)
v)
vi)
1.9 1.9.1
MISCELLANEOUS PVC nosing shall be provided for edge protection of R.C.C. stair treads. In case of granite, marble or any other stone finish in trades, half round nosing shall be provided for edge protection. Angles 50x50x6 mm (minimum) with lugs shall be provided for edge protection of cut outs / openings in floor slabs, edge of drains covering gratings, edge of R.C.C cable / pipe trenches of any other place where breakage of edges / corners is expected. Floors of switchgear rooms shall have embedded steel channel suitable for easy movement of breaker panel. SKIRTING / DADO 150 mm skirting matching with floor finish shall be provided in all areas unless specified otherwise elsewhere. Toilets and locker rooms shall be provided with dado of 2100 mm (litel level) high with glazed tiles of minimum 5 mm thickness generally as per IS:777. However shade and design of the tiles shall be of the choice of owner and shall be as per the trend in the market. For battery room and other areas coming in contact with acid / alkali spillage / fume, dado of acid / alkali resistant tiling as per IS:4457 shall be provided to a height of 2100 mm set in potassium silicate mortar and joints pointed with resin bonded mortar.
1.9.2
1.9.3 2.0 2.1
2.2
2.3

SPEC.NO. TCE.6417A-H-500-001
SHEET 135 of 267
2.4
Entrance lobby and lift area in Service building shall be provided with granite dado to a height up to 2100mm (lintel level) as per approved pattern and design. METAL CLADDING PERMANENT COLOUR COATED SANDWICHED INSULATED METAL CLADDING SYSTEM. Troughed zinc-aluminium alloy coated (both sides) M.S. sheet having 0.6 mm minimum thickness (or high tensile steel sheet of 0.5 mm minimum thickness) shall be used on external face (outer face) of cladding system. Weight of coating shall not be less than 150 gm / sq.m. The outer side (exposed face) shall be permanently colour coated with Polyfluro Vinyl Coating (PVF2) of Dry Film Thickness (DFT) 20 microns (minimum) over primer. Inner side of external sheet shall be provided with suitable precoating of minimum 7 microns. Galvanised M.S. sheets of minimum 0.6 mm thickness shall be used as inner liner (internal face) of cladding system. The exposed face shall be permanently colour coated with silicon modified polyester paint of DFT 20 microns (minimum) over primer. Inner face of external sheet shall be provided with suitable pre-coating of minimum 7 microns. The rate of galvanising shall not be less than 150 gm / sq.m. The permanent colour coated sheet shall meet the general requirements of IS: 14246 and shall conform to class 3 for the durability. Inner sheet shall be fixed directly to side runners and Z spacers made of at least 2 mm thick galvanised steel sheet of grade 375 as per IS:277. Inner sheet shall be fixed at the rate not more than 0.75 m centre to centre to hold the insulation and external sheeting. The insulation shall be of bonded mineral wool of minimum thickness 50 mm conforming to IS: 8183, having a density of 32 kg / cu.m for glass wool & 48 kg / cu.m for rock wool. PERMANENT COLOUR COATED (NON-INSULATED) METAL CLADDING SYSTEM Troughed zinc-aluminium alloy coated not less than 150 gm/sq.m M.S. sheets having 0.6 mm minimum thickness (or High tensile steel sheet of 0.5 mm minimum thickness) shall be used for the cladding system. The outer side (exposed face) shall be permanently colour coated with PVF2 paint of minimum DFT 20 microns over primer and the inner side (internal face) shall be coated with same paint of minimum DFT 12 microns over primer. These shall be fixed directly to runners. The sheets shall meet the
3.0 3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.2
3.2.1

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general requirement of IS: 14246 and shall conform to class 3 for the durability. 3.3 FLASHINGS, CAP, TRIM CLOSURES ETC. All flashings, trim closures, caps etc. required for the metal cladding system shall be made out of plain sheets having same material and coating specification as mentioned above for the outer face of the sandwiched metal cladding. 4.0 4.1 PLASTERING Details furnished below do not include special types of plaster / plaster finishes which may be provided to enhance the architectural appeal. BIDDER may propose such superior plaster finish in his Bid.
4.2
External face of all walls shall be provided with 18 mm thick cement mortar plastering with an under layer 12 mm thick in CM 1:6 and top 6 mm thick layer in CM 1:4 with approved water proofing compound.
4.3
For internal walls 18 mm thick plaster in CM 1:5 shall be provided on the uneven side of the wall and 12 mm thick plaster in CM 1:5 on the even side of the wall. Inside surfaces of walls shall be provided with 1.5 mm thick wall putty punning over plastered surfaces in office areas, entrance lobbies, and other areas as mentioned in finish schedule. Ceiling of all buildings except in cable vaults and over false ceilings shall be given 6 mm thick cement sand plaster 1:4. All plastering work shall conform to IS: 1661. PAINTING Details furnished here in below are the minimum acceptable standard for painting. Superior finish if any required by BIDDER to enhance overall appearance will be permitted if such finish meet with the technical requirements. Water proof cement based paint as per IS: 5410 shall be provided on building external surfaces.Power house building and all non plant buildings shall be provided with exterior grade acrylic emulsion pain on the external surface. Painting on inside surfaces shall be as per finish schedule (clause no. 12.9)
4.4
4.5
4.6 5.0 5.1
5.2
5.3

SPEC.NO. TCE.6417A-H-500-001
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5.4 5.5
Water bound distemper shall be provided as per IS: 427. Oil resistant paint as per IS: 161 shall be provided for oil canal and oil equipment room. All wood work shall be provided with fire resistant transparent paint as per IS: 162 over french polish as per IS: 348 or flat oil paint as per IS: 137. Painting for structural steel have been specified elsewhere in this document. Following general instruction for painting shall be followed. i) ii) iii) iv) v) vi) vii) For painting on concrete, masonry and plastered surfaces IS: 2395 parts I and II shall be followed. For painting on wood work IS: 2338 part I and II shall be followed. All paints shall be of brand and make as per the approval of OWNER. A minimum of two finishing coats of paint over a primer shall be provided to give a smooth uniform finish for the painted surface. All painting on masonry or concrete surfaces shall preferably be applied by rollers. Thinner shall not be used with textured paint (sandtex matt etc.) finish. All fire exits shall be painted in Post office red colour shade which shall not be used anywhere except to indicate emergency or safety measure. Wall and ceiling above false ceiling shall be white washed above cement plaster.
5.6
5.7
5.8
viii) 6.0 6.1 ROOF
Metal decking sheets shall meet the general requirements of IS: 14246 and shall conform to class 3 for durability. The sheeting shall be permanently colour coated galvanised M.S. troughed metal sheet decking of approved profile with minimum base metal thickness of 0.8 mm and minimum trough depth of 38mm. Silicon modified polyester (SMP) painting shall be used for permanent coating over galvanised surface with minimum rate of galvanising of 180 gm of zinc per sq.m. Dry film thickness (DFT) of SMP coating shall be at least 20 micron on the exposed surface and 5 micron on the other surface. SMP coating shall be on 5 micron primer. Roof of all buildings having R.C.C. frame work shall have cast in situ R.C.C. slab with conventional shuttering.
6.2

SPEC.NO. TCE.6417A-H-500-001
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6.3
Roof of conveyor galleries, steam generator shall be of permanently colour coated galvnaised M.S. troughed metal sheet of approved profile. Minimum base metal thickness shall be 0.8 mm. The rate of zinc consumption for galvanising shall be 275 gm/sq.m. The external face shall have permanent colour coating of PVF 2 paint of minimum DFT of 20 microns and inner surface shall be coated with silicon modified polyester paint with DFT of 20 microns. ROOF DRAINAGE AND WATER PROOFING For efficient drainage of rainwater, roof concrete shall be given a gradient of a minimum of 1 in 100. Gradient shall be provided using screed concrete of grade M20 using 10 mm downgraded aggregate. Roof water proofing on RCC slabs shall be provided with high solid content liquid applied elastomeric water proofing membrane. Thickness of the membrane shall be a minimum of 1.5 mm. TABLE- 2
SL N O NAME OF THE BUILDING TYPE OF STR UCTUR E Steel frame NO OF STO REY TYPE OF CLADDING TYPE OF ROOFING TYPE OF ROOF WATERPROOFING
7.0 7.1
7.2
7.3
1.
Steam Turbine Generator Building
Cladding shall be of brick wall up to a height of 3000 mm from ground level on gable ends as well as on A row side except bays having rolling shutters and transformers. Sandwiched insulated metal cladding shall be provided above 3000mm level up to roof level and this will cover the brickwork also. Walls in front of transformers shall be of adequate thickness to satisfy fire withstand capability as per TAC regulations. On the C row, brick wall shall be provided from ground floor up to 1000 mm above deaerator floor level. Cladding above 1000mm level shall be
A-B BAY: In-situ RCC slab of minimum 90mm thickness clearing trough laid to a slope of 1 in 100, constructed over permanently colour coated galvanised M.S trough metal sheet of approved profile
A-B BAY: Water proofing treatment using high solid liquid applied elastomeric water proofing as per ASTM C 836 & 898, 1.5mm thick over a layer of polymerised mastic to achieve smooth surface and a primer coat as per manufacturers specification. Wearing course shall be provided over the waISSUE R0 TCE FORM 329 R5

SPEC.NO. TCE.6417A-H-500-001
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SL N O
NAME OF THE BUILDING
TYPE OF STR UCTUR E
NO OF STO REY
TYPE OF CLADDING
TYPE OF ROOFING
TYPE OF ROOF WATERPROOFING
of permanent colour coated single skin non insulated metal cladding system in deareator bay. Brick wall above 3000mm all places shall be covered with single skin non insulated metal cladding and this will cover the brickwork also.
supported on steel purlins and trusses.
B-C BAY: In-situ RCC slab with conventional shuttering.
ter proofing course consisting of minimum 40mm screed of concrete M20 grade with 10mm downgraded aggregates, cast in panels of 1.2mx1.2m and reinforced with 0.56mm dia galvanised chicken wire mesh and joints sealed using sealing compound. Cement concrete chequered tiles of 25mm thickness over 15 thick cement mortar (1:3) bed shall be provided over water proofed area to a width of 1000 mm where movement of personnel is anticipated to approach roof extractor, AC/Ventilatio n equipment. ISSUE R0 TCE FORM 329 R5

SPEC.NO. TCE.6417A-H-500-001
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SL N O
TYPE OF STR UCTUR E
NO OF STO REY
TYPE OF CLADDING
TYPE OF ROOFING
2.
Control Room/ Electrical Bay Structures
Steel frame
Brick walls
In-situ RCC slab with conventional shuttering.
B-C BAY: Water proofing shall be provided as above. Screed shall be minimum 75 mm (average). Minimum Slope of 1 in 100 shall be provided by screed. Water proofing shall be provided as in the case of TG building. Screed shall be minimum 75 mm (average). The entire roof shall be made accessible by providing cement tile over the water proofing layer, set in cement mortar and pointed using neat cement mortar mixed with crude oil.
3.
Steam Generator/ ESP
Steel frame
Permanent colour coated galvanised profiled metal sheet with minimum of 0.6 mm base metal thickness.
Permanently colour coated galvanised MS trough profiled sheet with
------------------

SPEC.NO. TCE.6417A-H-500-001
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SL N O
TYPE OF STR UCTUR E
NO OF STO REY
TYPE OF CLADDING
TYPE OF ROOFING
4.
Mill and Bunker Bay Building
Steel frame
Bunker supporting structure is normally left uncladded up to the bottom of tripper floor. For tripper floor up to 3000 mm above finished tripper floor level, brick wall shall be provided. Above this level single skin non insulated permanent colour coated galvanised trough sheet cladding shall be provided and this will cover the brickwork also.
minimum of 0.8 mm base metal thickness. Tripper roof shall be of RCC supported on structural steel frame work with metal decking. Thickness of slab shall be from top of trough of metal deck.
Water proofing shall be provided as in TG building (A-B Bay). Screed shall be minimum 75 mm (average). Minimum Slope of 1 in 100 shall be provided by screed. Entire floor shall be provided with cement tiles set in CM 1:3, 25 thick and the tiles pointed with cement mixed with crude oil.
5.
Steam Generator Elevator supporting structure ESP control Building
Steel frame
Permanently colour coated galvanised single skin non insulated metal cladding system.
6.
Steel frame
Brick walls with wall in front of transformer yard made sufficiently thick to satisfy fire rating as per TAC regulations.
Permanently colour coated galvanised profiled metal sheet. In-situ RCC slab with conventional shutter-
---------------
Water proofing shall be provided as in TG building (B-C ISSUE R0 TCE FORM 329 R5

SPEC.NO. TCE.6417A-H-500-001
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SL N O
TYPE OF STR UCTUR E
NO OF STO REY
TYPE OF CLADDING
TYPE OF ROOFING
ing.
Bay). Screed shall be minimum 75 mm (average). Minimum Slope of 1 in 100 shall be provided by screed. Walkway with cement concrete tiles as specified elsewhere shall be provided as required. Water proofing shall be provided as in TG building (B-C Bay). Screed shall be minimum 75 mm (average). Minimum Slope of 1 in 100 shall be provided by screed. Walkway with cement concrete tiles as specified elsewhere shall be provided as required. Water proofing shall be provided as in TG building (B-C ISSUE R0 TCE FORM 329 R5
7.
Crushe r houses
Steel frame
Permanently colour coated galvanised single skin non insulated metal cladding system above 3000 mm wall on ground level and this will cover the brickwork also. For elevator & M/C room, permanent colour coated single skin non insulated metal cladding system.
8.
Junction houses
Steel frame
Permanently colour coated galvanised single skin non insulated metal cladding system above lowest working floor
In-situ RCC slab with conventional shutter-

SPEC.NO. TCE.6417A-H-500-001
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SL N O
TYPE OF STR UCTUR E
NO OF STO REY
TYPE OF CLADDING
TYPE OF ROOFING
level.
ing.
Bay). Screed shall be minimum 75 mm (average). Minimum Slope of 1 in 100 shall be provided by screed. Walkway with cement concrete tiles as specified elsewhere shall be provided as required. Water proofing shall be provided as in TG building (B-C Bay). Screed shall be minimum 75 mm (average). Minimum Slope of 1 in 100 shall be provided by screed. Walkway with cement concrete tiles as specified elsewhere shall be provided as required. Water proofing shall be provided as in TG building (A-B ISSUE R0 TCE FORM 329 R5
9.
Switch gear room/c ontrol room
RCC
Brick walls
10 .
DM plant building
Steel frame
Brick walls
RCC supported on structural steel frame

SPEC.NO. TCE.6417A-H-500-001
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SL N O
TYPE OF STR UCTUR E
NO OF STO REY
TYPE OF CLADDING
TYPE OF ROOFING
work with metal decking.
11 .
Emergency diesel generator + Compressor + Air washer Building
RCC
Brick walls
Bay). Screed shall be minimum 75 mm (average). Minimum Slope of 1 in 100 shall be provided by screed. Walkway with cement concrete tiles as specified elsewhere shall be provided as required Water proofing shall be provided as in TG building (B-C Bay). Screed shall be minimum 75 mm (average). Minimum Slope of 1 in 100 shall be provided by screed. Walkway with cement concrete tiles as specified elsewhere shall be provided as required. Water proofing shall be provided as in TG building (B-C Bay). Screed ISSUE R0 TCE FORM 329 R5
12 .
A C plant
Steel frame
Permanently colour coated galvanised single skin non insulated metal cladding system.above 3000 mm wall on ground level and this will cover
In-situ RCC slab with on colour coated trough

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SL N O
TYPE OF STR UCTUR E
NO OF STO REY
TYPE OF CLADDING
TYPE OF ROOFING
the brickwork also.
shaped permanent metal decking. Thickness of slab shall be from top of trough of metal deck.
shall be minimum 75 mm (average). Minimum Slope of 1 in 100 shall be provided by screed. Walkway with cement concrete tiles as specified elsewhere shall be provided as required. -------------
13 .
CW Pump House
Steel frame
14 .
Service building
RCC
5 (Min )
Wall of the pump house up to motor floor level at the pump discharge side shall be of RCC and colour coated galvanised single skin non insulated metal cladding system. above. In other areas, colour coated galvanised single skin non insulated metal cladding system above 3000 mm wall for bottom portion and this will cover the brickwork also. Brick walls
Permanently colour coated galvanised profiled metal sheet
Water proofing shall be provided as in TG building (B-C Bay). Screed shall be minimum 75 mm (average). Minimum Slope of 1 in 100 shall be provided by ISSUE R0 TCE FORM 329 R5

SPEC.NO. TCE.6417A-H-500-001
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SL N O
TYPE OF STR UCTUR E
NO OF STO REY
TYPE OF CLADDING
TYPE OF ROOFING
screed. Walkway with cement concrete tiles as specified elsewhere shall be provided as required. 15 . Workshop Steel 1 Sandwiched galvanised insulated permanently colour coated metal cladding system shall be provided above 3000mm brick walls on ground level and this will cover the brickwork also. Brick walls Permanently colour coated profiled sheet -------------
16 .
Any building other than stated above with RC Framing
RCC
Water proofing shall be provided as in TG building (B-C Bay). Screed shall be minimum 75 mm (average). Minimum Slope of 1 in 100 shall be provided by screed.
NOTE : 1. Roof shall mean any floor/ Roof/ stair roof exposed to atmosphere. 2. Screed shall be cast in panels and chicken wire mesh with joints sealed as specified. 7.4 Number and size of rain water down take pipe shall be decided based on the provisions of IS: 1742 and IS: 2527. The pipes shall be mild steel pipe conforming to class medium of IS: 1239 with welded joint. In the case of tall structures such as Turbine building, Bunker building, Boiler building

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where maintenance is not possible these pipes shall be galvanised. Where access is available for maintenance these pipes may be painted with synthetic enamel paint over primer. Preferably 150 mm dia pipes shall be used and minimum two number of pipes shall be provided for any roof area above 10 Sq m. The down comer pipes shall be suitably concealed within duct of masonry work, cement concrete or sheeting to match with the exterior finish. 8.0 8.1 FALSE CEILING AND UNDER DECK INSULATION False ceiling shall be provided in air conditioned spaces and other spaces as mentioned in finish schedule. Under deck insulation system shall be provided on the underside of the roof / floor slab of the air conditioned areas based on the functional requirement. Ceiling of air washer room shall also be provided with under deck insulation. Aluminium false ceiling system shall comprise of 84 mm wide 12.5 mm deep closed type plain panels of approved colour, roll formed out of 0.5 mm thick corrosion resistant aluminium alloy AA 5050 fixed on roll formed carriers. Additional hangers and height adjustment clips shall be provided for return air grills, supply air diffusers, light fixtures, AC ducts etc. Gypboard false ceiling system shall consist of concealed aluminium 600 x 600 grid framing with main aluminium member of 38x25x1.5 mm , cross tie of 25x25x1.5 mm and aluminium angle of 25x25x1.5 mm suspended by 6 mm diameter galvanised steel rods from main ceiling. Glass reinforced gypsum plaster boards (minimum 12 mm thick) shall be fixed to the aluminium frame with screws. All frame work shall be concealed behind the gypsum board and the surface shall be provided with smooth wall putty finish and two coats of approved acrylic emulsion paint over one coat of primer Suitable M.S channel (minimum ISMC100) grid shall be provided above false ceiling of T.G building control room area for movement of personnel to facilitate maintenance of lighting fixtures, AC ducts etc. CONTRACTOR shall prepare a layout of the false ceiling system incorporating light fixtures, supply air diffuser, return air grills, fire detectors, fire protection sprinklers etc. such that the ceiling looks aesthetically pleasing. Work shall commence only after the OWNER approves the layout. Under deck insulation shall comprise of 50 mm thick resin bonded mineral wool insulation mat conforming to IS: 8183. This mat shall be backed with 0.05 mm thick aluminium foil and 24 Gx25 mm wire mesh netting. These shall be fixed to ceiling or wall as the case may be with 100x50x6 mm slotted mild steel plate welded to M.S. plate inserts embedded at the soffit of the slab at 600 mm c/c and 14 G steel wire drawn through slots and fixed to wire netting. DOORS , WINDOWS AND PARTITIONS.
8.2
8.3
8.4
8.5
8.6
9.0

SPEC.NO. TCE.6417A-H-500-001
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9.1
9.2
Unless specified all windows and ventilators of air conditioned areas, entrance lobby of all buildings and windows/ventilators provided on the outer face of all buildings shall have, electro colour coated (anodised) aluminium framework with glazing. Buildings under coal handling system (like crusher house, pent house, transfer house, junction house etc) shall be provided with steel glazed windows. Doors for all air-conditioned areas, entrance doors to switchyard control building, office spaces, service building and all non-plant building shall be of anodised aluminium type fully glazed or partly glazed and partly panelled with pre-laminated (MDF exterior grade) particle board.. For toilet, pantry, janitor and spaces of similar nature shall be provided with PVC door. All other doors (unless otherwise specified) shall be of steel. Apart from main entry door all internal doors of office spaces shall be 40mm thick fully flush, solid core, wooden door with veneer facing on both sides. Internal doors shall have vision panel as required. Glazing for vision panel shall be tampered safety glass or wired glass. All fire doors and external doors shall be opened outside (towards egress). All exterior doors shall be provided with locking arrangement. Locking arrangement for internal doors shall be provided as per requirement of OWNER.
9.3 Double glazed wall panels with aluminium frame shall be provided between all air-conditioned and non air-conditioned areas. 9.4 Single glazed panels with aluminium frame work shall be provided as partition between two air-conditioned areas wherever clear view is necessary. All steel doors shall consist of double plate flush door shutters. The door shutter shall be 45 mm thick with two outer sheets of 18 G rigidly connected with continuous vertical 20 G stiffeners at the rate of 150 mm centre to centre. Side, top and bottom edges of shutters shall be reinforced by continuous pressed steel channel with minimum 18 G. The door shall be sound deadened by filling the inside void with mineral wool. Doors shall be provide with all hardware and fixtures like door closer, tower bolts, handles, stoppers, aldrops, etc. Both shutters and frames shall be factory galvanised, primed and field painted. All steel doors and frames shall conform to IS: 1038 & IS: 4351.
9.5
Wherever functionally required rolling shutters with suitable operating arrangement manual, mechanical or electric shall be provided to facilitate smooth operations. Rolling shutters shall conform to IS: 6248. 9.6 All windows and ventilators on ground floor of all buildings shall be lockable and provided with security grills of suitable anodised material used in windows..

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9.7
All Switchgear and cable spreader rooms shall be provided with minimum two fire proof steel doors to satisfy statutory requirement. Fireproof doors shall be provided with panic exit devices. These doors shall generally be as per IS: 3614 (Part I and Part II). Fire rating of the doors shall be as per TAC requirements. However minimum rating shall be 2 hours. These doors shall be double cover plated type with mineral wool insulation. The frame, shutter and hardware shall bear a certification label for class of opening and rating.
9.8
Hollow extruded heavy gauge section of minimum 3 mm wall thickness of reputed manufacturer like HINDALCO, Jindal Alumina Ltd. and as approved by OWNER shall be used for all aluminium doors, windows and ventilators. 9.9 Weather strip shall be provided to all external doors as well as in all air-conditioned area.
9.10 9.11
Specially fabricated sliding or double leaf side hung steel door shall be provided in mono rail location. Main entrance to control room of TG building shall be provided with air locked lobby with automatic closing sliding glass doors. Lobby shall be formed of anodized aluminium framing with toughened sheet glass 6 mm thick. Partition between control room and adjoining rooms shall be of glazed aluminium partition with 300 mm high brick wall at bottom for toe protection. All the doors in control room area shall be single leaf glazed aluminium doors. For movements of panels suitably sized double leaf aluminium glazed doors shall be provided. Battery room shall be provided with doors with louver at bottom. For airwasher room steel doors will be used which shall be made airtight. No window shall be provided in Air washer room. Standard duty hardware shall be used. Doors shall be provided with approved fittings, such as hinges, mortise, locks, oxidised lower bolts and handles, door stops, hydraulic door closer of approved make. Steel windows and ventilators for coal conveyer gallery shall be as per IS: 1061 and for other areas as per IS: 1038. Windows of coal galleries shall be provided with wire mesh. Ventilation openings shall be provided with drainable formed gutter type storm-proof blade louvers complete with bird screens. Operating damper blades shall be provided behind the fixed louvers to allow closing of the openings. On long expanses of louvers, a continuous blade concealed support system shall be provided. Louvers shall be fabricated from extruded aluminum, steel, or other tried and proven material which is resistant to the
9.12
9.13
9.14
9.15

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corrosive environment and shall be provided with a poly-vinylidene fluoride finish 10.0 10.1 GLAZING All inaccessible (where regular maintenance is not feasible) ventilators or windows of all buildings shall be provided with 6 mm thick Multiwall Polycarbonate plain or tinted sheet for preventing solar radiations. The multiwall Polycarbonate sheets shall be fire and u/v resistant, and suitable for continuous use up to a temperature of 100 C. Suitable aluminium beading shall be used. The open ends of the sheet shall be sealed as per manufacturers recommendations. Sky light/north light shall have multiwall polycarbonate sheet fixed with anodized aluminium frame of approved colour and the whole assembly shall be leak proof. All external windows of any air conditioned spaces and internal glazed partition between an AC and non-AC space, shall be provided with double glazing. Double glazing shall be consisting of two 6 mm thick clear toughened safety glass conforming to IS: 2553, hermetically sealed and separated by 12 mm thick gap for thermal insulation. External glass panel shall be tinted where exposed to sun. For single glazed aluminium partitions and doors, float glass of minimum 5.5 mm thickness shall be used. Ground glass / frosted glass of minimum 4 mm thickness shall be used for all windows / ventilators in toilets. Unless specified otherwise in this specification minimum thickness of float glass used for windows/ventilators shall be 4 mm. Float glass or flat transparent sheet glass shall conform to IS: 2835. 10.5 All glazing work shall conform to IS: 1083 and IS: 3548. All windows and ventilators located in fire prone areas shall be provided with minimum 6 mm thick wired glass conforming to IS: 5437.
10.2
10.3
10.4
11.0 11.1
WATER SUPPLY AND SANITATION Roof water tank of adequate capacity depending on the number of users and 8 hours requirement shall be provided for each building and pump house. Polyethylene water storage tank conforming to IS: 12701 shall be used. The tank shall be complete with all fittings including float valve, stop cock etc. For pantry and water cooler/purifier, separate supply shall be arranged for drinking water.

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11.2
Galvanised M.S. pipe of medium class conforming to IS: 1239 shall be used for internal piping works for potable water supply. Sand cast C.I. pipes with lead joints conforming to IS: 1729 shall be used for sanitary works above ground level. Minimum one toilet block with all the facilities shall be provided on each floor of main plant building and service building. Attached toilets shall be provided for all senior executive rooms and conference rooms. One toilet shall be provided in the boiler area. All other buildings where toilet is specified shall have one toilet block. The facilities provided in the toilet block shall depend on the number of users. However, minimum facilities to be provided shall be as stipulated below. IS: 1172 shall be followed for working out the basic requirements for water supply, drainage and sanitation. In addition, IS: 2064 and IS: 2065 shall also be followed. Each toilet block shall have the following minimum facilities. Unless specified all the fittings shall be of chromium plated brass (fancy type). i) WC (Indian type) Orissa pattern (580x440mm) as per IS: 2556 (Part-3) with all fittings including flushing arrangement of appropriate capacity and type 1no. WC western type 390 mm high as per IS: 2556 (part 2) with toilet paper roll holder and all fittings including flushing system of appropriate capacity and type 1 no. Urinal with all fittings as per IS: 2556 (Part-6, Sec.1) 2 nos. For service building all urinals shall be provided with photo voltaic control flushing system. Wash basin (oval shape) with all fittings as per IS:2556 to be fixed on concrete platform finished with 12 mm thick polished granite stone 2 nos. 600x450 bathroom mirror (minimum 5.5 mm thick float glass) with bevelled edges including all fittings 2 nos. Stainless steel towel rail (600 x 20mm) 2 nos. Stainless steel liquid soap holder cum dispenser 2 nos. Janitor room. Provision for installation of water cooler outside the toilet. Provision of ventilation shaft.
11.3
11.4
11.5
ii)
iii)
iv)
v) vi) vii) viii) ix) x) 11.6
Attached toilets provided for senior executive rooms and conference rooms shall have 1 WC, 1 urinal, 1 washbasin, 1 mirror, 1 no. Towel rail, 1 liquid soap holder cum dispenser. WC shall be of western type 390 mm high as per IS: 2556(Part-2) with toilet paper roll holder and all fittings including flushing valve of appropriate capacity and type. Toilets in service building and toilet adjacent to the control room in operating floor of TG building

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shall have provision for hot water supply to wash basins, by providing storage type geyser of approved make and capacity with suitable piping work. 11.7 Boiler area toilet shall have minimum 2 no. WC (Indian type), 4 no. Urinals, 4 no. Wash basins, 4 no. Mirrors, 4 no. Towel rails, 4 no. Soap holder cum dispenser, 2 no. Showers, janitor room and a provision for installation of water cooler. An eye and face fountain (combined unit with receptacle) conforming to IS: 10592 shall be provided in battery room, D.M plant and Chlorination plant. Unless specified all fittings and fixtures in the toilets shall have same specifications as stipulated in Cl.No.11.5. Stainless steel kitchen sink (750 mm size) for pantry shall be provided. Platform in pantry shall be finished with 12 mm thick polished granite stone. Laboratory sink shall be of white vitreous china of size 600x400x200 mm conforming to IS: 2556(Part-5) in laboratories and in battery room. In Main Turbine building and Service building at least one toilet block shall be provided for ladies. In case of spaces having ceiling height more than 3500mm, toilets shall be provided with false ceiling with moisture resistant Gyp board at 3000 mm from floor level. Soil and liquid waste from toilet shall be discharged to a manhole through separate pipe lines and from there it shall be routed to existing STP. For toilets of low usage and located at remote areas, separate septic tank and soak pit shall be provided. Water purifier (with RO system) cum cooler shall be provided for drinking water
11.8
11.9
11.10
11.11
11.12
11.13
11.14
11.15
12.0 12.1
MISCELLANEOUS REQUIREMENTS All external doors, windows, ventilators and rolling shutters shall be provided with sun and rain control arrangement either by projecting RCC chajja or by recessing the windows, ventilators at least by 400 to 500 mm from external surface. Minimum 750 mm projection from external surface shall be provided for Doors and rolling shutters with vertical fins. For windows projection shall be minimum 500 mm from exterior surface and at least 150 extra projection from window jamb in each side shall be kept. Continuous chajja shall be provided where doors or rolling shutter and windows are provided side by side. RCC chajja over openings shall have

SPEC.NO. TCE.6417A-H-500-001
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architectural feature to create a pleasing impact on the faade elevation. 12.2 Doors and windows on the external walls of buildings with metal cladding shall be fixed by creating recesses in the cladding system. No cable trenches shall be provided in TG hall, Boiler/ESP area, fuel oil pump house, Ash pump houses etc.
12.3
12.4
Duct banks consisting of MS/PVC conduits for cables shall be provided with proper sealing arrangement consisting of fire retardant sealing compound. All floor openings for cables below electrical panel shall be sealed with fire sealing compound after cables are laid. All openings in external walls provided for pipes, cables, ducts etc. shall be effectively sealed to prevent water seepage, after the routing of the services are over. NATURAL LIGHTING & VENTILATION The area of windows shall be a minimum 15% of the floor area to ensure adequate natural lighting. NBC and local building bylaws should also be adhered to in this regard Fans shall be provided in general office area as per standard norms. Wall mounted fans shall be provided in AC areas with false ceiling, ceiling fan shall be provided in other areas Sewerage system shall be provided with adequate ventilation for the pipe work as well as manhole.
12.5
12.6
12.7 12.7.1
12.7.2
12.8
12.9
Finish Schedule:
SL NO
NAME OF ROOM
FLOOR FINISHES
DADO / SKIRTING
INTERNAL WALLS
Turbine hall ground floor, mezzanine floor
50mm Granolithic floor with nonmetallic floor hardener
150mm high cement plaster skirting with neat cement finish
Acrylic Distemper
CEILING/FA LSE CEILING Acrylic Distemper

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Turbine hall operating floor
Unloading bay for TG building and other plant buildings. Switchgear room, cable spreader room, electrical room, MCC room, transformer room Mill and bunker bay
20mm thick mirror polished granite slab ( 1st quality ) 50mm Granolithic floor with nonmetallic floor hardener do
150mm high granite skirting
150mm high cement plaster skirting with neat cement finish do
Acrylic Emulsion paint over wall putty Acrylic Distemper
--
Acrylic Distemper
do
do
do
do
do
do
Workshop, , watch tower, package system generator building, areas in crusher house, junction house, pent house, transfer house etc
do
do
do
do
Pump room (all pump rooms except in Fuel Oil pump house) AHU and ventilation equipment room, PAC room, PRDS area, air washer room, etc. Areas under sheds like Lube oil storage shed, hydrogen
do
do
do
do
do
do
do
do
do
--
--
--

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10
11
Fuel Oil pump room and all other similar spaces with possibilities of oil seepage Chemical Dosing area
50mm Granolithic floor with nonmetallic floor hardener in checkered finish 300x300x20 mm thick acid/alkali resistant tile flooring
1500mm high cement plaster skirting with neat cement finish 1500mm high dado of acid/alkali resistant tiles
Acrylic Distemper
Acrylic Distemper
12
a)Battery room, battery charger room with lead acid batteries
a) 300x300x20 mm thick acid/alkali resistant tile flooring
a) 1500mm high dado of acid/alkali resistant tiles
Acid/alkali resistant chlorinated rubber based paint a) Acid/alkali resistant chlorinated rubber based paint
Acid/alkali resistant chlorinated rubber based paint a) Acid/alkali resistant chlorinated rubber based paint b) Acrylic Distemper
b) Battery room, battery charger room with Ni-cd batteries
b) 300x300x7 mm thick matt finish colored ceramic tile flooring
b) 150mm high skirting with 300x200x5 mm glazed ceramic tiles.
b) Acrylic Distemper
13
DM Plant area
As described in clause no.1.8 Acid/alkali resistant chlorinated rubber based paint
Acid/alkali resistant chlorinated rubber based paint

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14
Control Room, control equipment room, computer room, shift engineers room etc
a) PVC anti static tile for area with false flooring b) 600x600x10mm polished vitrified tiles in RCC floor slab area
a) 150mm high, PVC anti static tile
15
Office Room
600x600x10mm polished vitrified tiles
Acrylic Emulsion paint over wall putty b) 150mm For TG high, building 600x600x7mm main conpolished vitritrol room fied tile skirting wall surface shall be provided with aluminum lineal panels similar to false ceiling. 150mm high, Acrylic 600x600x7mm Emulsion polished vitripaint over fied tile skirting wall putty 1200mm high dado of 300x200x5mm glazed ceramic tiles Acrylic Emulsion paint over wall putty
Aluminum lineal false ceiling
16
Laboratory
300x300x7mm thick heavy duty ceramic tiles
Gypsum board false ceiling Gypsum board false ceiling in AC areas and Acrylic Emulsion paint over wall putty for non AC

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areas
17
Toilets in Service building and operating floor of PHB
Matt finish coloured designed 300x300x7mm thick ceramic tiles in 1:3 cement sand mortar. Floor tiles shall match with the concept of wall tiles. 20mm thick polished (1st quality ) granite slab (one piece ) shall be provided as wash basin platform
2400mm high dado of 300x600 coloured (in combination of plain and patterned) joint less, glazed ceramic tiles
Acrylic Emulsion paint over wall putty above dado
Acrylic Emulsion paint over wall putty Moisture resistant gypsum board false ceiling shall be provided at 3000 mm clear height, in case the RCC ceiling is more than 3500m m from FFL. Do
18
Toilets in all areas other than service building and operating floor of power house. Janitors and other similar wet areas
Matt finish coloured designed 300x300 ceramic tiles in 1:3 cement sand mortar.
2100mm high dado of 200x300 coloured glazed ceramic tiles On top of dado a border shall be provided with 200x75 coloured glazed ceramic tiles
Do

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19
RCC Staircase for Service building
20mm thick mir18mm thick ror polished gragranite for risnite for treads ers and skirtwith three nos. ing grooves 6x5mm along the length Granite slab shall be one single slab for each tread and riser. 20mm thick mir18mm thick ror polished Kota Kota stone for stone for treads risers and with three nos. skirting grooves 6x5mm along the length Kota stone slab shall be one single slab for each tread and riser. 20mm thick mirror polished ( 1st quality ) granite slab 2100 mm high dado with18mm thick mirror polished granite slab 150mm high skirting with, 600x600 x7mm thick polished vitrified tiles 150mm high skirting with, 600x600x7mm thick polished vitrified tiles
Acrylic Emulsion paint over wall putty
20
RCC Staircase for all plant and non-plant buildings
Acrylic Distemper
Acrylic Distemper
21
Service building entrance Lobby
22
Office spaces in service building
600x600 x10mm thick polished vitrified tiles
colour coated aluminium lineal ceiling system. Gypsum board false ceiling Decorative Gypsum board false ceiling with cove lighting proviISSUE R0 TCE FORM 329 R5
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Conference rooms in service building
600x600 x10mm thick polished vitrified tiles
Polished wooden veneer cladding up to 1500 mm from floor with teak moulding bead on top. Acrylic

SPEC.NO. TCE.6417A-H-500-001

Emulsion paint over wall putty above dado. Acrylic Emulsion paint over wall putty
SHEET 159 of 267
sion
24
Corridors in service building
do
do
25 Open Parking
area 26 Covered Parking area
27
Dozer shed. Diesel locomotive shed
interlocking solid concrete paver blocks 50mm thick granolithic floor with neat cement finish. Floor shall be provided with chequered finish 50mm thick granolithic floor with ironite topping.
Acrylic Emulsion paint over wall putty -
150mm high cement skirting with neat cement finish
Waterproof cement based paint
White wash
28
CHP Office complex
600x600 polished vitrified tiles
29
Pantry
Matt finish coloured designed 300x300 ceramic tiles in 1:3 cement sand mortar
150mm high cement plaster skirting with neat cement finish 150mm high skirting with, 600x600 polished vitrified tiles 2100mm high dado of 200x300 coloured glazed ceramic tiles
Acrylic Distemper
Acrylic Emulsion paint over wall putty Synthetic enamel paint above dado.
Gypsum board false ceiling Synthetic enamel paint above dado.
29
Exterior finishes
On top of dado a border shall be provided with 200x75 coloured glazed ceramic tiles External surfaces of all buildings shall be provided with plaster as described in clause no.4. Power house, Service Building and all non plant buildings shall be provided with exterior grade acrylic emulsion paint. For other buildings water proof

SPEC.NO. TCE.6417A-H-500-001

cement based paint shall be provided.
SHEET 160 of 267
12.9.1 The colour and pattern of finish shall be as per approved details. 12.9.2 The finish schedule as stated above shall be applicable to similar functional areas for all other buildings and facilities. 12.9.3 All the finishing materials shall be applied/provided as per manufacturer specification and guidelines under the supervision of manufacturer. 12.9.4 Wherever alternative materials are specified, the same shall be approved by ENGINEER In-charge. 12.9.5 All the finishes shall be of reputed and well established brand approved by ENGINEER In-charge, unless specified in the below list of preferred brands. 12.10 List of preferred brands for different finishes: SL no. 1. 2. 3. 5 6 7 8 9 10 11 12 Description Non metallic floor hardener Ceramic floor/wall tiles Vitrified tiles Gypsum board false ceiling Colour coated Aluminium lineal ceiling Wood Vineer and plywood. Wall putty Acrylic distemper Acrylic emulsion Synthetic enamel paint Acid/alkali resistant chlorinated rubber based paint Sanitary fixtures in service building and operating floor of TG building Sanitary fixtures in other areas Plumbing fixtures in service building and operating floor of TG building Plumbing fixtures in other areas Brand Sika, Fosroc, SWC Kajaria, Nitco, Johnson, do India Gypsum, Gyprock Luxalon Green ply, Centuryply, Euro Birla white, JK white, Nerolac, Dura shield Asian paints, Berger paints, ICI paints do do do Kohlar, Roca, Hindware(Italian collection or Art), Jaquar Hindware, Parryware, Kohlar, Roca, Jaquar(Astra or approved equivalent) Esco, Marc, Jaquar (Continental or approved equivalent). Parryware, Nirali, AnnuISSUE R0 TCE FORM 329 R5
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SS Sink

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pam, Jayna
12.11 All the fittings, fixtures and materials shall be of reputed and established brand approved by Engineer, unless specified in the list of preferred brands. 12.12 Wherever duplicity i.e. double specification for the same item is found, the bidder shall clarify before submitting the bids. 12.13 During detailed engineering stage, Owner may suggest some modifications, which shall be incorporated without any cost implications to Owner

SPEC.NO. TCE.6417A-H-500-001
1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA TECHNICAL SPECIFICATION PART G
SHEET 162 of 267
SECTION VI TECHNICAL SPECIFICATION PART G COOLING TOWER NATURAL DRAUGHT COOLING TOWER
1.0 1.1 SCOPE This specification covers the general requirements in respect of engineering by the BIDDER, of material, supply, manufacture, construction and performance testing of natural draught cooling tower including all associated works, appurtenances and equipment as well as electrical works. The scope of work shall not be deemed to have changed in case BIDDERs drawings submitted with their bid do not show some part of work as called for in the specification and the attached bid drawings unless categorically agreed to in writing before contract award. It is not the intent to specific completely herein all details of design and construction of works involved under this specification. However, the works shall conform in all respect to high standards of engineering, design and workmanship. APPLICABLE CODES AND STANDARDS The design, materials, manufacture, construction and performance of the natural draft cooling tower with is associated appurtenances and equipment shall conform to the following standard specification and code of practice. All the standard specifications and codes of practice referred to herein, shall be the latest edition including all applicable official amendments and revisions. A. Materials i. ii. iii. iv. v. vi. vii. IS:383 IS:432 IS:702 IS:780 IS:1536 IS1554 IS:1785 : : : : : : : Concrete and fine aggregates from natural source for concrete Mild steel and medium tensile steel and bars (parts 1 & 2) and hard drawn steel wire for concrete reinforcement Industrial bitumen Sluice valve for water work purpose (40-300mm size) Centrifugally cast (spun) iron pressure pipes for water , gas and sewage PVC insulated (Heavy duty) electric cables (Part 1). Plain hard drawn steel wire for pre-stressed (parts 1&2)
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concrete. High strength deformed steel bars and wires for concrete reinforcement. Hot applied sealing compound for joint in concrete Performed fillers for expansion joint in concrete pavements and structures (non-extruding and resilient type: Part-1 bitumen impregnated fibre) Hot rolled low, medium and high tensile steel Structural
viii. ix. x.
IS:1786 IS:1834 IS:838 (part1)
: : :
xi. xii xiii xiv. xv. xvi
IS:2062 IS: 2267 IS:3042 IS: 3384 IS:3589 IS:5620
: : : : : : : :
Polystyrene moulding and extrusion material Single faced sluice gate ( 200-1200mm size) Specification for bitumen primer for use in water proofing and damp proofing. Seamless or electrically welded steel pipes for water, gas and sewage (168.3mm - 2032mm). Recommendations for structural design for low head slide gates. Etch primer 43 Grade Ordinary Portland Cement Ready mixed paint brushing, bituminous, black, lead free, alkali, water and chlorine resisting. Sulphate resisting Portland cement.
xvii. IS:5666 xviii. IS:8112 xix. xx IS:9862
IS:12330 :
B. Codes of Practice i. ii. iii. iv. v. vi. vii. viii ix. x. IS:456 IS:800 IS:875 IS:1080 IS:1343 IS:1893 IS:2210 IS:2309 : : : : : : : : Plain and reinforced concrete.-Code of Practice General construction in steel. Code of practice for design loads other than (part 1 to part 5) earthquakes for building and structures). Code of practice for design and construction of simple spread foundations. Code of practice for pre-stressed concrete. Criteria for earthquake resistant design of structures. Criteria for the design of reinforced concrete shell structure and folded plates Code of practice for the protection of buildings and allied structures against lightning. Code of practice for painting, concrete, masonry and plaster surface Code of practice for bending and fixing bars for concrete reinforcement.
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xi. xii. xii. xiii. xiv. xv. xvi.
IS:2629 IS:2633 IS2751 IS:2911 IS:2950 IS: 3043 IS: 3370
: : : : : : : :
xvii. IS:4558
xviii. IS:11504 : xix. xx. xxi. IS:12200 : IS:1904 :
Recommended practice for hot dip galvanising on iron and steel. Methods of testing uniformity of coating of zinc coated articles Recommended practice for welding of mild steel bars for reinforced concrete construction. Code for practice for design and construction of (part 1 to 4) pile foundations. Code for practice for design and construction of (part 1) raft foundation. Code of practice for earthing. Code of practice for concrete structures for (Part 1 to 4) storage of liquids Code of practice for under drainage of lined canal Criteria for structural design of reinforced concrete natural draught cooling towers. Code of practice for provision of water stops at transverse contraction joints in masonry and concrete dams. Code of Practice for design and construction of foundations in soils general requirement Ductile detailing of reinforced concrete structures subjected to seismic forces Specification for water cooling towers.(All parts) Structural design of cooling towers. Specification for cooling towers-cooling tower institute USA B.S.Code of Practice for design of Concrete structures for retaining aqueous liquid.
IS:13920 :
xxii. BS:4485 : VGB xxiii. : Guidelines xxiv. ATC-105 : xvi. BS:8007 :
2.2
The applicability of the provisions for conformity to the various codes and standards stipulated shall be in the following order. a) Bureau of Indian Standards. b) British Standards Institution.
2.3
Wherever the above Standards are in conflict with the stipulations of this Specification, the latter shall govern. All local applicable statutes, regulations and safety codes for locality where the cooling tower will be installed, shall be fully complied with. GENERAL REQUIREMENTS
2.4
3.0
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3.1
The cooling tower shall be capable of cooling the rated quantity of water through the specified thermal range at the design wet bulb temperature and it shall conform to the other design parameters as stipulated in Data Sheet A. The scope of the BIDDERS work for a cooling tower shall include preparation of detailed designs and construction drawings and execution of work ,wind tunnel study including but not limited to supply of all material for foundations, shell, basin, fill with its supporting structure, staircases/walkways/platforms with hand railing, cold water outlet channels including gates, screens with handling arrangement, painting, access doors, water distribution system, aviation warning system, lighting, earthing , lightning protection system, with their associated hardware, etc., complete all as required to give satisfactory performance and as stipulated in various clauses in this document. CONTRACTOR shall submit detailed design calculations and construction drawings to OWNER for obtaining his approval prior to commencement of work at site. Owners/consultants approval to the design/drawings shall not absolve the contractor of their responsibility for correctness of design, accuracy of dimensions, loading details, etc of safety and stability of the structure including foundations, accessories, appurtenances etc. All design calculations and drawings shall be checked and signed before sending and shall be in English and in SI units. In the event, BIDDER has quoted in collaboration with another firm (either Indian or foreign), each and every drawing and design calculations submitted shall also bear collaborators seal and signature indicating their approval. BIDDER shall also furnish, along with the offer, back-up guarantee for the performance of the cooling tower from the collaborator. All modifications suggested by the OWNER to meet specification requirements and sound engineering practice shall be incorporated by the CONTRACTOR at no extra cost to the OWNER. In this respect, the decision of the OWNER shall be binding on the CONTRACTOR CONCRETE Cement used shall be Ordinary Portland Cement complying IS: 8112. Same brand of cement shall be used as far as possible throughout the construction of the entire structure to enable achieve uniform colour and surface finish throughout the shell. In locations where sulphate content in soil and ground water is high, sulphate resisting cement shall be used for all concrete work below the ground level. Fine and coarse aggregates shall be from natural sources complying with IS: 383. Particular attention shall be paid to the selection of dense aggreISSUE R0
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3.3
3.4
3.5
4.0 4.1
4.2
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gates of low drying shrinkage to reduce adverse effects on the strength, density, shrinkage, moisture movement and durability of the concrete. Aggregates shall be obtained from a single approved source and it shall be ensured that they are free from any impurities which could cause staining and affect achieving uniform surface finish and colour throughout the shell. Care shall be exercised to ensure maintenance of constant grading of the aggregates, particularly the fine aggregates. Maximum size of coarse aggregate shall not exceed 2/3rd the specified cover to the reinforcement less 5mm or 20mm whichever is lower. 4.3 While selecting the proportions of cement, aggregates and water to be used, specific attention should be paid to achieving the maximum possible density in-situ, having regard to the means of placing and compacting to be adopted at the site. Surface finish and colour of the concrete could also be affected by changes in the condition of formwork, release agent, stripping time, curing method, etc. All these factors shall, therefore, be maintained constant throughout the work on the shell. Cleaning of any droppings and closing up of any holes of the form work shall be carried out simultaneously as construction proceeds. Admixtures shall not normally be used unless such admixtures are proven to be wholly beneficial, as in special circumstances requiring retardation of setting time or on control of workability and further only with the written approval to this effect by the OWNER. Admixtures shall be free of all chlorides and in accordance with relevant IS codes. BIDDER shall furnish along with the bid, manufacturers literature and test certificates for the brand of admixture, if so contemplated to be used in the works. During execution no admixtures shall be permitted, unless its use has been accepted and made part of the contract. The OWNER reserves the right to direct the contractor to conduct laboratory tests or use test data, or other satisfactory reference before granting approval. The cost of all tests conducted shall be borne by the contractor. The admixture shall be used in strict accordance with the manufact urers directions and/or as directed by the Purchaser. No extra payment will be made to the contractor on account of using admixtures. Particular attention must be given to concrete placement because of the thin wall section and the presence of reinforcing steel. Consolidation of concrete shall be by vibration. Removal of air and water at the form surface shall be by vibration and rodding. Particular attention shall be paid to accurately shape the corners at all openings. Point of discharge of the concrete into the forms shall be 1500 mm above the concrete surface. Concrete shall be deposited in approximately level layers not greater than 400 mm deep unless permitted otherwise. Concrete in the cooling tower shell in each lift shall be so laid that the no. of vertical or inclined construction joints are minimized to the extent possiISSUE R0
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ble. Horizontal construction joints shall be maintained at uniform spacing throughout the height of the cooling tower as per the directions of the Purchaser. Special attention shall be paid to proper curing of vertical faces of the cooling tower shell so that these do not remain dry. All thin walled structural members shall be protected by means of curing agents. It is recommended to use a curing agent for the cooling tower shell providing additional protection like a single transparent cooling with a material based on vinyl mixed polymer. Inside face of the shell should be protected by a second pigmented coating of the name base material. Any other method of curing, if permitted by the Purchaser may be used. Sampling and testing of concrete shall be carried out as stated at the beginning of Section-VI (Part-C) and as per relevant Indian Standard Codes. However, following minimum tests shall be carried out, irrespective of whatever stated otherwise: Test of compressive strength Columns 1 cube per column Shell-2 cubes per climbing section
4.6
Minimum grade of concrete to be used for various structural elements shall be as follows in accordance with IS: 456. Foundation /Pile (if required)M30 Basin and Cold water channel : M30 Raker/Diagonal Column : M40 Ring Beam : M40 Shell : M40 Precast Elements : M35 Other Structural Elements : M30 PCC encasement : M20 Mud Mat PCC : M10 Mass concrete : M15 Structural concrete shall be of design mix complying with the relevant provisions of IS Codes or any International Code of Practice as approved by the Purchaser. Durability of concrete shall be as per IS: 456. Expose category shall be considered as severe for the basin and other underground structures. For Superstructure the expose category shall be taken as very severe. Cover to reinforcement, minimum cement content and minimum water cement ratio shall be as per requirements of IS456 for the appropriate exposure category (Refer Table 5 and 16 of IS456). Material, design, construction and workmanship in general shall conform to IS: 456 and IS: 3370.For prestressed concrete works,design,construction, and workmanship shall in accordance with IS:1343.
4.7
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4.8
4.9
Concrete in the cooling tower shell in each lift shall be so laid that the number of vertical or inclined construction joints are minimized to the extent possible. Horizontal construction joints shall be maintained at uniform spacing throughout the height of the cooling tower as per the directions of the Engineer. Maximum cement content shall be as follows: For shell and basin; 400 kg/m3 For others: 450 kg/m3
5.0 5.1 5.2
STEEL Reinforcement Steel Reinforcement shall conform to grade Fe 415D or Fe500D as per IS: 1786 except noted otherwise. All reinforcements used in RCC structure for Raker/Diagonal columns, Ring beams, complete Shell, hot water channel, precast elements shall be corrosion resistant variety (CRS of TATA STEEL,SAIL, RINL ). Deformed bars produced by rerolling finished products such as plates and rails (virgin or used scraps) or by rolling materials for which the metallurgical history is not fully documented or known, are not acceptable as per IS 1786-2008. Spacers to maintain the correct cover to the reinforcement shall be of dense concrete or mortar as per IS: 2502 or of other approved material of equivalent durability and colour as the shell concrete. Spacers that could lead to permeability of concrete and corrosion of steel reinforcement shall not be used. Not used Not used Structural Steel Steel for all structural steel works shall conform to IS: 2062. In view of particularly severe corrosive condition in and around the cooling tower, exposed steel work should be completely avoided. All exposed steel work shall be protected by hot dip galvanising. The minimum coating shall be 900 grams/sq.m. and comply with the requirements of IS: 2629 and IS: 2633. In addition galvanizing shall be followed by the application of one coat of etch primer conforming to IS: 5666 and painted with 2 coats of bituminous paint conforming to IS: 9862.
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5.4
5.5 5.6 6.0 6.1 6.2
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6.3
Exposed steel work which should be galvanized includes components/ general hardware such as access doors, hand railing, access ladders, door hinges/handles, manhole covers, monorails, bolts, nuts and washers etc. Manhole covers, door hinges/handles shall be of robust type. All welding for steel work shall be carried out before galvanizing. Any site joints required shall be either flanged or screwed type. Where galvanised mild steel bolts are used, the threads shall be coated with bitumen after assembly to protect areas which are damaged. Unprotected steel fixings for formwork, scaffoldings or for any other purpose shall not extend to the surface of concrete. Steel fixings left embedded in concrete shall have a concrete cover of at least 50mm and be adequately protected against corrosion. Fixings extending to the surface of concrete shall be of corrosion resistant material. Precast Concrete Components Materials for precast concrete components including joint fixings, lifting hooks and other exposed steel components shall conform to the requirements of Clause 5 and 6 of this specification. Prestressed Concrete Materials, design, construction and workmanship of prestressed concrete members shall be in accordance with IS:1343. Steel wires of prestressing shall conform to IS:1785 (part 1&2). Steel wire for prestressing shall conform to IS: 1785 (Part 1) (latest edition) or IS: 6003 (latest edition). Crack width control shall be limited to 0.1 mm. Particular attention shall be paid for achieving an effective bond of the wires in pretension units. For this purpose, use of indented wire is recommended. For this purpose, indented wire shall be used. Wires shall be corrosion resistant (marine grade) or should have coating system fit for seawater duty condition. Concrete and grouts used shall be sulphate resistant.
6.4
6.5
7.0 7.1
8.0 8.1
8.2
8.3
8.4 9.0
BIDDER shall furnish a write-up on the method proposed to be adopted for the manufacture of pre-stressed concrete elements. LOADINGS The natural draft hyperbolic cooling tower shall be designed for the following loads and combination
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9.1 9.1.1
WIND LOAD The wind pressure at a given height [P(z)] shall be computed as per the stipulations of IS: 875 (PART 3)-1987. For computing the design wind pressure at a given height the basic wind speed (Vb) shall be taken as Vb = 47 m/sec at 10.0 metres height above mean ground level. For computing design wind speed (Vz) at a height z, the risk coefficient K1=1.07 shall be considered. For coefficient K2, Terrain category 2 and class 'c' as per table 2 of IS-875 (Part-3)-1987 shall be considered. Coefficient K3 shall be determined by taking into account the local topography and tall plant structures in the vicinity. The wind direction for design purposes shall be the one, which would induce worst load conditions. However, Coefficient K3 shall not be less than one under any circumstances. The wind pressure at a given height shall be computed theoretically in accordance to the IS Codal provision given as under. Pz = 0.6 Vz2 N/m2 Steady pressure distribution around the shell for the wind loading shall be as per clause 5.1.3 of IS: 11504. The value obtained shall be increased by 10 percent to take into account any geometrical imperfections. The wind pressure distribution on the towers shall be assessed on theoretical basis as well as with the help of Model tests in a wind tunnel of turbulent boundary layer. The theoretical method outlined herein forms the basis only for assessing lowest limit of wind forces and shell structure interaction. For conducting model tests, bidders should survey the whole terrain including existing plant and future extension, if any, and make their own assessment of likely critical wind forces & wind structure interaction. It would be the responsibility of the bidder to collect necessary site specific meteorological data duly vetted from the recognized govt. agencies/institutions. After collection of necessary meteorological data, most critical wind speed, wind pressure distribution and other necessary parameter shall be determined by the bidder and get the same vetted by the above agency/appropriate agency(s). Then with the help of physical model tests in a wind tunnel, offering appropriate aerodynamic similitude, the bidder shall obtain the most critical forces, stresses etc. with cooling tower at various levels and locations. Such model test shall also include all adjacent topographical features, buildings, and other structures which are likely to influence the wind load pattern on the tower significantly including cooling tower. The model test shall be carried out in a well reputed institute/testing laboratory after obtaining prior approval from the Owner. The testing agency selected by the bidder shall have requisite experience and should have successfully carried out tests in the past for at least one coolISSUE R0
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9.1.3
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ing tower of similar capacity. The model tests shall be duly witnessed and approved by the Owner. The model test results shall be made available before final approval of the design. 9.1.4 The complete cooling tower shall be designed for all possible wind directions and on the basis of worst load conditions as obtained from Model test and theoretical methods. Under the theoretical method, the circumferential net - wind-pressure distribution and wind pressure coefficient (p) for the tower shell (without meridional ribs) shall be obtained from the "Criteria for Structural design of Reinforced concrete Natural Draft Cooling Towers" IS: 11504-1985. The above circumferential wind pressure coefficient (p1) shall be increased by multiplying it by 1.43 to account for turbulence in the incident wind and load intensification due to turbulence induced by the adjacent cooling tower or the other structures of significant dimensions. Therefore, the actual design circumferential net wind pressure coefficient (p) shall be computed as p = 1.43 (p1), where (p1) is the wind pressure coefficient as per IS: 11504-1985 increased due to geometric imperfection as per above clause no. 9.1.2.
9.1.5
. This design net pressure coefficient (p) and the distribution along the circumference of tower shall be used at all heights of the tower. The above design net pressure coefficient (p) includes the effect of internal suction. In order to compute the quasi-static design wind pressure at a given height along the circumference of the tower, the net design pressure coefficient (p) shall be multiplied by the wind pressure acting at that height [P(z)] as specified above. 9.1.6 The bidder shall also compute the wind pressure (Pz) along the wind direction by Gust Factor (GF) or Gust effective factor method (GEF). Method for estimating the wind load on the tower and other elements shall be based on IS-875 (part-3)-1987. While calculating the gust factor, the term `b' shall be taken as the diameter of the throat in Fig. 10 of IS: 875 (Part-3)-1987. Dynamic effects on the tower due to wind action shall also be investigated to ascertain the wind induced oscillation such as ovalling and excitation along and across the wind direction. Damping factor as 1% of critical damping shall be considered for dynamic analysis. Bidder shall carry out detailed analysis for the tower and consider the worst combination of static & dynamic effects. Design of the tower shall satisfy quasi-static method & Gust factor method. Entire analysis and designs adopted shall be fully supported with authenticated literatures/documents along with relevant references where the same has been successfully implemented. The wind load as specified in clause above shall be the minimum loading to be considered for analysis
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and design. However, bidder shall also carry out the entire analysis and design on the basis of BS 4485 (latest) for smooth shell surface. The design of entire tower including foundation shall be checked as per BS 4485 as the case may be. The final design shall be based on the worst case situation i.e. each element including foundation of the tower shall be designed on the basis of highest loading/ stresses computed as per above. However, the basis of wind speed shall be as per clause above. In case the bidder proposes to adopt aerodynamic rough surface such as provision of meridional ribs in the cooling tower shell, the pressure coefficients as given in the VGB-BTR KUHLTUMRE GERMAN SPECIFICATIONS (latest) (structural design of cooling towers) shall be permitted. The provisions of BTR may be adopted for choosing the value of circumferential wind pressure coefficient (p1) only. The wind pressure coefficient (p1), as obtained from BTR after accounting for internal suction shall be multiplied by a factor 1.43 to arrive at the net design pressure coefficient (p). The bidder shall furnish authorized English Translation of VGB-BTR KUHLTURME GERMAN SPECIFICATIONS (latest) for the review of the OWNER. All other stipulations as specified in these specifications shall be met with.
9.1.8
9.2 9.2.1
EARTHQUAKE LOAD The seismic analysis shall be carried out in accordance with IS: 1893 (all latest parts) by modal analysis for the hyperbolic cooling towers. The earthquake analysis of the shell and its support columns including the foundations shall be carried out by response spectrum method as described in IS: 1893 part 1 and part 4.For fill supporting structures also, response spectrum method shall be adopted. Entire analysis and designs adopted shall be fully supported with authenticated literatures/documents along with relevant reference where the same has been successfully implemented. Importance factor shall be as specified elsewhere. DEAD LOAD For assessing the self weight of the structure, the specific weight of the concrete shell shall be taken as 25 kN/cum. All other dead loads shall be assessed as per IS: 875. The loadings brought upon the shell by permanent fixings shall be minimised to the greatest extent possible. However, when these attachments are made, their effect upon the structure shall be thoroughly investigated.
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9.3 9.3.1
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9.4
CONSTRUCTIONAL LOADINGS Contractor shall be fully responsible for ensuring safety by checking the designs, for all the temporary construction loadings as applicable. Factors causing temporary loading may include the following depending upon the method of construction. a) Barrowing of concrete b) Scaffolding and formwork c) Loads produced by anchoring devices of climbing scaffolds. d) Hoist fixings e) Storage of materials on scaffolding f) Temporary access g) Tower crane fixings h) Works temporarily omitted for access purposes.
9.5
MISCELLANEOUS LOADS Effect on account of the following loads shall also be investigated. a) Loads due to temperature effects The cooling tower shell shall be designed for stress due to axisymmetric temperature distribution corresponding to external ambient temperature variation from -1.1 C to 48 C. However, the detailed analysis of actual thermal gradient by considering temperatures inside the tower and external ambient temperatures shall be carried out furnishing detailed references and justification for the same. The shell shall also be checked for thermal stresses arising due to partial operation of the tower in case the operational philosophy so demands. The analysis for the stresses resulting from non-axisymmetric temperature loading shall be carried out. In such non-symmetric temperature loading, the calculation shall be based upon the operating specification. Besides, the shell shall be designed for one sided solar radiation effect also. Nevertheless an effective temperature difference of at least 25C across the shell thickness constant over the height and following a sine functions along half the circumference shall be considered. Entire analysis and designs adopted shall be fully supported with authenticated literatures/documents along with relevant references where the same has been successfully implemented
b) Subsoil deformation.
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Differential settlement between adjacent sections of foundation shall be considered under most unfavourable load combination. All loads likely to act on cooling tower but not specified herein shall also be considered for the design of cooling tower structures 10.0 10.1 LOAD COMBINATIONS AND PERMISSIBLE STRESSES All RCC structures of the cooling tower shall be designed by both working stress and limit state method. The load combinations shall be as follows: a. For working stress method i. DL + WL ii. DL + 1/3WL + EQ For limit state method i. 1.5DL + 1.5WL iii. 1.5DL + 1.5EQ + 0.5WL iv.
b.
c.
For stability check i 0.9 DL + 1.5 WL ii 0.9 DL + 1.5 EQ + 0.5 WL
where
DL = Dead Load WL = Wind Load EQ = Earthquake Load
10.2
While considering the above load combinations, the appropriate stress resultants shall be superimposed most unfavourably. Stress due to subsoil deformation, temperature and constructional loads shall also be added to arrive at the most unfavourable load combination. Wind load indicated in the combination are enhanced load taking into account enhancement factors obtained from model study / from code of practice. Besides above load combination, other load combinations as per relevant IS codes shall be followed. Since cooling tower a wind predominant structure, increase in permissible stresses due to wind in combination with other loads shall not be allowed. Increase in safe bearing capacity for design of foundation under wind load combination shall also not be permitted. FOUNDATIONS The design and construction of cooling tower foundations shall be in accordance with the requirements stipulated in IS: 1080/ IS: 2911/ IS: 2950/IS
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6403 as applicable. Continuous foundations or continuous annular pile cap shall be provided for cooling towers based on type of foundation system. 11.2 The foundation structure shall be designed for loads indicated in clause 10.0 of this specification and shall in addition consider the following: a) Thermally induced local loading where supply culverts pass through the foundation structure without structural isolation. b) Cold water basin floor loading. c) Surcharge load of 20 KN /sq.m at the ground / grade level. d) In case of subsoil with varying degrees of stiffness, non uniform settlements due to the varying stiffness have to be determined. The redistribution of stresses resulting from interaction effects between the subsoil and the shell structure have to be taken into account. 11.3 The foundation design shall be based on the foundation criteria as indicated in Data Sheet-A. Permissible increase in safe bearing capacity of soil/safe pile capacity shall be 25% under seismic load condition. Such increase shall be only on the net bearing pressure of soil/pile capacity. No such increase in Safe bearing capacity of soil/pile will be permitted for wind load combinations. For the load combination 0.9DL+1.5WL, the arc over which lift off, if any, occurs should not exceed 300 of the circumference of towers provided the foundation is a continuous annular raft foundation. For the combination of DL+ WL no Lift off of foundation will be permitted. All back filling of excavation inside cooling towers shall be carried out with mass concrete. BASIN AND COLD WATER OUTLET The basin shall be divided into two compartments to facilitate complete isolation of one half of the basin for the purpose of cleaning and maintenance, while the other half is in service. A drain sump shall be provided for each half. The basin floor of each compartment shall be sloped at 1:120 towards a collecting sump for effectively draining the water to permit desilting/ desludging. To minimise obstructions to the flow of water, only the columns supporting the fill structure shall be projected above the basin floor. Water shall be drained out from the sump into a drain chamber outside the basin by providing a 300mm dia CI drain pipe conforming to class B of IS: 1536 embedded below the basin floor. Suitable sluice gates of the rising spindle type conforming to IS: 3042 or sluice valve conforming to IS: 780 shall be provided in
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the drain chamber with provision of platform with access ladder, rungs for operating the gates/valves and pump suction pipe with foot valves as indicated in Data Sheet-A. 12.3 A minimum of 300 mm free board shall be provided for the basin over the maximum design water level. The basin wall shall project a minimum of 500 mm over the surrounding grade level. Each compartment of the basin shall be provided with a concrete channel for outlet of cold water. The outlets for each compartment shall be combined into one channel and routed.PVC water stop 225mm wide shall be provided at the end of the channel in the wall and floor. Cold water outlet channels shall be provided with grooves formed out of hot dip galvanized steel channel sections for introducing the stoplogs and screens. Stoplogs shall be fabricated out of structural steel plate and rolled sections and provided with rubber seals conforming to IS:5620/ IS:11855 to prevent leakage. Musical note type of rubber seals shall be provided at the edges and wedge type at the base suitably fixed using clamps and stainless steel screws for effective water tightness. Two numbers of stoplog shall be supplied. Structural steel for stop log shall be hot dip galvanised and provided with etch primer and bituminous paint. All side guides of stoplogs and second stage embedments shall be of stainless steel of Grade AISI 316L. 12.6 Screens shall be out of 8 gauge 25mm clear opening stainless steel of grade AISI316L grade crimped wire netting welded to frame of structural steel section/ flats. Two numbers of screens shall be supplied per tower. Structural steel for screen shall be. hot dip galvanised with etch primer and bituminous paint Suitable arrangement of monorails with hoist shall be provided for handling stoplogs and screens.
12.4
12.5
12.7
12.8 The basin walls, floor slab and outlet channels shall be of reinforced concrete construction. The design and construction of these water retaining structures shall be in accordance with clause 4.5 of IS: 3370(2009) with provision of construction/ contraction and expansion joints. . Minimum thickness of structural concrete elements shall be 230mm. Basin walls shall also be designed for condition of external surcharge load along with ground water table at finished grade level and basin being empty. Construction of floor and wall shall take into account provisions of clause 11.3 and 11.4 of IS 3370 part-1-2009.. 12.9 Any loose pockets of soil below the basin floor shall be removed and filled back with plain cement concrete of mix M15
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12.10
Basin floor shall be cast in panels ensuring that the maximum width of the panel does not exceed 7.5m in alternate bays in chess board pattern. Curing shall be carried out for a minimum period of 10 days. Interval between castings of two adjacent strips/panels shall be a minimum of seven days period. Expansion joints in floor shall be spaced at not more than 30m apart. No through bolts for shuttering shall be permitted. During the construction stage of the cooling tower, basin floor shall always be covered with at least 50mm depth of water by forming suitable bunds using sand cement mix. The basin and channel walls shall be designed for a minimum surcharge load of 20 kN/m2 to allow for construction plant operating in the vicinity. In case the actual loading is higher than that specified, then appropriate loading shall be considered in design. External pressure due to earth and ground water shall not be relied upon to reduce the effect of the internal water pressure, but account shall be taken of the ground water pressure when considering buoyancy or stresses in the empty water retaining structure. The basin wall shall be designed to resist full water including the free board to take into account possible surge from normal pump operation. Basin floor slab shall be designed for uplift water pressure/buoyancy by adding suitable self weight. The effect of provision of flap valves/pressure release valves shall not be considered in the design of CT basin The cold water basin including sludge pits, cold water channels, shall be designed for the following condition: i) ii) Water filled inside up to maximum level and no earth outside. Earth pressure with surcharge load of 20 kN/m2, as applicable, and with/ without ground water table at final graded ground level outside and no water inside.
12.11 12.12 12.13
12.14
12.15
12.16
12.17
Construction of the basin and channel shall be watertight with the provision of 225mm wide approved quality PVC ribbed water stops at all construction joints and expansion joints. For Basin and channel base, kicker type of PVC water stops is preferred, whereas in walls water stops with Central Bulb and End Grip will be preferred. It shall be ensured that 225mm wide water stops are also provided all along the edges of comISSUE R0
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mon outlet channel and left projecting by half its width, to facilitate later construction. 12.18 The water retaining structures shall be tested for water-tightness in accordance with IS: 3370, without the backfill, if any, placed in position. The water level for test shall be full basin level including free board. Any rectification measures required to satisfy the test criteria shall be executed by the CONTRACTOR at his own cost all as per the directions of the OWNER. All round cold water basin, 2000 wide plinth protection shall be provided in. 150 thick RCC slab of M-25 grade. The minimum reinforcement shall be 10 mm dia spaced 150 mm centre to centre both ways top and bottom. The RCC slab shall be overlaid 100 mm thick M-15 PCC mat and 300 mm well compacted sand layer. RCC drain shall be provided all round the plinth protection with a minimum clear width of 300mm and minimum depth of 300mm laid to a slope 1:1000.The drain shall be provided all round the plinth protection to lead away water spillage to the project storm water drain. 13.0 13.1a TOWER SHELL SHELL GEOMETRY The shape of the tower shall be hyperboloid in vertical section and circular in plan The base diameter, air intake opening height, tower height and throat diameter shall be determined by thermal design consideration by the bidder and submitted to Purchaser for approval. As the range of possible hyperbolic shell shapes is infinite, the same shall generally conform to the following major proportions, which have been extensively adopted in cooling tower constructions. H/D=1.2 to 1.55 Where H is the total tower height above basin sill level Hb/H = 0.75 to 0.85 Hb is the vertical distance from the throat to basin sill level and `D' is the base diameter at basin sill level. However, other proven profiles may be permitted subject to approval from the OWNER. Bidders shall submit along with the offer complete details of the profile, in case the profile is not within the limits stated above, and the
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names of the sites where such shell profiles have been successfully constructed. Notwithstanding what is stated above, the OWNER reserves the right to accept / reject the shell profile. 13.1b Checking of shell geometry Check for absolute positions may be carried out from ground stations arranged at not more than 10 degree plan angle apart. Readings of horizontal radius shall be taken at every 6m height or weekly during construction period whichever is more frequent. If the permissible dimensional tolerances are exceeded, the OWNER will instruct the contractor, in writing, to stop construction of the shell. The Contractor shall then examine the situation and submit a report to the OWNER who may require the contractor to demonstrate by calculations that the structural integrity of the shell will not be impaired as a result of the imperfections. The calculations shall be submitted to the Purchaser, for approval, before construction will be permitted to proceed. If in the opinion of the OWNER, the calculations show that the integrity of the shell could be threatened, the Contractor will be required to submit to the OWNER detailed arrangement and supporting calculations to set right the shell geometry for approval, before construction will be permitted to proceed. The cost of carrying out the calculation, any remedial work required and idle time or any delays to the construction programme as a result of dimensional tolerances being exceeded will be borne by the contractor. Adjustment to the tower shell line on the basis of the survey results shall be made gradually, limiting the maximum change of direction from the existing vertical shell profile to be not more than an angular change of 10 mm measured over 1m of height. Any such adjustment shall be made with full knowledge and consent of the OWNER. The contractor shall carry out an as-built-survey of each lift of the shell. The results of these checks will be recorded on a suitably developed drawing of the shell from which it will be possible to locate the survey check point. A copy of these results will be presented to the OWNER prior to commencing the next shell pour. The contractors shell construction procedures shall include for providing the OWNER with the facilities and a reasonable time period as may be required to carry out an independent check of the completed works. Suitable communication system such as telephone, wireless equipments, etc. shall be provided by the contractor so that the communications are possible at different elevations of the tower from the ground during construction. 13.2 13.2.1 Tower Shell Boundary conditions Shell Analysis The complete cooling tower, including the shell, columns, ring beam and
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foundation, shall be structurally analyzed using a proven finite element modelling technique or an approved alternative method including validation of software used for analysis. For elastic analysis, concrete may be assumed to be uncracked, homogenous and isotropic. The design geometric profile, thickness variation and support conditions of shell shall be considered in the structural analysis.
A. The following boundary conditions shall be assumed for the design of cooling tower shell: a) At upper Edge
The top edge of the shell shall be gradually thickened to form a ring beam to guard against possible instability of the top of the shell due to high velocity wind gusts. Top edge shall be considered as a free edge in the analysis. The thickness transition from shell to upper ring beam shall be smooth. b) At Lower Edge
The lower edge of the shell shall be thickened to form a lower ring beam. The thickness transition from shell to lower ring beam shall be smooth and shall be considered as an integral part of the shell. The lower boundary of the shell shall be considered as elastically supported by discrete columns. The influence of both support structure flexibility and foundation settlement shall be considered in the analysis and design of cooling tower shell. The shell analysis should include following information at every 10 plan angle and at not more than 0.05 of the shell height interval: i) Meridional and circumferential direct stress resultants and the tangential shear stress resultants. ii) iii) B. Meridional and circumferential bending moments. Displacements normal to the shell mid-surface. Buckling of Tower shells
Critical dynamic pressure (wind pressure), at buckling shall be as given below: Pcr = 0.07 Ec ( d /rth)7/3 where, Pcr = Critical buckling pressure. Ec = Modulus of elasticity of concrete of the shell (short term modulus)
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d = Thickness of the shell rth = Throat radius of the shell The shell buckling shall be checked using the design dynamic wind pressure and other relevant loads acting on the tower. The factor of safety against buckling shall be not less than 5 for the completed tower as well as whilst under construction. Besides above, a buckling analysis with wind forces should be made using the theoretical tower geometry and boundary conditions, including the influence of dead weight, by the method of buckling stress state (BSS) approach in accordance with the provisions of VGB. The buckling safety factor shall be at least 5.0 for load combinations of dead load + wind load. When imperfections in the shell geometry are larger than specified tolerances, the analysis should be rechecked to account for such imperfections and ensure that the desired buckling capacity remains.
13.2.2
The tower shell shall have a minimum thickness of 230mm duly considering exposure category very severe specified for shell.
13.3
DESIGN
13.3.1The tower shell shall be designed based on bending analysis and as per elastic theory for thin shells. The relevant provisions of IS: 2210 Criteria for the design of reinforced concrete shell structures and folded plates and IS: 2204 `Code of Practice for construction of reinforced concrete shell roof` shall also be deemed to be applicable. All other design criteria for the cooling tower shell which are not specified above shall be in accordance with BS: 4485 Part 4 and BTR.
13.3.2
Consideration shall also be given to the following effects of temperature and moisture variations that occur in the shell: a) The strain resulting from a temperature gradient across the shell thickness. b) The strain resulting from moisture content variations through the shell thickness, and c) The strain resulting from variations of conditions (a) and (b) caused by rain and sunshine on one side of the tower or partial operation of the tower.
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13.3.3
The effect of stress concentration due to any fixtures shall be taken into account. In working stress method of design, design of structures like shell, columns, beams, fins, walkways, slabs, etc. which are in contact with water / water spray / moist air, shall be carried out adopting concrete stresses as given in IS: 456 & limiting the stresses in reinforcement to the values as given in clause 4.5.3.2 of IS: 3370-2009 and the crack width shall not exceed 0.1 mm in tensile zone. In Limit state method of design, design of structures like shell, columns, beams, fins, walkways, slabs, etc. which are in contact with water / water spray / moist air, shall be carried out as per limit state method of IS:456. The stress in the reinforcement steel shall not exceed 87% of the specific characteristic strength of reinforcement steel and the compressive stress in the concrete shall not exceed 45 % of the specified 28 days cube strength of the concrete as per IS:456. The crack width shall not exceed 0.2 mm in tensile zone.
13.3.4
13.3.5
13.4 13.4.1 13.4.2
REINFORCEMENT AND COVER Reinforcement shall be provided on each face of the shell in both directions. Minimum shell reinforcement as percentage of concrete cross section, using high yield strength deformed bars, shall be as follows: Top one - third portion of shell 0.4% in circumferential direction and 0.35% in meridional direction. Remaining two - third portion of shell 0.35% in both the directions.
13.4.3
The maximum spacing of reinforcement in either direction on each face shall be restricted to twice the thickness of the shell or 200 mm whichever is less. Minimum lap lengths in shell shall be 1.3 times Ld where Ld is the development length as described IS: 456. All laps shall be staggered. Not more than one-third of the total number of bars at a level shall be lapped. Minimum distance between centre to centre between two consecutive laps shall be kept as per IS 456.
13.4.4
13.4.5
Column reinforcing bars shall be carefully anchored in the shell and in the foundations. The minimum anchorage length in the shell shall be 2Ld. Minimum size of deformed bars used shall be 10mm for circumferential reinforcement and 12mm for meridional steel. Not used.
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13.4.8
13.4.9
The minimum clear cover to shell reinforcement shall be 50 mm. Rigorous control in reinforcement positioning, concrete quality, placing and compaction shall be exercised to ensure this requirement of minimum cover. For all components other than the shell, cover to reinforcement shall be as specified in IS: 456. The two layers of reinforcing meshes shall be adequately joined by S-hook over the total shell surface. At least two S-hooks in each square meter area of shell surface shall be provided. The hooks shall be of minimum 6 mm diameter bars.
13.5 13.5.1
Openings in Shell Openings through the shell shall be avoided wherever possible. Any openings through the shell, if required, shall be kept to the minimum size and shall be so shaped to avoid sharp corners to minimize stress concentrations. Openings through the shell shall be at right angles to the middle surface of the shell, so as to avoid acute angled edges to holes. Any thickening necessary at the edges shall be smoothly tapered back to the shell thickness. No horizontal thrust due to inlet piping shall be transmitted to the shell. Openings through the shell shall be provided with additional reinforcement at each edge, equal to 75% of the reinforcement intercepted by the opening, in the direction parallel to the edges. Extension of vertical reinforcement shall be equal to 1.3 Ld + B/2 where B=width of opening. In addition, diagonal reinforcement shall be provided at each corner equal to a cross sectional area in cm2 of 0.5 d, where d is the thickness of the shell in cm.
13.5.2
13.5.3
13.5.4 13.5.5
13.6 13.6.1
Formwork Design and execution of form works shall conform to National safety code and relevant IS code The type of formwork proposed to be adopted and its effect shall be considered in the design and analysis of the shell. All the scaffoldings and temporary platforms shall be designed for a minimum superimposed loads of 400 kg/m2 and appropriate wind load at that elevation.
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13.6.4
Formwork shall be properly designed so as to avoid vertical construction joints.
13.6.5 The supervision, setting out, checking and shuttering system shall be such as to ensure production of a smooth surface, without geometrical discontinuities and achieving a high degree of dimensional accuracy. 13.6.6 Latest and hydraulically operated jump formwork equipped with sophisticated instruments to check the accuracy of shell geometry alignment and profile shall be used.
13.6.7 The BIDDER shall submit the details of jump formwork to be used in construction of shell to the OWNER for approval at least 2 months before the start of construction of shell. A scheme showing various checks to be performed and methodology for checking shall accompany the formwork details. 13.6.8A shell lift check card as desired by the Engineer-in-charge of the OWNER for total quality control shall be submitted by the VENDOR before concreting of shell. 13.6.9 Special inspection hoist shall be provided for checking the form works, placing of reinforcement and pouring of concrete. No concreting shall take place without the erection of inspection hoist and checking the formworks and reinforcement. TOLERANCES The shell should be constructed within the dimensional tolerances stipulated in clause 7.3 of IS: 11504. Permissible allowances for survey inaccuracies while checking of shell geometry shall be as per clause 7.4 of IS: 11504. 13.8 Provision of meridional ribs in Cooling Tower Shell Meridional ribs in the cooling tower shell may be provided subject to the following conditions: a) Minimum thickness of shell excluding ribs shall not be less than 200 mm. b) Co-efficients for pressure distribution around the cooling tower circumference including suction may be taken as per VGB-BTR KUCHLTURMEN SPECIFICATIONS (latest). All other factors including load intensification factors shall be as specified else where in these specifications. c) Shell buckling and strength shall be checked as per clause-b
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above without considering the effect of ribs. d) All other stipulations as specified in this specification shall be met with. e) Bidder shall furnish an authorized English translation of the VGB-BTR KUHLTURME GERMAN SPECIFICATIONS (Latest) during detailed engineering stage.
14.0
RAKER/ DIAGONAL COLUMNS
Inclination of the column shall closely match the meridional slope at the shell so that the load transfer to foundation takes place through predominantly axial force in columns. Raker columns shall be designed for the most critical forces transferred to an individual rake column from super-structure considering various load combinations. For selecting effective length of the raker columns, following restraints shall be considered: In case columns restrained at both the ends, the effective length shall be 0.8 and 0.6 times the length of the column radially and tangentially respectively. In case columns are restrained at one end only, the effective length of columns shall be 0.9 and 0.7 time the length of columns radially and tangentially respectively. 15.0 15.1 15.2 FILL Type and material of fill shall be as per Data Sheet-A. The fill shall be adequately supported to minimize sag, possibility of dislodgment and damage as a consequence of induced vibrations in the fill. In case of film type of fill, the supporting hanger rods/tubes shall be of stainless steel conforming to AISI 316L. FILL SUPPORTING STRUCTURE Fill supporting structure with its foundation shall be of reinforced concrete construction. Fill supporting structure, where formed of precast concrete units, shall be made stable by use of either bolted, cast-in-situ or glued joints. Members of precast concrete structure shall be either pre-stressed or reinforced concrete units. Where bolts are used for permanent connections, they shall be of a
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material highly resistant to corrosion or fully protected by embedment or coating. 16.3 The columns and beams supporting the fill shall be adequately braced in all directions. The design of all members shall be checked for resistance to buckling. The stability of the fill support structure shall be checked for its capacity to resist a horizontal force of 2% of self-weight, the fill and supporting structure, assumed to act horizontally in any direction. The structure shall also be checked for the appropriate earthquake loading as applicable. During erection, care shall be taken to ensure the stability of the potentially unstable, partially completed structure. The fill support structure members shall be designed to cater for the likely loads to be imposed thereon, including: a) temporary loadings they are subjected to during handling, transportation and erection at normal design stresses. b) loading due to scaffolding for the erection crew if so envisaged to be supported. c) loading of personnel during maintenance of pipe work and sprinkler system. The appropriate parts of the pack support structure shall be designed to support a point load of 1.5 kN at any position. 16.7 Reinforced concrete members shall be designed for self-weight and permanent loadings by working stress method with allowable stresses limited to 80% of those specified in IS: 456. Fill support structures, which are made up by the use of a large number of similar prefabricated members shall be manufactured to close tolerances to prevent unacceptable cumulative errors being introduced during erection. Concrete work for the Fill and Fill supporting structure shall be of a very high standard of construction so that deterioration through spalling of concrete, rusting of reinforcement or damage during transport, handling and erection are avoided MAINTENANCE ACCESS FACILITIES All areas of the cooling tower requiring inspection, cleaning, repairs and/or adjustment shall be easily and safely accessible by suitable provision of stairs, platforms, etc., as per the requirement described herein below:
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16.5
16.6
16.8
16.9
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17.1 17.1.1
STAIRS The cooling tower shall be provided with two numbers external dog-legged reinforced concrete stairs. Stairs shall give access to the water distribution system through hot dip galvanised steel doors, provided with etch primer and bituminous paint. The stairs shall have a minimum width of 1000 mm with landings of a minimum length of 1 m at not more than 2.5 m height intervals. The stairs shall have risers not exceeding 150 mm and treads of 250 mm minimum. All access doors shall be of size 1200 mm wide and 2100 mm height, minimum.
17.1.2
17.1.3
17.1.4 Design of structures such as staircase etc. which are not in contact with water / water spray / moist air shall be carried out adopting material stresses as given in IS: 456. 17.2 17.2.1 PLATFORMS Reinforced concrete platform of 1.5 m clear width shall be provided all round the circumference at the top of the cooling tower on the outside with RCC parapet minimum 1300mm high for fixing aviation warning beacons. 20 mm wide radial gaps shall be provided in the platform at locations approved by the OWNER. 75mm internal diameter puddle flanged C.I. pipes totaling 48 numbers and equally spaced, shall be embedded in the platform to facilitate passing ropes during maintenance of the tower shell.
17.2.2
17.2.3
17.4 17.4.1
WALKWAYS Walkways having a minimum clear width of 1.20 m shall be provided all round the circumference inside the cooling tower above the fill to provide access for inspection and maintenance of all hot water distribution pipes/ducts and nozzles. Walkways shall be supported independent of the Fill structure. Walkways shall be free from all obstructions. Walkways along with the bearers supporting them shall be designed to carry such loads as would be encountered during the maintenance of the towers. The minimum live load, however, shall not be less than 500 kg/ m2.
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17.5 17.5.1
LADDERS Four numbers of hot dip galvanised mild steel rung ladders with etch primer and bituminous painting shall be provided equally spaced around the circumference of the tower. Galvanization work shall have 610 grams/sqm of deposit. Ladders shall be 600mm wide fabricated out of 60mm x 10mm flats with 20mm diameter rungs at 300mm centers. Stays shall be provided at every 2.25m intervals connecting the ladder with the concrete shell. Safety cage for the ladder shall be fabricated out of 5 nos. verticals of 50mm x 6mm flats with 50 mm x 6 mm flat straps at 800 mm centres. Safety cage shall be provided for the ladders located on the external surface of the tower up to the throat level. Two diametrically opposite ladder out of above four ladders shall be continued along the inside surface of the tower up to the top of the tower and then on to the top platform. At the throat level access will be provided for access to the throat level platform with hot dip galvanized doors at the interchange. The internal ladders to be of stainless steel SS316L Intermediate landings of reinforced concrete of size not less than 750mm x 1500mm shall be provided at every 8 to 10m height of the ladders. Some of these landings shall be suitably adjusted/spaced to give access for maintenance of aviation warning beacons. Two of the ladders leading to the platform at the top of the tower shall have approach from the reinforced concrete stairs. Other two ladders shall be directly from the ground level itself. HAND RAILINGS Hand railing shall be provided at the edges of platforms, landing slabs sides of stairs, walkways and cold water outlet channel. Hand railing shall be of hot dip galvanised construction and shall be out of 32 mm NB pipes of medium class conforming to IS: 1239 and provided with etch primer and bituminous painting. Hand railing shall be 1300 mm high with two intermediate rails at 450mm and 900 mm with the top rail at 1300 mm above the surface of slab/steps. Handrail posts shall be spaced at not more than 1.5 m centres. A toe plate of hot dip galvanised mild steel of size 65 mm x 8 mm shall be provided for all hand railing. All galvanization work shall have 610 grams/sqm of deposit.
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SHEET 189 of 267
18.0 18.1
PAINTING TO CONCRETE SURFACES Painting to the concrete surfaces specified herein below shall consist of one coat of primer and two finish coats of bituminous paint conforming to IS:3384 and IS:9862 respectively, resulting in a total dry film thickness of 225microns. a) Basin floor. b) Internal and external surfaces of basin wall including the partition wall. c) Fill support columns and beams for the full height and length respectively. d) Internal and external surfaces of hot water duct. e) Internal and external surfaces of cold water channel. f) Internal and external surfaces of the drain chamber. g) Complete surface of the shell for at least 1 meter on the outside of the shell at top and bottom.
18.2
Protection of Raker/Diagonal Columns Raker/Diagonal columns shall be protected by providing polymer treatment with Monobond of minimum 10mm thickness, as specified: Thoroughly clean the concrete surface of all dirt, oil, grease etc and lightly roughen the surface to remove any loose material which cannot be removed by cleaning. Bond Coat - Bond coat of polymer shall conform to ASTM 1059 Type II. Mix the polymer epoxy latex as specified below EL-Monoband Part A 400grams EL-Monoband Part B 400grams Water 200grams Stir thoroughly to achieve brushable consistency and apply over the prepared surface by brush. Within approx. 30 minutes apply the polymer plaster as under Polymer Plaster (10mm thick) Over the bond coat, apply polymer plaster as per following composition and conforming to ASTM 1059 Type-II Mix design (per cubic meter)
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Cement Graded Quartz sand EL-Monobnd Part A EL-Monobond Part B Water
400 kg 600 kg 40 kg 40 kg 80-120 kg
The well graded silica quartz cement will be mixed in small batch sizes and mixed thoroughly to get a homogeneous mix. Mix EL-Monobond Part A and Part B as per specified proportion separately with part of the batch water and add to the dry mix. Add remaining water to achieve workable consistency. Trowel apply in layer of 10mm. Air curing will be done for 48 hours The mixing of the product and application of bond coat and plaster shall be got executed in the presence of authorized supervising staff of the Monobond supplier. CONTRACTOR shall submit the paint manufacturers recommended method of painting for the approval of OWNER before commencement of work. Painting shall not be carried out on wet concrete surfaces. Workmanship shall generally conform to the requirements of IS: 2395. 18.3 Complete internal surface of the shell as well as bottom surface of the ring beam between raker/diagonal columns shall be provided with polyglass coating minimum of 1000 micron thick after surface preparation and primer application as recommended by the approved polyglass coating manufacturer. The work shall be carried out by under direct supervision of the coating manufacturer who shall provide an extended warranty for 5 year for the safe working of the protective system All other exposed concrete surfaces shall be given two coat of waterproof cement painting over a coat of primer after the surfaces are rubbed down suitably and as approved by the ENGINEER. Painting to the hot water inlet pipe and distribution pipes shall consist of one coat of primer and two finish coats of bituminous paint conforming to IS:3384 and IS:9862 respectively, to result in an overall dry film thickness of about 250 micron. WATER DISTRIBUTION SYSTEM The arrangement of water distribution system shall permit a satisfactory distribution of water over the whole area of the tower at all reasonable loads.
18.4
18.5
19.0 19.1
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19.2
Distribution system shall be designed to handle turbid water during monsoon months. The hot water inlet pipes shall be properly embedded in the flume or shell. No horizontal thrust due to inlet piping shall be transmitted to the shell. Inlet and distribution pipes shall conform to the requirements of Class I of IS: 3589 and steel shall conform to IS: 2062. The distribution troughs/pipes shall be independently supported from the structures and shall be easily removable. Provision shall also be made for easy flushing or cleaning of all troughs/pipes. All sections of the water distribution system shall have adequate flow capacity to meet the maximum requirements of thermal design of the tower. The structural design of the water distribution system shall also consider the following loading, combined as appropriate: a) Self weight. b) Hydraulic pressures during normal operations, including pressure surges. c) Hydraulic pressures due to mal-operation of tower or supply pumps.
19.3
19.4
19.5
19.6
19.7
19.8 19.9
Seismic loading on the water distribution system shall also be considered. The design of water distribution system and its supports shall be capable of accommodating all thermal stresses and movements due to changes in inlet water temperature, outlet water temperature and ambient temperature. The possibility of vibrations being imposed on the distribution system shall be investigated in the design. The distribution troughs/pipes shall not be laid on top of walkways to avoid obstruction to movement on the walkways. Access ladder shall be provided from the top of hot water duct to surge shaft. LIGHTNING PROTECTION The cooling tower shall be protected against damage by lightning. The installation work shall conform to the requirements of IS: 2309.
19.10
19.11
19.12
20.0 20.1
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20.2
CONTRACTORs scope of work includes supply and installation of the complete system up to and including the earth electrodes and connected to the plant earthing grid. Contractor shall furnish a detailed drawing of the lightning protection system and execution of the work shall be commenced only after obtaining approval to this from the OWNER. The lightning protection system shall comprise the following items: One circumferential conductor on top of the tower, suitably anchored to the top platform. This conductor shall be G.I. of size not less than 75 mm x 10 mm. The air termination rods shall be mounted on G.I. inserts embedded on the top platform, and connected to the circumferential conductor. The number of air termination rods shall be same as that of the down-conductors. Down conductors of G.I. of size not less than 75 mm x 10 mm in continuous lengths with minimum number of any intermediate joints shall be clamped on the outside surface of the shell at 750 mm centres by anchors embedded in the shell during concreting. The number of down conductors shall comply with the requirements of IS: 2309. However, there shall be at least one down conductor for each 10 m or part thereof of the perimeter at roof level or ground level, whichever is the greater. Each of the down conductors shall be terminated on an earth. The earth electrode shall conform to IS: 3043. Test joint shall be provided for each down conductor before termination on earth electrode at a height of 2.7 m from the grade level. The entire lightning protection system shall be designed and erected with the following considerations: The ohmic resistance of the lightning conductor system when isolated from earth electrode shall be less than one ohm. The earth electrode resistivity also shall be less than 0.5 ohm, when measured after disconnecting from the grid. In view of the highly corrosive atmosphere prevalent around the tower, all exposed conductors, connections, clamps, welded joints, base plates, etc. shall be protected by hot dip galvanising with etch primer and bituminous painting. All reinforcement bars of the tower and metallic structures like ladders, handrail, light fixtures, etc. shall be bonded to the down conductors/circumferential conductor by G.I. strip of size not less than 25 mm x 6 mm, either by welding or by bolting. The down conductors on the base diagonal columns shall be protected from mechanical damage for a height of 2.5 m from the grade by taking them through AC pipe fixed on the face of the column, the pipe in turn encased in concrete of 1:4:8 nominal mixes. During the construction of tower, temporary lightning protection shall be maintained by connecting the reinforcement bars to two grounding conductors of size 75 mm x 10 mm.
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20.8During the construction of tower, temporary lightning protection shall be provided such that lightning should not damage construction work. 21.0 21.1 AVIATION WARNING SYSTEM, LIGHTING AND POWER RECEPTACLES CONTRACTORs scope of work includes supply and installation of the complete aviation warning system, lighting and power receptacles including the cabling between the main incoming 63A switch and aviation warning beacons and 30A receptacles. Contractor shall furnish a detailed drawing of the aviation warning system lighting and power receptacles including power distribution scheme and execution of the work shall be commenced only after obtaining approval to this from the OWNER. CONTRACTOR shall provide and fix aviation warning beacons with their supports at the top platform, at the throat level of the tower and at every 45m height or part thereof, between the ground level and the throat level. The beacons shall conform to the requirement of the civil aviation department, Govt. of India and ICAO guidelines. The beacons at the top of the tower should be at least 2 metres below the top of the tower to prevent them from being obscured by vapor. There shall be four beacons at each level equally spaced around the circumference at 90 deg apart. All the beacons except those on the top platform shall be so located as to be easily accessible for maintenance from the ladders provided for this purpose. The beacon lights shall be adequately secured to the tower shell/platform against wind forces. (a) The low intensity lights shall be red in colour having an intensity sufficient to be conspicuous considering the intensity of adjacent lights and the general level of illumination against which they would normally be viewed. The flash frequency shall be between 60 and 90 per minute. The lamp used in beacon shall be of neon type and not of filament type subject to approval by OWNER. (b) The medium intensity light shall be flashing red light and should be used either along or in combination with low intensity light. The flash frequency shall be between 40 and 60 per minute.18.6 650V/1100V, stranded copper conductor, armoured, PVC insulated cableconforming to IS: 1554 (part I) shall be used for wiring the aviation warning beacons lighting fixtures and power receptacles. The cables shall be clamped by the side of the ladder at 750 mm centres by means of GI clamps. Weather-proof terminal boxes with cable glands made of brass, tin plated shall be provided at the location of each of the aviation warning lights for termination of cables.
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21.6
21.7
21.8
21.9
21.10
21.11
One 415V, TPN distribution panel consisting of an one transformer to convert 3PH 3 wire system to 3PH 4 wire system and an incoming switch fuse unit of suitable rating for OWNERs incoming cable and switch fuse outlets for aviation warning lights and power receptacles, shall be installed at a height of 1.5 metre from the grade level on a column supporting the tower shell. The distribution panel shall be supplied with tinned brass glands and tinned crimping type copper cable lugs for termination of cables. One number 30A, 3-phase, 4 pin industrial type power receptacle with controlling switch mounted in a weather-proof box shall be supplied and installed at all the landings provided at the throat level of the tower, for OWNERs use, along with a loose matching plug. Beacon supports etc. shall be fitted to the tower shell/platform by GI nuts on to GI inserts projecting from the concrete surface. All bolts, clamps, etc. used shall be hot dip galvanised. Contractor shall submit detailed drawings for approval by OWNER before starting fabrication work. The distribution of power to the aviation warning lights, lighting fixtures and receptacles shall be carried out to meet the following requirements. a) To balance the loading of all the three phases. b) The lamps on the same vertical line shall be fed from different phases, so that failure of any one phase will not cause total black-out on one side. c) The aviation warning lights and receptacles shall be on separate circuits. All the receptacles can be fed from the same circuit. Lighting of the platforms of the cooling tower shall be carried out with industrial well glass, weatherproof and dust light with reflector integral mounted control gear with 1x70 W HPSV lamp mounted on brackets of the platform handrails. The number and location of fixtures shall be such as to achieve an illumination level of 100 lux on the platform. The lighting design calculations shall be submitted to OWNER/CONSULTANT for approval, before execution of work. Temporary warning lights shall be installed during construction suitably located above the top most point of obstruction and shall be shifted up as the construction progresses. These lights need be installed only after the level of obstruction is greater than 45 m above the grade level. DRIFT ELIMINATORS Drift eliminators shall be provided in the tower, as called for in Data SheetA. PERFORMANCE TESTS After the cooling tower is completely erected and commissioned, tests on its performance shall be conducted. The method of testing shall generally conform to provisions of BS: 4485 : Part 2 or procedures of Cooling Tower Institute, USA, unless otherwise specified in Data Sheet-A.
22.0 22.1
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23.2
CONTRACTOR shall submit the detailed test procedure, correction curves, etc. for performance testing for OWNERs approval. The test shall be carried out on a day when the atmospheric condition and heat load on the tower are as close to the design conditions as possible. While efforts would be made to arrange the tests within the guarantee period, BIDDER shall agree to conduct the test at any time after the guarantee period as mutually agreed between him and the OWNER, subject to the tower being in good condition. For this purpose, each half of the tower would be isolated for inspection before the test. Owing to the difficulty of reproducing on the test, the exact conditions of wet bulb temperature, wind and heat load under which the tower duty is to be guaranteed, a compromise formula shall be reached that will be acceptable to both the CONTRACTOR and the OWNER. BIDDER, in their proposal, shall submit formulae for OWNERs consideration, it being understood that agreement shall be reached between the CONTRACTOR and the OWNER on the acceptability of the formulae or a revision thereof, before the contract is signed. It shall be the responsibility of the CONTRACTOR to carry out all the tests as specified to the full satisfaction of the OWNER and the cost of such tests including supervision shall be borne by him entirely and is deemed to be included in the quoted lump sum price. CONTRACTOR shall be fully responsible to make good any and every deficiency in the guaranteed performance of the cooling tower. VENDOR shall include in his bid for the supply on loan and mounting with all necessary fixtures/accessories, of all the instruments required for performance testing including the following instruments. a) Two calibrated pitot tubes for each of the water risers of each tower along with associated isolating valves as indicated in Data Sheet-A, for measurement of flow. b) Three Assman type identical aspirated psychrometers or wet/dry bulb thermometers for measuring wet bulb and dry bulb temperatures. The thermometers shall be with graduations not exceeding 0.1 deg C and located at three equidistant stations near the tower. c) Mercury in glass thermometers, with graduations not exceeding 0.1 deg C for measurement of hot and cold water temperatures. d) e) Anemometer for measuring wind velocity. Pressure gauge for measuring hot water inlet pressure.
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23.7
All the instruments supplied and used shall be calibrated by a National laboratory or by an independent laboratory approved by the OWNER. CONTRACTOR shall furnish necessary test certificates for the same to the OWNER. PERFORMANCE GUARANTEE Performance guarantee shall be as per Vol.-II (Section C3).
24.0 24.1 . 25.0
PENALTY If during the performance testing of the cooling tower, the actual cooling water temperature obtained is higher than the guaranteed cooling water temperature (obtained from the performance curve) corresponding to the flow, wet bulb temperature, relative humidity and cooling range prevailing during the test, then penalty will be levied at the rate as indicated in General Condition of contract / Special condition of contract. If during detail engineering pump head required at terminal point (Corresponding to normal water level in basin) deviate from the guaranteed values indicated by the Bidder in the schedule of Performance Guarantee (Without any tolerance), then penalty will be levied at the rate as indicated in General conditions of contract / special condition of contract.
26.0
QUALITY ASSURANCE The contractor should provide complete quality assurance plan, well in advance, for approval by the engineer. Only after receipt of such approval, works shall proceed at site. The plan should include, profile checking of hyperbolic shell and diagonal columns, testing of construction materials, sampling, concrete cube testing, checking of form works, reinforcement, concreting etc. and documenting of all such works. Format for all such documents must be included in the quality assurance plan. Quality control for achieving prescribed strength of shell concrete for each lift shall be ensured before climbing to the next lift. BS: 4485 may be followed for this.
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NATURAL DRAUGHT COOLING TOWER DATA SHEET A SPECIFIC TECHNICAL REQUIREMENTS
1.0 2.0 2.1 2.2 2.3 2.4
Number of cooling towers DESIGN & OPERATING CONDITIONS Design atmospheric wet bulb temperature Cold water outlet temperature Design relative humidity Wind velocity for performance Pumping head at Hot water inlet T.P. w.r.t. normal water level in the basin including frictional losses in the hot water inlet risers FEATURES Drift eliminator Type of Fill MATERIALS OF CONSTRUCTION Fill Water distribution pipes
1 Nos.
27 33 48
C C
% MPH
2.5
During detail engineering
3.0 3.1 3.2 5.0 5.1 5.2 5.3
Access doors, stoplogs and screens. Hot dip galvanized mild steel with etch primer and bituminous painting. TYPE OF CEMENT a) Below ground (i) (ii) Ordinary Portland cement conforming to Sulphate Resisting Portland cement conforming to IS: 8112
5.4
IS: 12330
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b)
Above ground (i) OPC conforming to IS: 8112
6.0 6.1
PRIMARY LOADS WIND LOAD a) b) c) d) e) Basic wind speed Factor K1 Terrain category factor K2 Factor K3 Intensification factor 47 1.07 As per IS: 875 1 m/s
6.2
EARTHQUAKE LOAD a) b) c) Zone as per IS: 1893 Soil foundation system coefficient Importance factor As per IS: 1893,Part-4 IV
7.0 7.1 7.2
FOUNDATION CRITERIA Ground water table Type of foundation At finished grade level As per soil report
7.3 7.4 7.5
Safe bearing capacity of soil Type of pile Pile capacity and termination depth below ground level
7.6 7.7
Minimum thickness of basin base slab Pressure relief valves in the basin floor slab
300 mm Not to be provided
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8.0 8.1
PENALTY Penalty for non-fulfillment of guaranteed performance As per Vol.I of the specification
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1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA TECHNICAL SPECIFICATION PART G DRAWINGS/ DATA TO BE FURNISHED BY THE BIDDER ALONG WITH THE BID
SHEET 200 of 267
1.0 1.1
DRAWINGS Cooling tower general arrangement drawing clearly indicating scope, arrangements of basin, fill and hot water distribution system. Thermal performance curve DIMENSIONS Height of top of tower above sill Height of throat above sill Height of top of air inlet above sill Depth of Fill at periphery/centre above sill : : : : m m m m
1.2 2.0 2.1 2.2 2.3 2.4
2.5
Internal diameter of tower a) at sill level b) at throat c) at top THERMAL PARTICULARS Cooling water flow per unit fill area Dry air flow per unit fill area Ratio of water to air weight Temperature of air at Fill outlet wet bulb / dry bulb Total dry air flowper tower Inlet air enthalpy above 00 C L G L/G
: : :
m m m
3.0 3.1 3.2 3.3 3.4
: : :
kg/m2/hr kg/m2/hr
: : :
/0C x 106 kg/hr k.Cal/kg.

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3.7 3.8 3.9 3.10 3.11
Exit air enthalpy above 00 C Total heat exchange per hour Evaporation loss (maximum) Drift loss (maximum) Tower coefficient Kav L
: : : :
k.Cal/kg. k.Cals kg/hr kg/hr
3.12
Total pumping head required at terminal point. a) Frictional losses in inlet pipe up to distribution trough b) Static height from normal water level in basin to water level in distribution trough
MWC
: TOTAL :
MWC MWC
3.13 3.14 3.15
Performance coefficient (C) Duty coefficient (D) Fill a) b) c) d) e) f) g) Type Material of Fill Material of Fill support Total surface area Shape and thickness (enclose sketch) Total volume Manner of support
: :
: : : : : : :
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3.16
Water distribution system type and material a) b) c) Riser pipe Primary Distribution pipe Secondary Distribution pipe : : :
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SPEC.NO. TCE.6417A-H-500-001
1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA TECHNICAL SPECIFICATION PART G DRAWINGS / DATA TO BE FURNISHED BY THE VENDOR AFTER THE AWARD OF CONTRACT
SHEET 203 of 267
1.0
Dimensioned outline drawing of the tower showing plan/ elevation, details. Detailed design calculations and construction drawings of the tower in its entirety. Drawing of basin clearly indicating outlet channel and drainage arrangement. Drawing indicating fill arrangement. Drawing of hot water distribution system. Drawing showing lightning protection system and aviation warning beacons. Thermal performance curve covering the following ranges : a) b) c) d) 80% to 120% design flow. 80% to 120% cooling range. Relative humidity ranging from 30% to 100%. Wet bulb temperature - minimum to maximum as specified in Data Sheet-A
2.0
3.0
4.0 5.0 6.0
7.0
8.0
Consultant/Owner will review and approve the drawings listed above. Any other drawings, if submitted by Vendor or called for by Owner will be only for information and record.
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1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA TECHNICAL REQUIREMENT PART H PART H -TECHNICAL SPECIFICATION FOR REINFORCED CONCRETE CHIMNEY
SHEET 204 of 267
1.0
SCOPE
1. This specification covers the general requirements for design and construction of a reinforced concrete single flue chimney of circular cross section including foundations, RCC shell, steel flue, appurtenances, fixtures, fittings, conduit and other embedments , lift etc., complete. 1.1 The scope of work shall not be deemed to have changed in case BIDDERs drawings submitted with his bid do not show some parts of the works as called for in this specification and the attached bid drawings unless categorically agreed to in writing before contract award. The CONTRACTOR shall not be entitled to any extra claim on account of his having, in OWNERs opinion mis-interpreted, mis-judged or overlooked any aspect called for in this specification. It is not the intent to specify completely herein all the details of design and construction of works involved under this specification. However, the works shall conform, in all respects, to high standards of engineering, design and workmanship. APPLICABLE CODES, SPECIFICATIONS & REFERENCES The following specifications, standards and codes are made a part of this specification. These shall be the latest edition including all applicable official amendments and revisions. In case of discrepancy between this specification and those referred to herein, the former shall govern:
1.2
2.0 2.1
IS: 6 IS:158 IS:456 IS:732 IS:800 IS:808 IS:814 IS:816 IS:875
: : : : : : : : :
Moderate heat duty dire clay refractories Ready mixed paint, brushing, bituminous, black, lead free; acid, alkali and heat resisting. Plain and reinforced concrete.-Code of Practice Code of practice for electrical wiring installations Code of Practice for General construction in steel. Dimensions for hot rolled steel beam, column, channel and angle section Covered electrodes for manual arc welding of carbon and carbon manganese steel- specification Code of practice for use of metal arc welding for general construction in mild steel Code of practice for design loads (other than earthquake) for buildings and structures: Part 3 Wind Load.
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IS:1080 IS:1161 IS:1786 IS:1893 IS:1904 IS:2062 IS:2309 IS:2750 IS:2911 IS:2932 IS:2933 IS:3043 IS:3150 IS:3346 IS:3677 IS:3696 IS:4014 IS:4289 IS:4456 IS:4457 IS:4687 IS:4832 IS:4860 IS:4998 IS:4998
: : : : : : : : : : : : : : : : : : : : : : : : :
Code of practice for design and construction of shallow foundations in soils (other than raft, ring and shell) Steel tubes for structural purposes specification. Specification for high strength deformed steel bars and wires for concrete reinforcement Criteria for earthquake resistant design of structures Code of Practice for design and construction of foundations in soils: General requirements Steel for General Structural Purposes - Specification Code of Practice for protection of buildings and allied structures against lighting Specification for Steel scaffoldings Code of practice for design and construction of pile foundations. (Parts 1 to 4) Enamel, synthetic, exterior (a) under coating (b) finishingSpecification Enamel exterior (a) undercoating, (b) finishing Code of practice for earthing Specification for Hexagonal Wire Netting for General Purposes Method for the determination of thermal conductivity of thermal insulation materials (two slab guarded hot-plate method) Specification for Unbonded rock and slag wool for thermal insulation Safety code for scaffolds and ladders (Part 1 &2 ) Code of practice for steel tubular scaffolding Part 1&2 Specification for Flexible cables for lifts and other flexible connections : Part 1 Elastomer insulated cables Methods of test for chemical resistant mortars: Part 1 Silicate type and Resin type Specification for Ceramic unglazed vitreous Acid resisting tiles- Specification Gaskets and packing Gland packing asbestos- Specification Specification for chemical resistant mortars Part- 1 silicate type Specification for Acid resistant bricks Criteria for design of reinforced concrete chimneys: Part 1 Design criteria 1975 Criteria for design of reinforced concrete: Part 1 Assessment of loads-1992
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IS 5410 IS:8112 IS:8183 IS:12330 IS:13311 IS:13947
: : : : : :
Cement Paint Specification for 43 grade ordinary Portland cement Bonded Mineral wool Specification for sulphate resisting Portland cement Non destructive testing of concrete Method of test part-1 Ultrasonic pulse velocity Low voltage switchgear and control gear: Part 1 General rules International Standards and Recommended Practices Aerodromes - International Civil Aviation Organisation. Indian Electricity Rules.
Annexure14
Indian Electricity Rules.
2.2
The following is the list of publications referred to in this specification. Manohar,S.N Tall Chimneys-Design and Construction", Tata McGraw Hill Publishing Co.Ltd., New Delhi. Pinfold,G.M "Reinforced Concrete Chimneys and Towers", View Point Publication, Cement and Concrete Association, U.K. Vickery,B.J. "Wind Induced Loads on Reinforced Concrete Chimneys", Paper presented at National Seminar on Tall Reinforced Concrete Chimneys, 25-27 April 1985, New Delhi. Vickery,B.J. And Basu, R.I. "The response of reinforced concrete chimneys to vortex shedding", R I Journal of Eng. Struct., 1984, Volume 6 ACI 307 - Standard Practice for the Design and Construction of Cast-inplace reinforced concrete chimneys ASCE 1975 Design and Construction of Steel Chimney Liners. Task Committee on Steel Chimney liners, Fossil Power Committee, Power division, ASCE.
2.3 3.0 3.1
SI units shall be adopted for all design and drawing work. DESIGN REQUIREMENTS The principal design parameters for this chimney are indicated in DATA SHEET- A.
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3.2 3.3
The design shall be based on working stress method. The design and construction of the chimney and its foundation shall conform to the requirements of all statutory rules and regulations of local and national authorities. Where such requirements are less conservative than the corresponding requirements of this specification, the latter shall govern. The chimney and its foundation shall be designed to resist stresses due to the most critical combination of any of the following: (a) (b) (c) (d) (e) Weight of the chimney with or without lining, platforms, accessories and all other dead loads. Wind loads (both along-wind and across wind) or earthquake forces whichever is governing. Temperature gradient across the chimney shell. Eccentric loads from platforms supporting the flue, roof slab soot hopper, etc. Live loads on platforms. Also weight of equipment and materials and other live loads during construction including structures for erection of flues. For the foundation and portion of the shell below grade level, appropriate earth pressures, hydrostatic forces, surcharge etc., as applicable. Local moments due to ovalling. Forces from the lift and operating equipment. Also load from staircase if supported from intermediate platforms. Loads from flue duct supports. Construction loads such as those due to plant and equipment, stacked materials, live loads due to movement of plant, materials and personnel, etc.
3.4
(f)
(g) (h) (i) (j)
3.5
The total design stresses at a section shall include all secondary effects, viz. eccentric loading due to platforms, secondary moments due to p- effect, etc. The total design stress in no case shall exceed the permissible stresses specified in clause 7.0 of IS: 4998 (Part-1) 1975 and modified as below. Stress in concrete shall be restricted to 0.275 cu under the combination of Dead load + Wind load against the value specified in Clause 7.1.1 (a) of IS: 4998 Part I-1975. If the circumferential tensile stress in concrete due to wind induced ring moment exceeds the value specified in clause 7.1.1 (g) of IS:4998-Part I,
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additional reinforcement shall be provided in two layers limiting the stress in reinforcement steel to value specified in clause 7.1.2(g) of IS 4998 Part I. 3.6 The safety factor against overturning under worst combination of loads, shall not be less than 1.5 in any direction during construction and 2.0 after construction is complete. For the purpose of calculating safety factor against overturning, only 90% of the dead loads as calculated from dimensions and densities of materials shall be taken into account. For estimating the deflections of the chimney in lined and unlined conditions, the modulus of elasticity of concrete shall be as specified in clause A3.1 of IS: 4998 (Part-1) -1992. Stresses in the shell shall be shown to be within permissible limits at 10 metre intervals along the height of the shell and in addition, at the critical locations across openings. Air inlets, sloped up towards inside, shall be provided near the base with GI wire mesh cover over the openings so as to prevent dirt or tiny creatures entering the air gap. The number and size of the inlet openings in the shell shall have a total area of not less than two third of the area of the minimum air gap at top of chimney. Air outlets with stainless steel wire mesh mounted on stainless steel frame shall be provided at the top of the shell. These openings shall be suitably spaced and their total area shall not be less than that provided for air inlets. The maximum width of the openings shall normally be limited to an angle of not more than 60 subtended at the centre of the concrete shell. Where the extent of shell left between two openings is limited such that the subtended angle is less than 45deg, procedures as normally adopted for column design, shall be adopted to check the adequacy of the shell in this region. The total plan area of the openings at a particular section shall not be more than 15 percent of the plan area of the concrete shell at that location. The opening size for the purpose of stress calculations shall be taken as 1.1 times the actual width of the opening. An opening will be permitted in the windshield at the grade slab level for erection of steel flue cans. Based on detail geotechnical investigation report approved by the owner, foundation system shall be designed. The analysis of the windshield for wind and earthquake forces shall be done as per the requirements of clause 15 and 16 of this specification. The foundation shall be designed as a rigid member. The thickness of the foundation below the shell shall not be less than 0.40 times the overhang of
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the foundation beyond the shell. Foundation diameter to depth ratio shall not exceed 12. The foundation shall be of solid raft type with no tapering at outside & inside is allowed. Minimum earth filling on top of foundation shall be 1m. 3.16 For the purposes of analysis/ design, the following shall be assumed: a) b) Stiffness of shell shall not be considered for design of the foundation. Shell fixed to foundation for shell design.
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4.1
REQUIREMENTS IN RESPECT OF CONCRETE All concrete work shall be carried out strictly in accordance with the IS: 456 except as otherwise specified hereunder. The source and type of the basic ingredients of concrete, viz. cement , aggregates, water and approved admixtures, if any, shall be unchanged throughout the construction of the chimney shell, particularly in case, slipforming technique is adopted for shell construction. The maximum size of coarse aggregates, unless specified otherwise, shall not be larger than 1/8th the narrowest dimension between forms nor larger than one half the clear distance between reinforcing bars nor more than 40mm. However, for wind shield and roof slab 20mm downgraded aggregates shall be used. Natural gravel and rounded aggregates of acceptable quality shall be preferred to broken stone with sharp angular corners for slipform work, in particular. When slipforming is adopted, the slump shall be between 100 mm and 150 mm at the point of placement. However, precise requirements in this regard shall be established from field tests and shall be subject to OWNERs a pproval. If necessary, approved admixtures such as retarders/ plasticizers to maintain the workability shall be used with the prior consent of the OWNER. Such admixtures shall be identified after preliminary tests to prove their satisfactory performance and compatibility with the particular type of cement envisaged to be used in the shell construction. After identification and determination of dosage for varying weather conditions, the total quantity of admixture required for complete work shall be estimated and shall be procured in batches to ensure that the same is utilised before expiry of its shelf life. In no case shall the admixtures be used if its shelf life has expired due to delay in construction activities. No additional payment shall be made to CONTRACTOR for providing retarders / plasticizers.
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4.7
The minimum cement content per cubic meter of concrete shall be as per Table 5 of IS 456. This shall be ensured for all concreting items of work even if mix design yields lower values. Cement used shall be OPC conforming to IS: 8112 unless DATA SHEET A different type of cement for substructure. In case geotechnical investigation reveals presence of sulphate in the subsoil, high sulphate resistant cement conforming to IS: 12330 shall be used below ground level. Duly considering the need to support the main girder supporting the steel flue without causing eccentric loading to the wind shield the minimum thickness of wind shield, shall be kept as 400mm at top. The clear concrete cover over the vertical reinforcement in the shell shall not be less than 50mm. In foundations, the clear concrete cover shall be 75mm. For roof slab minimum clear cover shall be 45 mm. The grade of concrete in chimney shell shall be minimum M30 unless otherwise specified in DATA SHEET- A. All other RCC works including grade slab and foundation, unless otherwise specified in DATA SHEET- A, shall be with minimum M25 grade concrete. For roof slab minimum grade shall be M30. For design of chimney raft/ pile cap enhancement of shear strength near support as per clause 40.5.1 and 40.5.2 of IS 456 will not be permitted. The shear shall be checked at a distance of d from the face of support for foundation resting on soil and d/2 for pile caps. The design strength shall be calculated in accordance with table 23 of IS 456 and appropriate shear reinforcement shall be provided. For transfer of vertical reaction to wind shield from the supporting beams at platform level, increase in permissible bearing pressure in concrete shall not be considered as permitted at the base of column as per clause 34.4 of IS 456. REQUIREMENTS IN RESPECT OF REINFORCEMENT Reinforcement used shall be high strength deformed reinforcement bar conforming IS 1786 grade Fe500. As per clause 1.6 of IS 456 1786-2008, deformed bars produced by rerolling finished products such as plates and rails (virgin or used or scrap) or by rolling materials for which the metallurgical history is not fully documented or not known are not acceptable. The minimum vertical reinforcement on each face with deformed bars shall be 0.125% of the concrete area of the section under consideration. The minimum diameter of vertical reinforcing bars shall be 12 mm and they shall not be spaced at more than 300 mm centres. Vertical reinforcement percentage for the bottom 30meter height of the shell shall be increased to 0.25% on each face.
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5.3
Laps for the vertical reinforcement shall be staggered. Not more than onethird of the bars shall be lapped at any one level. The laps at a level should be distributed around the perimeter and not concentrated in only one part of the perimeter of the shell. Where vertical reinforcement is required to be lapped above openings, lap shall be allowed only after a height of B/2 above the opening for the whole section, where B=width of opening. While curtailing the reinforcement above openings, care shall be taken to ensure proper transfer of tensile forces if present in the section to the subsequent section by provision of adequate reinforcement. The bars shall not be curtailed abruptly and an adequate development length shall be allowed.
5.4
The circumferential reinforcement on each face of shell, for deformed bars, shall not be less than 0.1% of the concrete area of the section. The minimum diameter of these reinforcing bars shall be 10 mm and they shall be spaced at a centre to centre distance not exceeding 300 mm or the shell thickness whichever is less. Circumferential reinforcement shall be evaluated so as to satisfy the minimum requirements as mentioned above and to safely withstand the circumferential forces and moments. However, for a height from the top equal to half the shell outer diameter, the quantity of circumferential reinforcement shall be twice that arrived at as stated above. Particular attentions shall be paid to placing and securing the circumferential reinforcement so that it cannot bulge or get displaced during the placing and working of the concrete. Dowels, wherever provided, shall extend on either side of the construction joint by a length equal to the full development length of the bars in tension. In addition to the reinforcement determined from structural considerations as well as to meet temperature and other stresses, extra reinforcement shall be provided around and at corners of openings. The extra reinforcement shall be placed near the outside surface of the chimney shell as close to the opening as proper detailing of reinforcement will permit. Unless otherwise specified, all such extra reinforcement shall extend past the opening by a length equal to its development length in tension. At each of the openings, the extra vertical reinforcement shall have a total area equal to the design reinforcement for one-half of the width of the opening. This steel shall be placed on each side of the opening within a distance not exceeding 1.5 times the shell thickness wherever column design procedure specified in clause 3.11 above is not applicable. The extra reinforcement shall extend past the opening by a length equal to 1/2 the width of opening plus its development length in tension.
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5.10
At both top and bottom of each opening, extra horizontal reinforcement shall be placed having an area at least equal to one-half of the design circumferential reinforcement interrupted by the openings but the area 'As' of this extra reinforcement shall not be less than that given by the following: As (mm2) = fck.t.s/c Where, fck = characteristic strength of concrete in N/mm2, t = shell thickness at opening in mm, s = width of opening in mm, c = 16000 and 13000 for high yield strength deformed bars and mild steel bars, respectively.
5.11
One half of this extra reinforcement as stipulated in clause 5.10 above, shall extend completely around the circumference of the chimney and the other half shall extend beyond the opening to a length equal to the development length of the bars in tension. This steel shall be placed within a height not exceeding the thickness of the shell. Diagonal reinforcement with a total cross sectional area in sq.mm of not less than 5 times the shell thickness (in mm) shall be placed at each corner of an opening. These bars shall also extend on either side of the corner a distance equal to the development length of the bars in tension. Additional steel of a total cross sectional area in sq. mm of not less than 3.5 times the shell thickness (in mm) shall be placed horizontally/vertically. These bars which shall extend to a distance equal to the development length in tension on either side shall be in addition to the entire steel already provided as per clauses 5.8 to 5.12. At both top & bottom of each opening, required additional reinforcement shall also be checked as per clause 4.4.7 of ACI: 307. The maximum of these (5.8 to 5.13) shall be adopted at top and bottom of the opening. Foundation raft/ pile cap of the Chimney shall be provided with minimum 12 mm deformed bar. Minimum reinforcement of 0.06% of cross sectional area shall be provided both ways at top and bottom. In addition chairs of suitably shaped of 25 mm minimum dia. shall be provided in a grid of 1000x1000 to ensure that the top reinforcement cage does not sag. STEEL FLUES AND DUCTS General
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6.1.1
Flues shall be fabricated from structural steel and shall be hung type (i.e. of tension type) suspended from support floors as shown in the BID drawing, with expansion joint above support floor. Top most portion of the flue to a height of 1.5 times the exit diameter of the flue shall be fabricated out of stainless steel. The Structural steel shall conform to Grade E250 (Fe410W), quality A (semi killed) of IS: 2062 for rolled steel members and plates up to and including 20 mm thickness. For plates above 20mm thickness and welded construction, steel conforming to Grade E250 (Fe410W), quality B (Killed and normalized) of IS: 2062 shall be used. Stainless steel used for top portion of the flue shall conform to AISI type 304L. Design of Steel Flue Steel flue shall, in general, be designed to meet the requirements of the document, Design and construction of steel chimney liners, prepared by Task committee on steel chimney liners, Fossil power committee, Power division published by ASCE-1975, 6.2.2 Inside diameter of flue shall be as furnished in DATA Sheet A. The plate thickness of the liner shall be arrived at from structural considerations and corrosion allowances. The flue shall be fabricated out of structural steel of Grade E250 (Fe410W) quality B (Killed and normalized). The minimum thickness of the flue including 4 mm corrosion allowance shall be 10mm. Stainless steel used for top portion of the flue shall conform to AISI type 304L. Minimum thickness of the stainless steel flue shall be 8mm. Minimum size of the angle stiffeners for the flues shall be 130x130x10. The supporting / restraining arrangements of the flue/duct shall be such that the movement of the flue longitudinally or circumferentially is not restrained. The bottom of the flue shall extend below the invert level of the flue duct by 3000mm or half the width of the duct whichever is higher. The bottom supported portion of the flue shall terminate to a circular skirt girder with bearing support at 45deg and restraint support at 45deg. Two manholes shall be provided above the conical hopper.
6.1.2
6.2 6.2.1
6.2.3
6.2.4
6.2.5
6.2.6
The flue diameter shall be so sized to ensure that the flue gas exit velocity is of the order of 20-25 metres/second at normal continuous operating load or as per MoEF clearance specific to the Project at. It should be ensured that the flue gas exit velocity at the lowest continuous unit load is high enough (of the order of 15 meters/second) to enable adequate dispersion of the flue gases. For the purpose, 100 percent turbine MCR condition with design coal firing shall be considered as normal continuous operating condition, and 60 percent turbine MCR condition with design coal/worst coal firing (whichever yields lesser flue gas quantity) shall be
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considered as the lowest continuous load condition

6.3 6.3.1 DESIGN OF FLUE DUCT The CONTRACTOR has to design, and install flue gas duct. The duct will be of rectangular / square cross section. The duct will be connected to the flue inside chimney by means of bolted flange connection with gasket at approximately 300mm from inside the flue. The duct shall be supported on steel frame inside and outside the chimney shell. The distance from the outside face of wind shield to the duct support shall not exceed 500mm. The duct work and its supporting structures shall be designed for the most adverse of possible load combinations of gravity loading accounting for ash accumulation, wind loading, seismic loading, flue gas pressure loading and thermal loading along with loading due to insulation and live load of 500kg per square meter at top. Suitable structure/bracing arrangement shall be provided inside the duct to maintain the correct cross section at all junction point. The duct shall be fabricated out of structural steel of grade E250 (410W) quality B (killed). Minimum thickness of plates shall be 8mm. ASH HOPPER Ash hopper shall be suspended from the bottom portion of the flue. The angle of inclination of the hopper to the horizontal shall be a minimum of 30deg. The hopper shall be fabricated out of structural steel of grade E250 (Fe410W) quality grade B (killed and normalized) of minimum 10mm thickness ,with 5mm thick liner of stainless steel grade AISI 304L. Just above the ash hopper an inspection platform 1000mm wide with removable GI gratings and adequate toe protection shall be provided spanning two manholes. Suitable flange connection shall be provided at the bottom of the hopper to facilitate periodic emptying of the hopper. The flange shall have OD of 483mm and ID of 303.2mm with 12holes for M24 bolts at a PCD of 431.8mm. FLUE SUPPORT ARRANGEMENT The support brackets and bearing assembly shall be welded to the locally thickened portion of the flue and which in turn support the flue on the support platform. The arrangement shall cater for thermal movements of liner elements in a smooth and easy manner.
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6.5.2
The support arrangement shall typically consist of the flue support bracket. The bracket in turn is welded to a bearing assembly. The bearing assembly is later bolted to the support beams. The arrangement shall cater for thermal movements of linear elements in a smooth and easy manner. The bearing assembly shall consist of 3 units and shall be fabricated as described herein. The first unit shall consist of a MS base plate on which MS sole plate shall be welded & interfaces shall be machined. The sole plate shall be provided with recess to seat a PTFE film conforming to BS: 5400 dimpled on the upper surface and lubricated with silicon grease. The unit shall be bolted to the support beam, using restraint brackets. Four slotted holes shall be provided through base and sole plate to connect brackets which restrains movement of second and third units to 5mm on either side. The second unit shall consist of MS plate of adequate size and thickness connected to stainless bearing plate of adequate thickness with counter shunk screws connected at the bottom. The stainless steel surface shall be placed on the PTFE surface of the first unit. On top of MS plate 3mm thick lead sheet shall be provided. The stainless steel shall be of grade AISI 304L. The third unit consist of two layers of load bearing insulation blocks each within a minimum thickness of 50mm, factory bonded by 100mm long load bearing insulation dowels. MS cover plates of adequate size and thickness shall be provided at the top and bottom of insulation block with appropriate restraining guides of MS both at top and bottom to prevent movement of insulation block. A MS bearing plate of adequate thickness shall be welded to the bottom of the bottom cover plate, with exposed bottom surface machined. This plate will rest on the lead sheet provided on the top of second unit. The bearing assembly shall be levelled by use of suitable MS shims as required. Suitable restraint brackets and stop plates of MS shall be provided to avoid excessive movement, and keep the different units of the bearing assembly in position. The insulation block shall be of natural grade fabric reinforced asbestos or an equivalent material which shall primarily possess of the physical properties: a) Minimum compressive stress prior to onset of compression yield not less than 12N/sqmm. Permissible stress for design of bearing shall be restricted to 8N/sqmm.
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b) Minimum shear strength of 30N/sqmm when tested in accordance with BS:3497 c) Thermal conductivity shall not exceed 0.6kcal/m/hr/deg.C to a mean temperature of 200deg.C and coefficient of linear expansion not to exceed 1.2x10-5 per deg.C. d) Adhesive used for bonding purpose shall be material with equivalent high temperature properties as approved by the OWNER/MANUFACTURER of insulation block. 6.5.5 At flue restraint platforms, necessary restraint with load bearing insulation blocks and stainless steel bearing plates fixed to the insulation blocks shall be provided. Restraint brackets shall also be provided for the bottom portion of the flue which is restrained at the bottom platform provided at the base. Fabrication Fabrication shall commence only on the basis of fabrication drawing prepared by the CONTRACTOR. OWNER reserves the right to scrutinise the fabrication drawings if deemed necessary in OWNERs opinion. The CONTRACTOR shall establish a fully fledged fabrication shop at site with adequate machinery for cutting, bending, welding, testing and proper handling facilities. Complete fabrication shall be carried out at site. The individual cans of the flue shall be joined together using high tensile structural steel of property class 8.8, and product grade C as per IS 1367, conforming to IS 3757. Nuts shall be of high strength structural steel hardened and tempered nuts (property class 8.8 as per IS 1367) conforming to IS 6623 with hardened and tempered washers conforming to IS 6649. All nuts shall be provided with helical spring locking washers. After tightening of the bolts at the flange location, the cans shall be butt welded all round from inside to result in gas tight joint. The weld shall not be considered to participate in load transfer. Duly considering the fact that the steel is always subjected to high temperature and the same is hung from the top and is subjected to movements, additional factor of safety of at least Two (2) shall be considered for design of the joints over and above normal factor of safety. Each flue can shall have only two circumferential joints, thus forming a maximum of three rings. These rings shall be provided with full strength butt welding. Root runs of all the butt welds shall be tested by DPT. Seam welds in adjacent rings shall be staggered at least by 2000mm. seam welds shall also be provided with full strength butt welding. Root runs of all seam welds shall be inspected with DPT. The CONTRACTOR shall arrange inspection of welds in the presence of OWNERs representative as described below.
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6.6.5.1
100% of the welds shall be subjected to visual inspection to detect imperfection.
visual
6.6.5.2
At least 10% fillet welds shall be subjected to Dye penetration tests (DPT) at random. 100% of the root runs for butt welding shall be subjected to DPT after back gouging. 10% of butt welds chosen at random both for circumferential and seam welds shall be subjected to spot radiographic tests. All welding / weld testing procedure shall in general follow AWS standards. Proper spiders shall be provided at both ends of individual flue cans to prevent distortion of flue/ flanges during transportation and erection. Fabrication drawing for the flue cans shall also incorporate all bracket required for connecting wire ropes during erection. Local strengthening of flue skin plate at location of the bracket if needed shall be incorporated in the fabrication drawing. The factor of safety of brackets and the connection shall be at least 2 over the values specified in IS 800. Erection CONTRACTOR shall submit to the OWNER a method statement for erection of the steel flues and loading on the roof framing due to erection of flues, erection equipment to be deployed, equipment and accessories complete for approval. CONTRACTOR shall make sure that there are adequate spares for the erection equipments and at no cost will a delay be permitted due to inferior or faulty erection equipment. CONTRACTOR shall furnish necessary details such as number of jacks he proposes to use, their supporting arrangement, collars, rod hangers, high tensile steel cables/rods to lift or suspend the flue, temporary staging arrangement and fixing details. The capacity of the jacks, etc. shall be double the actual load proposed to be lifted / borne by them. Factor of safety for cables shall however be five on their rated capacity. All jacks shall be hydraulically operated and no manually operated jacks will be allowed. CONTRACTOR shall ensure that deviations shall not exceed the specified tolerances spelt out herein below for fabrication and erection of steel flues. The permissible deviations from the true form are as under: Internal diameter shall not differ from the true or design diameter by more than +20mm in the horizontal plane.
6.6.5.3
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6.7.5
Horizontal centre of any section shall not deviate more than 12 mm from the shell vertical centre line in any 15 m height and never more than 1:2500 of height plus 12 mm at any level considered. Locally, the variation of the bent plates from true circular form (flat spots) should not exceed the plate thickness. All measurement/ checking shall be done by a segmental circular template having the design radius and a chord length of 0.15 times the design radius. INSULATION STEEL FLUE The flue shall be insulated externally. The insulation shall be semi-rigid, resin bonded type, in the form of slabs and shall conform to IS: 8183. Blanket type insulation shall not be used. The density of insulation shall not be less than 80 kg/cum for resin bonded glass insulation and 200 kg/cum for resin bonded rock wool. Maximum coefficient of thermal conductivity shall be 0.062 Kcal / m/ hr/ C at a mean temperature of 150C. The insulation shall be a minimum of 50mm in two layers of 25mm. The insulation thickness shall be chosen based on the maximum ambient temperature, surface air velocity worked out based on the draught of ventilation air in the annular space between the flue liner and chimney shell, insulation surface emissivity of 0.3 and the insulation cold face maximum temperature not exceeding 50C. The draught of air in the annular space shall be the natural draught by the heating of air by the flue liner and the air being vented out through the opening in the chimney shell. The increase in the annular air temperature due to the rising heated air shall be taken into account while calculating the insulation thickness. The insulation shall be tightly secured to the exterior surface of the liner by impaling them on studs welded to the surface at 450 mm c/c both horizontally and vertically. The studs shall be plated and be of a minimum thickness of 10 gauge. The studs shall extend a minimum of 25 mm beyond the thickness of insulation and 63 mm circular or square metal plate speed washers of standard thickness shall be placed on the extended portion of the studs to hold the impaled insulation material well in place. Further, 20 gauge galvanised wire mesh with a 25 mm hexagonal pattern conforming to IS: 3150 shall be wrapped around. Where the wire mesh is jointed, a minimum 150 mm overlap shall be provided. The mesh shall be bound and tied in place with a 16 gauge GI wire at 300 mm centres. Any form of lacing the mesh fibres together will not be permitted. Insulation for the exposed portion of flue at the top shall consist of 6 layers of insulation material each of a minimum thickness of 25 mm and all joints shall be staggered. The material shall have a minimum density of 200 kg/cum. This shall be protected from the elements by means of a stainless
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steel cladding, flashing and hood of 3.15mm thick stainless steel grade AISI 304L. 7.2 7.2.1 DUCT AND ASH HOPPER The duct work and ash hopper shall be insulated externally with 3 layers of 25mm thick insulation as above. The insulation for duct and hopper shall be protected with aluminium foil of minimum 1mm thickness. Testing of insulation material shall be to satisfy the specific requirements and properties as outlined in this specification, IS: 8183 and in the relevant drawings by the contractor. STRUCTURAL STEEL FRAMING FOR PLATFORMS & ROOF Structural steel framing for roof, flue support platform, flue restraint platforms and bottom platforms are to be provided at elevation shown in bid drawing and data sheet A. Roof frame work shall be designed to support a live load of 1000 kg per square meter during erection of flue, in addition to heavy, concentrated loads transmitted by the flue erection. This frame work will support R.C.C slab of a minimum 150 mm thickness clearing trough of metal deck sheet with Acid resistant tile finish laid over screed concrete. The platform for restraining and supporting the steel flue shall be designed for imposed load 10 kN/sqm in addition to the load from flue can & electrical load, if any. However, for RCC shell design imposed load 5 kN/sqm shall be taken on each platform. This floor will be provided with 40mm thick electro forged G.I grating with toe protection at the flue openings and handrails at other edges. The floor shall be provided with plan bracings as required. Deflection of girders for supporting platform shall be restricted to L/500. Girders of restraining platform shall be restricted to L/325. The bottom restraint platform shall be designed for a live load of 500 kg/sqm. This frame work will be supported by 4 steel columns. The flooring will be of 25 thickness electro forged G.I gratings. All structural steel including staircase shall be blast cleaned using shot blasting to grade Sa 2 and shall be coated with in organic zinc silicate primer of minimum 75 microns (DFT) generally as per BS 5493, including touch up painting of damaged surface of primer. Over the primer coat an intermediate coat of epoxy based Titanium dioxide / Micaceous Iron oxide pigmented high performance epoxy coating 75 microns (DFT) generally conform to BS: 5493 shall be provided. Finish coat shall be 75 microns
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(DFT) epoxy based colour pigmented finish poly amide cured paint with a final finish coat 25 microns (DFT) polyurethane colour pigmented finish paint. Including touch up painting for damaged portion. 8.7 All site connection shall be of grade 8.8 or 10.9. No welding will be permitted on main beams after painting. All the main beams shall be supported on the wind shield with anchor bolts and grillage bearing using steel plates. The bearing shall be so designed that only vertical load is transferred to the wind shield without any temperature effect and local torsional / local bending moment. Through openings in wind shield will be permitted for erection of beam. However the CONTRACTOR shall ensure that the openings are properly sealed using steel shutters of pleasing design after erection of beams. No corbel is allowed for supporting the platform beams. Fabrication of beams shall commence only based on fabrication drawings prepared by CONTRACTOR. OWNER reserves the right to scrutinise the fabrication drawings if deemed necessary in OWNERs opinion. Galvanising of grating shall be using 610 gram of zinc per square meter of exposed surface. All round the platforms 1350 mm hand rails shall be provided using 32 NB MS pipe, type medium, as per IS 1161 with toe protection of 65X8 plate. Complete hand rail assembly shall be hot dip galvanised and provided with bolted connections to the beams. There shall be 3 hand rails at 500 mm, 900 mm and at 1350 mm from platform level. Posts shall be spaced at about 1500 mm c/c. Height of the RCC parapet above roof shall be 1500mm. Floor supporting plate girders shall take support on shell by making an opening in the shell. Stool with stainless steel bearing plates with 3mm thick lead strip in between or elastomeric bearings with seismic stops shall be provided below the plate girders.
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8.14 8.15
Corrosion allowance 2mm (min) shall be kept in the design of girders The plate girders shall be tested on ground for a load of 1.25 times the actual load before erection by the bidder at no extra cost. No payment shall be admissible on this count. Secondary beams may rest on steel brackets fixed to the shell. But, such brackets shall be tested on ground for a load of two times the actual load prior to erection
8.16
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9.0 9.1
EXPANSION JOINTS Each suspended portion of the liner shall be connected to the next supported portion of the liner by an expansion compensator. The joint shall be able to compensate for the large thermal movements of the steel flue, be gas tight, acid resistant, heat resistant and provide an adequate insulating medium to avoid excessive overheating in the access void. The materials used for the fabrication of the expansion compensator shall be suitable for the flue gas conditions specified, and shall not deteriorate during transit, site handling, storage and installation. The expansion compensator shall be manufactured by a specialist agency. The CONTRACTOR shall furnish outline proposals for the expansion joint during the bid stage along with the manufacturers qualifications and experience for the ENGINEERS review. On award of contract, full details of materials to be supplied along with fabrication drawings shall be supplied by the CONTRACTOR. The CONTRACTOR shall procure the units only after obtaining the ENGINEERS approval. The expansion compensator shall be made of flexible fabric and bolster. They should be air tight and impermeable and should withstand the maximum serviceable temperatures of the flue gas. CONTRACTOR shall ensure that the units are transported, stored and installed in proper manner. The joints shall conform to all the requirements specified herein. The contractor shall replace the whole unit if the expansion joint is not manufactured/ installed as per the instructions of the manufacturer nor does it satisfy the tolerance limits specified by the manufacturer approved by the ENGINEER during procurement stage. The flexible type of expansion fabric shall typically consist of 5 layers of materials as indicated below. The layers are described from inside to outside. a) Two layers of texturised glass cloth with anti dust treatment having minimum 1.6mm thickness and weight of minimum 1300gms/m 2 of each layer b) One layer of needled glass felt having minimum thickness of 10mm and minimum weight of 1500gms/m2 c) One layer of PTFE film having minimum thickness of 0.2mm and minimum weight of 450gms/m2 d) One layer of fluropolymer coated glass fibre fabric having a minimum thickness of 0.95mm and minimum weight of 1200gms/m2 e) In addition the flanges shall be reinforced with one layer as described in a).
9.2
9.3
9.4
9.4.1
9.4.2
Bolsters shall be manufactured of glass felt of density not less than 24kg/m 3 confined in texturised glass fabric of weight not less than 400grams/sqm and thickness not less than 0.25mm to withstand a temperature of
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300degC. The bolster shall have a final covering of stainless steel wire mesh having a mesh size not more than 16mmx16mm made of wires of dia. not less than 0.3mm. The glass fibre and SS wire mesh shall extend up to end of the flange and shall be bolted along with the expansion joint material to keep the bolster in position. 9.4.3 The type of expansion joint outlined above is only a typical joint. If the CONTRACTOR wishes to deviate from the above, he shall propose an alternative arrangement clearly spelling out its advantages/superiority over the one outlined herein for the ENGINEER In-charge's review during bid stage. The CONTRACTOR shall furnish complete an installation, dismantling and maintenance manual. A draft of the manual shall be submitted to the ENGINEER In-charge for his approval well before the installation commences. The CONTRACTOR shall also supply spare expansion joints for one flue to suit the requirements of this specification, complete with instructions for storage, fitting instructions, spare accessories, tools for installation, etc., to replace faulty/used expansion joints at a later date. The spares should withstand a storage period of not less than 10 years. The CONTRACTOR shall test the materials for chemical and physical properties, namely acid resistance, maximum and minimum temperatures, pressures and movements. The test procedures along with their acceptance standards shall be submitted by the CONTRACTOR to the ENGINEER In-charge for his review and approval well before the procurement of the units. The CONTRACTOR shall procure the units from an experienced specialist manufacturer, fabricating the type of expansion compensator outlined above. Installation of the expansion compensators shall be strictly as per the manufacturer's instructions. The CONTRACTOR shall submit a manual indicating installation procedure and tolerances at various stages from the manufacturer, to the ENGINEER In-charge for his review and approval. The manual shall indicate the sequence of installation procedure and shall be strictly adhered to, once approved. The compensators shall be prevented from distortion at all stages, during transportation, handling, site storage, erection and jointing. All distortions shall be kept well within the specified tolerances, indicated by the manufacturer in his manual. ACCESSORIES LOUVRES
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9.8
9.9
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Louvres shall be provided in front of air inlet and outlet as per the requirement of this specification. The louvre fins shall be of Z- shape in cross section and made from anodised aluminium plates of a minimum thickness of 4 mm. The frame work supporting the louvre fins shall be made from extruded aluminium channel sections of minimum 150x75x6 mm. The louvres shall be mounted in the form of panels. The fins shall be closely spaced to cut off any driving rain entering the chimney wind shield. All panels must be approved by the ENGINEER In-charge before installation. 10.2 STAIRCASE The structural steel staircase shall be supported by a structural steel frame work supported from platform independently of the wind shield. Connection of the structural support to the platform beam shall be so chosen as to permit unrestrained deflection of the platform supporting beam. Clear width of the stair treads inside stringers shall be 750 mm. Tread shall be of 25 mm thick electro forged M.S. gratings hot dip galvanised using 610 grams with anti-skid nosing. Tread shall be minimum 250 mm wide. Maximum riser shall be 175mm. Handrail shall be of M.S. pipe type medium of 32 mm NB as per IS: 1161 with toe protection of 65x8 mm flats, the complete handrail being hot dip galvanised. Steel pipes posts at not more than 1500mm spacing shall be provided for handrail. Height of hand railing shall not be less than 1350mm. There shall be minimum of three horizontal rails at 500mm, 900mm & 1350mm above platform level. All field connection shall be by bolting only. The arrangement of staircase shall ensure easy accessibility to elevators. Staircase and its connection shall be designed for a live load of 5 kN/sqm. 10.3 10.3.1 LIFT Lift shall be provided for the chimney inside the wind shield. The lift shall be of open cage type which can operate in the corrosive and dusty atmosphere that generally exists in thermal power stations/industrial complexes
10.3.2 The lift shall have a minimum carrying capacity of 500 kg at a speed of 0.70 metre per second. The lift shall be of rack and pinion driven service type of approved make. 10.3.3 All the control devices inside the car shall be housed in a dust free and water proof enclosure. All cables shall be of copper conductor FRLS insulated armoured cable of suitable size. Landing at all locations of platforms shall be provided unless otherwise specified in the DATA SHEET- A. Some of the essential features of the lift are give in Data Sheet A
10.3.4
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10.3.5
Construction of guard cage and supply of other accessories required for satisfactory and safe operation of lift shall be included in CONTRACTORS scope. CONTRACTOR shall also supply and install safety devices such as automatic stop equipment, over speed governor etc. all complete as per MANUFACTURER's recommendation.
10.3.6 All the embedments for the lift structure, approach platforms at landing levels and the lift supporting structure including lift car shall be hot dip galvanised. 10.4 10.4.1 DOORS One access door of size 1000 x 2100 mm size shall be provided at ground level for access across the chimney shell, 150 mm above grade elevation. The door shall be fabricated from mild steel plates. The minimum thickness of mild steel shall be 3mm for sheets and 6mm for rolled section. The door shall be hinged and provided with an aldrop. It shall be painted with two coats of zinc phosphate primer, each coat having a DFT of 35 microns and two finish coats of synthetic enamel paint each coat having a DFT of 25 micron. Manholes Flues shall be provided with 2nos clean out/ access manholes at location of each platform. Manhole covers shall have an inner and outer plate and shall be bolted to the flue with suitable gasket to prevent flue gas leakage. Removable insulation shall be provided to cover the manholes. 10.5 10.5.1 FLUE GAS MONITORING INSTRUMENT PORTS For flue gas continuous emission monitoring system (CEMS) SOX,NOX, CO monitor 01 no., Dust Monitor 1 set, Oxygen Monitor 1 No. & Flue gas velocity monitor 01 set. shall be installed. The monitors shall be installed at the nearest platform, which is at a minimum height of 8D (D Flue can diameter) above the centre line of the ID inlet duct to the stack. The monitors will be mounted on the flanges installed on the vertical face of the MS flue can with stiffeners as required. The exact detail of the flanges shall be as per vendor input, which shall be available during detail engineering. In addition to this, four numbers of manual gas sampling ports on vertical face of MS flue duct, for collection of gas sample for laboratory test purpose and pollution control board norms. The manual sampling ports shall have blind flanges with handle and insulation as required. The location, orientation and level of ports inclusive of size and thickness of material to be used shall be decided during detailed engineering. The flanges shall be installed at a height between 0.90and 1.5 meter above the floor of the working platform. The complete supply & commissioning of the CEMS equipments are in the scope of the contractor. It shall also include providing UPS power
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connection at the platform. Access platforms for installation/maintenance of sampling ports shall be provided by the contractor. Necessary instrument air supply shall be provided near holes for purging purpose with necessary fittings etc. 10.5.2 Necessary arrangement shall also be done for locating instrument control panels on the platform. LINER HOOD/CAPS Hood shall be fabricated from 6 mm thick stainless steel of grade AISI 304 L. The hood shall completely cover the annular area packed with insulation material between stainless steel flue and cladding. Stainless steel hood shall also provide to cover the annular space between the SS flues and openings provided in the roof slab. All section of the hood shall be anchored in place with stainless steel bolts and nut. Slotted holes shall be provided to make allowances for differential expansion/movements. LADDER Steel cage ladder of hot dip galvanised structural steel shall be provided from the flue support platform to the roof slab. Stringers shall be of L75x75x8 with a clear distance of 400 mm in between. These stringers shall be supported from box column which in turn supported from top most support platform and roof beam so chosen as to permit unrestraint deflection of the roof beam. Rungs shall be 20 mm diameter mild steel rods spaced at 300 mm centre. Ladder stringer shall be provided with suitable stays connected to the column. The ladder and connections shall be designed for a load of 175 kg at any location. An open able hatch of stainless steel grade AISI 304 L shall be provided in the roof slab for above the cage ladder to prevent entry of rain water. STRAKES Strakes, if required shall be provided for controlling effect from vortex excited oscillation. The strakes shall be designed for a pressure of not less than four times the wind pressure computed at top of chimney. Strakes shall be made up of mild steel/high tensile plates and rolled sections of thickness not less than 10 mm. A corrosion allowance of 3 mm in the structural members shall be provided for, beyond the design values.
10.6 10.6.1
10.6.2
10.6.3
10.7 10.7.1
10.8 10.8.1
10.8.2
10.8.3
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10.8.4
Fixing arrangement of strakes to the chimney shell shall ensure full fixity for the design load. All strakes, embedded parts, bolts, nuts, washers, etc., shall be hot dip galvanised using 900 grams of zinc per square meter of exposed surface. REMOVABLE CLADDING / ROLLING SHUTTERS Opening provided near the base of the wind shield for the purposes of flue can erection shall be closed using a removable type of colour coated galvanised aluminium sheet min 0.6 mm thick on structural steel framing which also can be dismantled if required. Within the cladding area, a rolling shutter 4000mm wide and 4500 high shall be provided. The surfaces shall be provided with 2 coats of zinc phosphate primer of 35 microns (DFT) each and two coats of synthetic enamel paint of 25 micron (DFT) each. The door shall be provided with suitable locking arrangement. The contractor will be permitted to use the space around rolling shutter as air vents providing louvers as described elsewhere. Under such condition area of removable cladding could be reduced.
10.9
10.10
OPENINGS IN WIND SHIELD
10.10.1 The gap between opening in wind shield and insulated flue duct shall be effectively sealed using compressible material. Special precaution shall be taken to ensure that the packing is protected against ingress of water. 10.10.2 Openings provided in the wind shield to facilitate supporting girder at platform level shall be properly sealed using steel shutters of pleasing design. These shutters shall be of minimum 6mm thick and shall have anticorrosive painting and also to match with painting colour of wind shield. 11.0 11.1 CHIMNEY ROOF CAP & ROOF DRAINAGE The chimney roof cap shall be of RCC deck slab suitably supported on MS beams. The roof shall be sloped towards rain water down take catch pits covered with C.I. gratings. The roof shall be designed to cater for differential movement between the shell and the liners including circumferential expansion and contraction due to temperature variation. The roof shall be provided with a hatch for access from the flue support platform. The hatch shall have a single leaf door with a minimum thickness of 6 mm to cover a clear opening of 750 mm x 1000 mm. The hatch shall include the door, metal curb, draft seal, spring latch, hold-open device and all hardware. All joints shall be welded and ground smooth. The curb shall be 300 mm in height with a suitable lip which shall include a continuous neoprene seal strip to make the hatch air-tight when the cover is closed. The hatch shall be operable from both inside and outside and shall be provided with automatic hold open arm, easy one hand release and spring latch. All the items of the door shall be of stainless steel of grade 304 L.
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11.3
The roof slab and the inside surfaces of the wind shield above roof shall be lined with acid proof tiles conforming to IS: 4457. Bedding mortar shall conform to IS: 4832 Part I and shall be of potassium silicate base. The tiles shall be pointed using a phenolic based resin cement mortar conforming to IS: 4832 ( Part-2). The bedding mortar and phenolic based resin mortar should be acid-proof, chemical resistant and water-proof. They shall in particular be resistant to sulphuric acid and hydrochloric acid. Two number 150dia UPVC rain water pipes shall be provided within the interior of the shell to remove rain water collected on the roof cap. Rain water inlet into the pipes at roof cap level shall be provided with CI grating. The rain water down take pipe shall be led to a sump inside wind shield suitably lined with acid / alkali resistant brick lining. The rain water pipes shall be provided with vent ports at roof level and shall be connected to the stair case column to bring the roof drainage to the sump at grade level. GRADE SLAB AND FLOOR DRAINAGE Inside the chimney wind shield 150mm thick R.C.C grade slab shall be provided with nominal reinforcement of 8 dia. HYSD bars 200 c/c both ways at top and bottom. The grade slab shall be provided over well compacted ground, 230 thickness stone soling and 75 mm PCC of grade 10. The grade slab shall be sloped towards the peripheral drain. Roof drainage shall be directed through roof drainage pipe, to the central drain chamber. From the central drain chamber the drainage water will be taken out of the wind shield through a 200 mm dia. C.I pipe with a sump outside the wind shield. Necessary pipe sleeve has to be left in the wind shield to take out the drain pipe. A 300 mm wide R.C.C drain shall be provided all round the chimney, located at a distance of 1500 mm from the edge of chimney. This drain will take the roof drainage from the drain chamber to the nearest drain of the project storm water drainage system. All drain including sump shall be provided with A.R lining and shall be provided with 40 mm thick C.I & G.I grilles at top. The space between wind shield and the drain shall be provided with 100 mm thick plinth protection with nominal concrete of grade M20. PAINTING
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12.2
12.3
12.4
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13.1
Two coats of acid and heat resistant high build polyurethane paint, with DFT not less than 150 microns over a coat of compatible primer shall be given to the following surfaces as per MANUFACTURER's recommendations: a) b) Parapet above roof slab including embedment etc. Top 50m height of the chimney externally.
13.2
The external surfaces of the chimney shell below the portion covered above shall be painted with two coats of synthetic enamel paint over 2 coats of primer as per MANUFACTURER's recommendations. The entire height of the chimney shell shall be painted with alternate bands of Orange or Red and White shade, each band with a band width of H/7 metres (H=Height of chimney) and bands at the extremities being of Orange or Red shade. This shall be done after removing all loose and foreign matter to give a smooth and uniform finish. External painting shall commence immediately after the shell construction/platform is completed and the concrete is well cured. The painting shall preferably be started from the top. This is to ensure visibility of stack to low flying aircraft during day time even during the period of construction of the internals of the chimney. The internal surfaces of wind shield shall be provided with two coats of acid and heat resistant black bitumen paint conforming to IS: 158 over a coat of primer. DESIGN AND DRAWINGS The CONTRACTOR shall submit his method of analysis, design paramters, allowable stresses, method and sequence of construction including staging, details of proposed site testing facilities, etc., strictly as per specifications for the OWNER's review and approval within 15 days from the date of Purchase Order, letter of intent, whichever is earlier. The contractor shall submit his design/drawing submission schedule and a construction schedule within 15days of award of contract. In case the CONTRACTOR adopts computerised designs, only validated computer programs shall be used for the analysis and design. The computer output listing should include all input data covering the loads and load combinations. The CONTRACTOR shall submit typical manual calculations in order to validate the computer program / Spread sheets used for analysis / design.
13.3
13.4
14.0 14.1
14.2
14.3
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14.4
Timely submission of design/drawings to the CONSULTANT for review is the sole responsibility of the CONTRACTOR and postal or other delays will not be entertained as reasons for late/non-submission of design/drawings. All modifications suggested by the CONSULTANT to meet specification requirements and sound engineering practice, shall be incorporated by the CONTRACTOR at no extra cost to the OWNER. In this respect, the decision of the OWNER shall be binding on the CONTRACTOR. The CONSULTANT will accord his approval only after the CONTRACTOR has incorporated in his design/drawings all modifications required by the CONSULTANT. Any modifications/change in subsequent revisions of design/drawings shall be clearly marked and identified with a revision for the OWNER's review/approval. Construction of work shall commence only after the written approval of drawings by the CONSULTANT. However, the CONSULTANTs approval of the design/drawings shall not absolve the CONTRACTOR of his responsibility for correctness of design, accuracy of dimensions, loadings, details, etc., or safety and stability of the structure including foundations, accessories, appurtenances, etc. The contractor has to support flue duct supporting columns by boiler vendor, from the chimney foundation.
14.5
14.6
14.7
14.9
15.0 15.1
WIND LOAD ANALYSIS WIND SPEED The basic wind speed (Vb) for the location of the project shall be as indicated in DATA SHEET- A. The estimation of wind speed/ pressures shall conform to the requirements of IS: 875 (Part-3).
15.1.1
3-sec Gust Wind Vz = Vb K1 K2 K3 .......... (1) here, K1 = a probability factor as obtained from Table-1 of the Code. The mean probable design life of the structure may be taken as: a) 100 years for shell alone condition; b) 100 years for completed chimney condition K2 = Terrain category factor obtained from Table-2 of the Code. The terrain category for the project and class of the structure shall be as indicated in DATA SHEET- A
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K3 = 15.1.2
Topography factor shall be as indicated in DATA SHEET- A.
Mean Hourly Wind Vz = Vb K1 K2 K3 ........ (2) here, K1 and K3 shall be as in clause 15.1.1. K2 as per Table-33 of the Code depending on the terrain category as indicated in DATA SHEET- A.
15.2
WIND PRESSURE Pz = 0.60 V z ........... (3)

2
15.3
ALONG WIND RESPONSE This response will be evaluated by the following two methods: Method-1 For 3-sec gust wind, 2 Fz = 0.60 Cd Dz V z ............ (4) Here, Cd = Coefficient of drag DZ = Diameter of chimney at height Z Deflections, moments and shears shall be evaluated for lateral loads Fz acting on the chimney as a cantilever. Vz to be as per clause 15.1.1 Method-2 For mean hourly wind analysis the Gust factor Approach as outlined in clause A.5 IS: 4998 (Part 1)-1992 shall be followed. Deflection, moments and shears shall be evaluated for the lateral loads Fz (Load per unit height at an height 'Z' on the chimney) acting on the chimney as cantilever. Vz to be as per clause 15.1.2 .
15.4
ACROSS WIND RESPONSE
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The across wind response shall be evaluated for the first two modes as per requirement of clause A.5.3 a) of IS: 4998 (Part 1)-1992 for chimney having taper less than or equal to 1 in 50. If chimney taper is more than 1 in 50 then procedure outlined in paper by Vickery B. J. and Basu R. I. as indicated in clause 2.2. 15.5 COMBINATION OF RESPONSE This shall be checked as under : (a) The critical wind velocity for across wind response shall be evaluated from:
Vcc Here,
ni Dc = -------S
...... (5)
Vcc = Critcal wind speed ni = Natural frequency of chimney in the ith mode of vibration
Dc = Effective diameter of chimney S = Strouhal number
(b) Knowing the height (Zc) at which Vcc acts, corresponding value of K2 is read from table 33 of the Code for the particular terrain category. Vcc = ---------K1 K2 K3
' Vb
(6)
' V Z = Vb .K2 .K3
'
(7)
'
Then, response will be evaluated by equation (4) substituting V Z
for Vz
(c) Response evaluated as per 15.5 (b) above will be vectorially combined with that obtained for the particular condition outlined in clause 15.4 above. NOTES The response under wind load at any level to be used for design shall be the highest of the following values:
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a) As obtained for 3-sec gust wind, as per Eqn. (4) b) As obtained for mean hourly wind, as per clause 15.3 Method 2 c) As obtained vide description in Cl.15.5(c), above. d) values obtained from Wind Tunnel studies 15.6 MAGNIFICATION FACTOR In the absence of results of wind tunnel studies, magnification factor on account of aerodynamic interference shall be considered for the design of chimney from clause 4.2.3.4 of ACI-307.
16.0
SEISMIC ANALYSIS Seismic analysis shall be carried out using the Response Spectra Method according to IS: 1893-2002. The importance factor of 1.75 and 3% damping shall be considered for the analysis. The number of modes to be used in the analysis should be such that the sum total of modal masses of all modes considered is at least 90% of the total seismic mass.
17.0 17.1 17.1.1
CONSTRUCTION GENERAL CONTRACTOR shall ensure that the excavation and substructures are free from water during construction and shall take all necessary precautions and measures to prevent ground water, storm water, etc., from entering the excavation so as to carry out the work in reasonably dry conditions in accordance with the construction schedule. The CONTRACTOR shall dewater and maintain reasonably dry, the excavation for structures and all other areas of the site, where build up of water (in the opinion of ENGINEER In charge) is likely to obstruct the progress of work, or lead to insanitary conditions by stagnation, or retard the speed of construction, or is detrimental to the safety of men, materials and equipment or is undesirable due to any other reasons. The concreting of pile cap foundation shall be done in segments. Number of construction joints in foundation can be to suit at site. However the total number of segments shall always be odd. Adjacent pours shall be cast after minimum gap of 7 days from the end of concreting of earlier pour. Concrete surfaces to be joined shall be cleaned with a wire brush and well watered at least 3 hrs. prior to placing of new concrete. The surface shall then be cleaned with water jet and neat cement slurry applied over it just before placing fresh concrete.
17.1.2
17.1.3
17.1.4
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17.1.5
Backfilling of chimney foundation excavated area shall be done in layers not exceeding 150mm thickness & compaction shall be done to achieve dry density not less than 90% of proctors dry density at optimum moisture content (OMC). The backfilling should be completed before taking up the erection work. STAGING Design and erection of staging shall conform to the requirements of all relevant IS Codes and National safety standards/regulations. CONTRACTOR, at his own cost, shall prepare a detailed erection scheme. If called upon, he shall submit to the CONSULTANT detailed drawings with supporting calculations showing all details of formwork, staging, scaffolding, member sizes, connection details and other arrangements for slipforming and for the concreting work and submit the same for review. Any suggestions/ comments on the scheme/details conveyed to the CONTRACTOR shall be carried out by the CONTRACTOR at no extra cost. Scheme submitted for approval shall incorporate separate provision of material hoists and a passenger hoist. As the staging serves a dual purpose, viz., as an access tower and as a bearing structure to support construction loads, it shall be designed for all possible loads that could be imposed on it such as self-weight, weight of ladder and timber platforms at all levels, weight of men, weight of construction materials and equipment, wind loads, seismic loads, etc. Minimum live load on staging due to labour and personnel movement shall be considered at 300 kg/m2. It may be taken as 150 kg/m2 when earthquake loads are also taken into account. No increase in stresses shall be considered for wind and seismic conditions. Special inspection hoist of approved make shall be provided by the CONTRACTOR for regular inspection, checking of scaffolding members, joints, etc. Fortnightly detailed inspection record shall be maintained by the CONTRACTOR and shall be produced to the ENGINEER In-charge whenever required for his verification. Notwithstanding the approval from the ENGINEER In-charge, the CONTRACTOR will be solely responsible for the safety, security and proper functioning of the staging and formwork. Conventional / Jump form shuttering may be permitted only up to a height of W/2 above breach opening where W is the width of breach opening. Above this level only slipforming will be permitted. Where conventional/jump form shuttering is adopted, minimum stripping time of formwork shall not be less than 12 hours for sides of RCC shell. However, the stripping time to be adopted on the works shall be subjected to the ENGINEER In-charge's apISSUE R0
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proval. The CONTRACTOR shall not be permitted any increase in construction period if the stripping time for shell exceeds 12 hours. 17.3 17.3.1 SHELL CONSTRUCTION The CONTRACTOR shall prepare and submit a detailed quality assurance plan within 15 days of award of work. This plan shall include the following : a) Design criteria The CONTRACTOR shall give the criteria to be adopted for design of various temporary works and the slipforms. The following requirements shall be met. i) Staging materials shall conform to IS: 2062. ii) Minimum design live load from personnel shall be 300 kg/sq.m. To this shall be added the self- weight and weight of construction materials and equipment, etc. iii) The staging shall be designed as per the requirements of IS: 800 (for conventional type) and IS: 4014 (for tubular scaffolding type). The CONTRACTOR's design calculations shall be based on normally accepted calculation techniques for the structural forms which the CONTRACTOR adopts for staging. b) Statement of detailed 'Construction Method This shall include at least the following: i) Structural analysis providing adequacy of jacks, slipforms, and their supports and staging. ii) Planned interruptions. Also the operations during planned interruptions such as retrieval of jack rods, resetting of form panels, etc., shall be stipulated. iii) Method of preparing, transporting, pouring, vibrating and finishing concrete. iv) Quantity of various materials required during each stage of construction including inserts, cut outs, reinforcement, dowels, etc. for procurement and timely supply. v) Properties of concrete such as w/c ratio, strength, workability, etc. vi) Rate of slipping which shall be adopted.
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vii) Treatment at construction joints during unplanned interruptions. c) Construction Equipment The CONTRACTOR shall furnish a detailed description of the following: i) The type and number of equipment and facilities to be used for slip forming such as jacks, working platforms at various levels, yokes, walers, etc. There shall be at least a 50% standby capacity of jacks, jack rods, hydraulic pump, hose pipes, etc. ii) Provision, including standby, of concrete mixing units and pumps to cater to the planned rate of progress of slipping. iii) Material hoists and buckets for transport of concrete, reinforcement, scaffolding components, etc. iv) Curing arrangements consisting of pumps, pipelines, etc. There shall be at least 50% standby pumps v) Provision of precision survey instruments including lasers for verticality check. The laser instrument shall emit a long range visible laser which has a self-levelling platform which electronically levels the instrument and has a fail-safe system that shuts off the beam when out of level. There shall be a standby. vi) Stipulation of power requirement for operation and the CONTRACTOR shall provide adequate standby diesel generating sets. Details of night lighting shall also be specified. vii) Communication arrangements between ground and working deck. 17.3.2 Concreting a) Particular attention must be given to concrete placement because of the thin wall section and the presence of reinforcing steel. Compaction of concrete shall be by vibration. b) Under no circumstances shall the point of discharge of the concrete into the forms be more than 1.5 m above the concrete surface on which it is to be deposited. Also, not more than 2 metres height of chimney shall be concreted on any one day. c) Concrete in the shell shall be poured in about 200 mm layers uniformly. The concrete in each lift (where jump form is used) shall be laid in one continuous operation for the full circumference of the shell so that there will be no vertical or inclined construction joints. Horizontal construction
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joints shall be maintained at uniform spacing throughout the height of the chimney. d) Pulse Velocity (UPV) test on the bottom portion of the wind shield concrete, to a height of 30metre from top of raft shall be conducted immediately after the construction up to 30m. In addition if the ENGINEER Incharge so requires, the CONTRACTOR shall make immediate arrangements, through an approved agency, to undertake ultrasonic tests to prove the quality of concrete in other areas. The quality of concrete shall be considered as satisfactory if it meets specification requirements and the sonic velocity is at least 4000 m/s. If the tests prove that the quality of concrete is not satisfactory, then all costs associated with the tests and any rectification shall be borne by the CONTRACTOR. e) The interior and exterior surfaces of the shell shall be kept moist for 14 days after exposure from the forms as the chimney construction progresses upwards. For this purpose, circumferential perforated pipes shall be hung from immediately below the forms and raised along with them. f) The vibrator needle size should normally be 62 mm dia, however the size shall be restricted to 37 mm dia for sections wherein the use of 62 mm dia needle size vibrators are not amenable to use. Standby vibrator units shall be maintained on top of the working deck at all times during the slipforming operation. g) The vibrator poker shall only be lowered into the concrete to a depth corresponding to the height of the last placed layer of concrete. During the first pouring, when the forms are empty, vibration should be avoided or carried out with utmost care in order to prevent bending of the yokes. The achieve good bond between the foundation and the first lift of the shell, or at horizontal joints caused by interruptions to sliding, an initial layer of rich mix cement/sand slurry of 1:1 proportion shall be placed. h) The slipping rate of the forms shall be such that the concrete, when exposed has already achieved enough strength to support the vertical pressure from the concrete still in the forms as well as to withstand lateral pressure caused by wind, inclination of walls, etc. The slipping rate shall be limited to 200mm/hour. i) Small openings and pockets less than 600 x 300 mm can be formed by inserting blocks. Larger openings shall be formed using frames which shall be formed well in advance of the sliding. All frames, blocks, bolts, tubes, etc., must be 12-15 mm narrower than the nominal wall thickness to allow for form taper. When jacking rods unavoidably have to pass through openings more than 600 mm high, the jacking rods must be braced laterally against buckling.
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17.3.3
Reinforcement laying a) Normally bar diameters should range from 10 mm to 25 mm. The preferable length of the bars should not exceed 8 m. Horizontal bars should be fixed nearest to the face of the wall. These bars should be pre-bent.
b)
17.3.4
Physical Checks Some of the mandatory physical checks to ensure that construction tolerances are met with shall be carried out by the CONTRACTOR, as under: a) b) c) d) The twist or rotation of the slipform every 60 minutes. Level of top of jacks every thirty minutes. Verticality with the help of lasers at least once in four hours. Inside and outside diameters/dimensions and wall thickness, once in each shift of 8 hours. Level of top of form panels once initially and subsequently after each interruption. Level of working platforms once initially and subsequently after each interruption. Batter of the form panels and yoke legs once on erection and subsequently after each interruption. Condition of jack rods for ovality, indentation, buckling, moving out of alignment, etc., before fixing each rod. Bracing of jack rods passing through openings. Live load on working deck to avoid accidental overloads. Workability of concrete at mixer and at point of placement, once an hour. Temperature of concrete, once in 4 hours.
e)
f)
g)
h)
i) j) m)
n) 17.3.5
Construction Tolerance The following shall be the limiting construction tolerances to be strictly adhered to by the CONTRACTOR.
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a) Verticality : 1 in 1000 subject to a maximum of 75 mm. In addition, no two points 10 m apart vertically shall be more than 20 mm out of plumb w.r.t. each other b) Wall thickness : 10 mm, - 0.
c) Shell diameter : 10 mm for every 3m diameter without any abrupt changes but in no case more than 40 mm. d) Spiralling : Rate of spiralling of forms not greater than 10 mm circumferential rotation at the outer face of the concrete per metre of vertical travel. e) Openings, inserts, pocket f) Cover : : 12 mm
+ 5 mm, - 0. : 20 mm
g) Level of any part of structure
17.4 17.4.1
CONSTRUCTION TOOLS AND MATERIALS CONTRACTOR shall provide and maintain at the site necessary number and type of machinery and equipment including survey instruments in good working condition for proper setting out and timely completion of the works covered under this specification. All arrangements for transporting the equipment to and from the site shall be done by the CONTRACTOR at his own expense. It shall be ensured by the CONTRACOR that work shall proceed uninterrupted even in the event of power failures. As such, adequate number of diesel generator sets and diesel operated equipment (such as concrete mixers, vibrators, etc.) shall be provided by the CONTRACTOR, as an alternative arrangement. All materials supplied by the CONTRACTOR shall be of the best quality and shall conform to this specification. Approval in writing shall be obtained from ENGINEER In-charge, before any alternative or equivalent material is proposed to be used by the CONTRACTOR. CONTRACTOR shall furnish MANUFACTURER's test certificate for the materials supplied by him. Where such certificates are not available, the specimen of the material shall be got tested at a recognised testing laboratory at CONTRACTOR's cost. Testing shall be done as per quality assurance plan (QAP) even in case of manufacturers test certificate if required by ENGINEER IN-CHARGE. All cost related to testing shall be borne by contractor. The material if found rejected shall be removed from the site within
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17.4.2
17.4.3
17.4.4
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10 days. In case, contractor does not remove the rejected material from the site the same shall be removed by the owner and the cost shall be deducted from the running bill. 17.4.5 Climbing or slipforms shall be controlled by linked hydraulically operated jacks that are reversible, driven by an electrically operated pump and with provision for manual operation in the event of a break down. CONTRACTOR shall provide all fuels and lubricants required for the operation and maintenance of construction machinery and equipment as well as for his transport vehicles. CONTRACTOR shall, at his cost, arrange for all his requirements of materials such as, but not limited to, oxygen, acetylene, welding electrodes, ropes, form ties, turn-buckles, clamps, wiping rags, sand paper, etc., which are required to satisfactorily perform his work. WORK EXECUTION AND SUPERVISION CONTRACTOR shall have at the site accredited and qualified engineers and foremen/supervisors with adequate number of years of experience in execution of similar works and operators of machinery and equipment, for satisfactory progress and timely completion of the works. The number, qualification and experience of such staff shall be subject to OWNER's approval. All temporary electrical installation shall be supervised by a qualified electrical supervisor of the CONTRACTOR. CONTRACTOR shall be fully responsible for the correctness and accuracy of the works, which shall be executed in a professional manner. The OWNER reserves the right to order from time to time, during progress of the work, removal and re-execution of any work which is not, in the opinion of the ENGINEER In-charge, in accordance with the specification. During inclement weather, rains, etc., CONTRACTOR shall suspend concreting for such time as the ENGINEER In-charge may direct and shall protect from damage all work already in progress or completed just then. All such temporary protective measures shall be at CONTRACTOR's cost and any damage to works shall be made good by the CONTRACTOR at his own expense. Should the work be suspended by reason of strikes/riots by CONTRACTOR's own employees or any other cause whatsoever, save and except the force majeure condition, CONTRACTOR shall take all precautions necessary for the protection of works and make good, at his own expense, any damage arising from any of these causes.
ISSUE R0
17.4.6
17.4.7
17.5 17.5.1
17.5.2
17.5.3
17.5.4
17.5.5
17.5.6
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17.5.7
In the event of occurrence of any accidents at/or near the site of the work or in connection with execution of the work, a report shall be made within 24 hours to the ENGINEER In-charge, giving full details of the accident. He shall also report promptly such accidents to all the competent authorities wherever such reports are required by them. One hoist for passengers/supervisory staff and one for transport of goods shall be provided by the CONTRACTOR. These hoists shall be operational not later than the time when construction first reaches 30 m and should be available throughout the construction period. Access between various working levels shall be provided by an approved system of ladders. Under no circumstances shall staging or scaffolding be relied upon to provide such access. The CONTRACTOR shall give enough notice to ENGINEER Incharge of his intention to remove access to the various areas of work as construction proceeds which would therefore be rendered inaccessible, to allow final inspection by ENGINEER.
17.5.8
18.0 18.1
ELECTRICAL REQUIREMENTS SCOPE The following equipment/systems are included in Bidders scope.
18.1.1
Lighting system equipment comprising of Lighting panels , wires, cables, plugs and sockets, lighting fixtures, conduits, junction boxes, GI pull boxes, etc., Day marking and aviation warning lights with associated accessories. Earthing system Lightning Protection system Cables, Cable trays, cable tray supports and cable tray covers etc, as required for Cabling system. All cable terminations for all equipment including cable glands, cable lugs, terminals, clamps, etc Complete installation accessories for cables, lighting, earthing, lightning protection system including all structures, supports, conduits, Marshalling boxes, Junction boxes, Terminal blocks, hardware, consumables, etc 3 Phase, 63 Amps, 415V, Power receptacles for maintenance equipment such as portable grinders and welding sets & 15A, 1 phase power receptacles.
ISSUE R0
18.1.2 18.1.3 18.1.4 18.1.5
18.4.6
18.1.7
18.1.8
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18.1.9
Any other electrical equipment which are not specifically listed above but are required to make the system complete in all respects as per specification TERMINAL POINTS 415V, 3 ph, 4 wire Power supply(5 Nos. feeders) for normal and aviation lighting & power receptacles will be made available by PURCHASER at the respective lighting panel/junction box to be provided by the BIDDER at grade level. Further distribution to all other platforms will be by BIDDER. Risers from the below ground Main earthing grid will be given at (4) four points near chimney bottom. Connection of BIDDERS earthing system to purchasers main earth grid shall be done by BIDDER. Air termination and down conductors up to test links and connection from the test links of the lightning down conductors to earth pit & to the Purchasers main earthing grid shall be by Bidder. SPECIFIC REQUIREMENTS Bidder shall quote for the complete electrical system on lumpsum basis with individual break-ups for earthing, lighting and lightning protection systems. Bidder shall also furnish unit prices as called for in the price schedule which will be used for making contract price adjustments. In the event of an order, CONTRACTOR shall submit construction drawings for lighting, earthing and lightning protection for PURCHASERS a pproval and CONTRACTOR shall take up the work after the drawings are approved by OWNER. The installation of electrical system shall be in strict accordance with the latest editions of relevant Indian Standards, Codes of Practice and Regulations existing in the locality where the system is installed. In particular, the following standards shall be applicable: a) b) c) d) e) Earthing - IS:3043 Lightning protection IS2309 Indian Electricity Rules ICAO Standards Civil Aviation Department, Government of India
18.2 18.2.1
18.2.2
18.2.3
18.3 18.3.1
18.3.2
18.3.3
18.4 18.4.1
LIGHTING The day marking and aviation warning lights shall conform to the requirements of Civil aviation department, Government of India, ICAO, FAA
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and/or other international standards. LED based aviation lights of high intensity Type-A obstacle lights shall be used on alternate platforms. Control of the aviation lighting shall be possible in both modes: Timer as well as photo sensors through selection.
18.4.2
Each platform shall be provided with one no. single phase, 15A receptacle and one no. 3-phase 63A power receptacle. Each platform shall be provided with sufficient platform lighting. Every staircase landing shall be provided with 1X70W HPSV lighting. 20% of staircase lighting and platform lighting shall be fed from emergency supply. Minimum cable size for these lighting fixture and receptacle shall be of 2C x 2.5 mm Cu. & 2C x 4 mm Cu respectively. Separate JB shall be provided for each fixture for loop-in loop-out of lighting cables. 3-phase 63A power receptacles of protection IP-55 shall be installed in platforms. CONTRACTOR shall supply, install and wire all the lighting panels, lighting fixtures, receptacles, GI pull boxes, conduits, junction boxes and other accessories. Detailed lighting design calculations shall be furnished during design stage. Light fittings for the staircase shall be suitably clamped to the staircase handrail and platform light fittings shall be suitably fixed to the hand railing or at roof at each level. Wiring of aviation warning lights and other light fixtures shall be carried out using 1100V grade, copper conductor, PVC insulated, FRLS PVC outer sheathed cables conforming to IS-1554 part-1. For detail electrical requirement refer the respective section of Electrical specification attached with this document. During construction, the temporary aviation warning lighting shall be provided to meet the requirement of Civil Aviation Department. The temporary warning lights installed during construction shall be lifted up as the construction progresses. These lights need to be installed only after the height of obstruction is more than 45 meters above grade level. Lightning protection and earthing required during the construction stage of the chimney shall also be provided by the CONTRACTOR. Chimney lighting & Aviation warning lighting shall conform to the requirements of air port authorities & international standards (ICAO). CONTRACTOR shall supply and install one no. of 300 wide and one no. of 150 wide cable trays of 2.0 mm thick galvanised steel inside the chimney shell, one for power cables and one for I&C cables. These trays shall run up to the top of the chimney along the side of the staircase. Cable trays shall be covered with cable tray covers of 16 SWG after laying of cables. One junction box with MCB shall be provided at each platform where aviation lights are to be provided.
ISSUE R0
18.4.3
18.4.4
18.4.5
18.4.6
18.4.7
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18.5 18.5.1
LIGHTNING PROTECTION SYSTEM The design and installation of the lightning protection system shall conform to IS2309. Pointed vertical air terminal rods shall be provided at the top of the chimney shell. Air terminals shall consists of lead covered copper rods each not less than 20 mm in diameter (unless specified otherwise on the drawing) and of height not less than 1000 mm and securely anchored and braced with at least two lead covered copper alloy anchors spaced not more than 750 mm on centres. Air terminals shall be mechanically and electrically connected by the use of pressure type fittings to the chimney shell periphery and to a continuous circumferential conductor specified below. The installation work shall conform to IS: 2309. The circumferential conductor shall be lead covered, stranded, tinned copper conductor and the same shall be mounted at the top of the chimney shell. The circumferential conductor shall be suitably anchored to the top of the concrete shell at an interval not more than 1.0 m. Further these circumferential conductors round the flue shall be interconnected by lead covered, tinned copper conductors. Minimum 75mm X 10 mm GI flat down conductors shall be provided. These shall not be more than 10m apart on the periphery of the stack at the ground level. The flue pipes that extend beyond last platform shall be bonded at minimum 2 points to the lightning conductor at EL of 268 m. All lightning conductors at this level shall be lead coated copper conductor. Down conductors shall be connected to the circumferential conductor at the top of the chimney and to the testing point at the chimney base. There shall be no intermediate splices in the down conductors. The down conductors shall be brought outside the shell at the bottom to facilitate connection with the test link. Conductors embedded in concrete shall have minimum cover of 50 mm. Each of the down comers from the test link shall be connected to separate treated earth pits at ground level which in turn shall be connected to buried earth mat around the chimney. Each down conductor shall be provided with a testing point at around 1500 mm above ground level. Test link shall be enclosed in 200 x 200 x 100 mm GI box fabricated from 16 SWG sheet steel. All connections, clamps anchors, etc. of the lightning protection system shall be made of copper or suitable alloy fittings. All electrical connection, unless otherwise specified, shall be clamped or bolted by high pressure contact or by copper brazing of the metal to form a connection of adequate current carrying capacity and mechanical strength.
ISSUE R0
18.5.2
18.5.3
18.5.4
18.5.5
18.5.6
18.5.7
18.5.8
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SPEC.NO. TCE.6417A-H-500-001
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18.5.9
All vertical reinforcing bars at the top and at the bottom of the chimney shell shall be electrically connected to the nearest horizontal reinforcing rods and these rods shall in turn be connected to the down conductors. Where vertical reinforcing bars are spliced, each spliced bar shall be electrically connected to at least one horizontal reinforcing bar which in turn shall be electrically connected to each of the down conductors. Air terminals, connections, conductors, clamps, fixtures, anchors, etc. exposed within 8000 mm of the top of the chimney shall have a continuous covering of a sheath of commercially pure lead not less than 1.6 mm in thickness extruded and fused upon bare copper, the ends being covered by soldering or puddling. Where lead covering is specified, connection shall be made from copper to copper and after the joints have been made, they shall be again covered with solder or lead either by wiping or casting so that copper will not be exposed. During construction, temporary lightning protection should be maintained still the installation of the chimney lightning protection system. EARTHING SYSTEM The grounding installation work shall confirm to the requirements of the Indian Electricity Rules and code of practice for earthing (IS: 3043) as amended up to date. Earthing system shall consist of main earthing conductor MS (40 mm dia.) earth mat buried in the soil (600mm below) around the chimney. Two (2) nos.of 75X10 sq mm (minimum) GS flats that shall run from bottom to top of the chimney. Connection of these conductors to the main earth mat shall be done by BIDDER. These conductors shall be embedded in the chimney shell on the opposite sides. The conductors shall be brought outside the shell at the bottom to facilitate connection with the buried conductors. Risers shall be provided at every platform. All the earthing leads from the equipments shall be electrically connected to the nearest riser. All the exposed earthing conductors shall be of galvanised type. The buried earthing conductor (earth mat) around the chimney bottom shall be connected to minimum two (2) treated earth pits & in turn shall be connected to purchasers main earth grid at minimum two points. Raisers will be provided by purchasers so as enable bidder to connect his earthing conductors to purchasers grid. Earth electrode of size 40 mm dia. X 3 mm length driven into the ground and connected to the ground grid conductor shall be provided as required to bring down the ground resistance. Above grade main ground conductors shall be securely fixed at intervals not exceeding 1500mm.
ISSUE R0
18.5.10
18.5.11
18.6 18.6.1
18.6.2
18.6.3
18.6.4
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18.6.5
Chimney ladder shall be electrically connected to the down conductors both at top and bottom. For this, the two lower pairs of inserts supporting the ladder shall be adequately connected to the grounding system and the top pair of inserts shall be connected to the circumferential conductor connecting the down conductor. All intermediate breaks in the ladder should be electrically bonded to form a continuous supports from top to bottom. Ground grid resistance of the grounding system hall be less than one (1) ohms. Earthing of lighting panels, lighting fixtures, receptacles, junction boxes, cable trays and other steel structures shall be included in the scope of work. All the metallic parts such as platform railings, pull boxes, junction boxes etc. shall be grounded using 75 sq.mm conductors tied to the down conductors provided by the CONTRACTOR. MAKES Make of all the items used shall be of reputed and reliable make. These makes shall be subject to purchasers approval. APPROVAL All equipment supplied and all works executed under this contract including system design and detailed engineering, shall comply with the statutory requirements of the Government of India, the Government of Haryana, the Grid Authorities, the Indian Electricity Rules, etc. The scope of work includes obtaining necessary statutory approvals/clearances from all the concerned authorities for various systems covered in this contract. INFORMATION TO BE FURNISHED BY THE BIDDER ALONG WITH BID All the Data Sheets and Schedules duly filled up with soft copies of the same. Description literature/catalogues and write-ups for the offered equipment/systems. Type test certificates/reports for the equipment covered in the specification. DATA TO BE FURNISHED AFTER AWARD OF CONTRACT
ISSUE R0
18.6.6
18.6.7
18.6.8
18.7 18.7.1
18.8 18.8.1
18.9
18.9.1
18.9.2
18.9.3
18.10
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18.10.1
Documents for Review/Approval SL.No a) Documents Quality Control Plans for all equipment with detailed procedure for the proposed equipment/material Technical data sheets, general arrangement drawings, control schematics, etc. for all equipment Earthing & lightning protection system layout drawings, lighting layout drawings, cable carrier system layout drawings, etc. Inspection & Test Plan (ITP) with detailed procedure for the proposed equipment/material
b)
c)
dl)
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SPEC.NO. TCE.6417A-H-500-001

REINFORCED CONCRETE CHIMNEY DATA SHEET A
SHEET 247 of 267
1.0 1.1 1.2 1.3
GENERAL NO. OF CHIMNEY DISTANCE BETWEEN CHIMNEYS/NDCT METHOD OF SHELL CONSTRUCTION
: : : : 1 285m (approx)/204m (approx) SLIPFORM ABOVE BREACHING LEVEL / JUMP FORM BELOW THIS LEVEL/AS PER BIDDER & APPROVED BY THE OWNER
2.0 2.1 2.2
DIMENSIONS OF CHIMNEY CLEAR INSIDE DIA OF CHIMNEY AT EXIT ELEVATION a) CLEAR INSIDE DIA OF FLUE AT EXIT ELEVATION b) NUMBER OF FLUES c) MATERIAL FOR CONSTRCUTION OF FLUES d) CENTER TO CENTER DISTANCE OF FLUES : : : ONE (1) STRUCTURAL STEEL GRADE E250(410W) QUALITY B (KILLED) AND STAINLESS STEEL GRADE AISI304L NA : : By bidder DDE
2.3
TOP ELEVATION OF CHIMNEY
275m ABOVE FFL OF STATION BUILDING. EL 0.00 WILL CORRESPOND TO FFL OF STATION BUILDING By bidder By bidder (+)0.000m By bidder
ISSUE R0
2.4 2.5 2.6 2.7
BATTER OF EXTERNAL SURFACE FROM EL. .. TO EL. .
MAXIMUM EXTERNAL DIA OF SHELL : AT CHIMNEY GRADE SLAB LEVEL SILL ELEVATION OF ACCESS DOOR SILL ELEVATION OF CLEAN OUT : :
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DOOR 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 GRADE SLAB CHIMNEY ELEVATION INSIDE : EL 0.00 EL(-)0.200 EL(-)0.500 As per soil report 1000 mm ONE(1) : : : : : Later 8mm
GRADE SLAB ELEVATION OUTSIDE : CHIMNEY GRADED LEVEL OF GROUND MINIMUM FOUNDING LEVEL OF RAFT MINIMUM EARTH FILLING ON TOP OF FOUNDATION RAFT (REF. 2.ABOVE) NUMBER OF FLUE GAS DUCT OPENING CENTRE LINE ELEVATION OF FLUE GAS DUCT OPENING INSIDE DIMENSION OF FLUE GAS DUCT (LXB) THICKNESS OF FLUE GAS DUCT THICKNESS OF MATING FLANGE DISTANCE FROM CL. OF CHIMNEY TO TERMINAL FLANGE OF FLUE DUCT SUPPLIED BY OTHERS FOUNDATION DATA ALLOWABLE SAFE BEARING CAPACITY OF SOIL AT FOUNDING LEVEL SPECIFIED IN 2.11 ABOVE PILE TYPE, CAPACITY, DIAMETER AND LENGTH FLUE GAS DATA MAXIMUM QUANTITY OF FLUE GAS THROUGH FLUE DUCT MAXIMUM FLUE GAS TEMPERATURE AT ENTRY TO CHIMNEY MINIMUM FLUE GAS TEMPERATURE AT ENTRY TO CHIMNEY DURING OPERATION SULPHUR CONTENT IN FUEL AVAILABILITY OF FLUE GAS DESULPHURISATION PLANT : : :
3.0 3.1
: : As per soil report
3.1.2 4.0 4.1 4.2 4.3
: : : : : Later Later Later
4.4 4.5
: :
Later Later
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4.6 5.0 5.1 5.1.1
AVAILABILITY OF PREHEATING AFTER DESULPHURISATION DESIGN PARAMETERS TEMPERATURE OUTSIDE AMBIENT TEMPERATURE MAXIMUM MINIMUM
: : :
Later
: : : : : : : : : : : : : : : m= 280/(3. cbc) IV 0.24 As per IS:1893, Part 4 1.07 47m/sec
5.1.2 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.3 5.3.1 5.3.2 5.3.3 6.0 6.1
THERMAL GRADIENT IN SHELL BELOW HOPPER RING BEAM WIND FORCE (IS 875) BASIC WIND SPEED TERRAIN CATEGORY RISK CLASS OF STRUCTURE(k1) TOPOGRAPHY FACTOR (K3) Cd = DRAG CO-EFFICIENT SEISMIC FORCES SEISMIC ZONE ZONE FACTOR IMPORTANCE FACTOR DESIGN DATA MODULAR RATIO FOR STRESS COMPUTATION WHERE cbc IS THE ALLOWABLE COMPRESSIVE STRESS IN CONCRETE IN BENDING
6.2
(a) (b)
MAXIMUM GRADE OF CONCRETE IN CHIMNEY SHELL MINIMUM GRADE OF CONCRETE IN FOUNDATION
: : : :
M30 M 25 NIL 1.2 T/M3 for structural design, 0.8 T/M3 for volume calculation
ISSUE R0
6.3 6.4
INCREASE IN CONCRETE STRESS PERMISSIBLE DUE TO AGEING DENSITY OF ASH IN HOPPER
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6.5
MAXIMUM CO-EFFICIENT OF THERMAL CONDUCTIVITY OF GLASS / MINERAL WOOL INSULATION AT 150 DEG. C MEAN TEMPERATURE FOR COMPUTATION OF TEMPERATURE STRESS THE MODULUS OF ELASTICITY OF CONCRETE
0.06 KCAL/HR/DEG. C
6.6
Es/m - WHERE m IS THE MODULAR RATIO AS PER CLAUSE 6.1 ABOVE AND Es IS TAKEN AS 210000 N/mm2 11 x 10-6 / DEG. C
6.7
CO-EFFICIENT OF LINEAR THERMAL EXPANSION OF CONCRETE AND REINFORCEMENT DESIGN OF REINFORCEMENT IN SHELL AT LOCATION OF CORBEL AND PLATFORM
6.8
AS PER REINFORCED CONCRETE CHIMNEYS AND TOWERS BY PINFOLD GM H/500 WHERE H IS THE HEIGHT OF CHIMNEY ABOVE THE TOP OF FOUNDATION
6.9
PERMISSIBLE DEFLECTION
7.0 7.1 7.2 7.3
ACCESSORIES STRAKES CAGE LADDER PROVISION FOR SEPARATE HOISTS FOR MATERIALS AND PASSENGER DURING CONSTRUCTION PLATFORM EXTERNAL ELEVATIONS PLATFORM INTERNAL ELEVATIONS GASKET AND BOLTS FOR FLUE GAS DUCT SUPPLY OF MATING FLANGE ERECTION OF MATING FLANGE INSTRUMENTATION 8 OPACITY/DUST Type Of Instrument : : : YES YES YES
7.4 7.5 7.6 7.7 7.8 8.0 8.1. 8.1.1.
: : : : : :
NA
YES YES YES
IN-SITU Cross duct
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8.1.2. 8.1.3.
Operating Principle Measuring Range
: :
Infra Red Transmission & Absorption Fully selectable ranges0 100 % opacity 0 1.8 extinction 0 999 mg/m3 0 999 mg/Nm3 0 5 Ringlemann Smart control unit accepts analog, serial, keypad input for temperature, pressure, moisture & oxygen/CO2 correction. 5 seconds +/_0.2% opacity of measurement +/_0.1% opacity +/_0.1% opacity Selectable from 10 second to 1 Hr. Suitable for 0.5 15 m duct size Periodic auto zero & span verification check. Up to 850 deg. C Transceiver unit suitable up to 90 deg.c Smart control unit suitable up to 60 deg. C In-situ Infra Red transmission absorption Fully selectable ranges CO, NOX: 0 3000 vpm SO2 : 0 25000 vpm Smart control unit accepts analog, serial, keypad input for temperature, pressure, moisture & oxygen/CO2 correction. 30 seconds +/_10 vpm or 2% of measurement
ISSUE R0
8.1.4.
Normalisation
8.1.5. 8.1.6. 8.1.7. 8.1.8. 8.1.9. 8.1.10. 8.1.11. 8.1.12. 8.1.13.
Response time (T90) Accuracy Linearity Repeatability Averaging Path length Calibration Flue Gas temperature Ambient temperature
: : : : : : : : :
8.2. 8.2.1. 8.2.2. 8.2.3.
SOX,NOX, CO MONITOR Type Of Instrument Operating Principle Measuring Range : : :
8.2.4.
Normalisation
8.2.5. 8.2.6.
Response time Accuracy
: :
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8.2.7.
Linearity
+/_ 2 vpm for CO, NO,NO2, SO2 +/_ 2 vpm for CO, NO,NO2, SO2 Selectable from 10 second to 1 Hr. Suitable for more than 2m duct size Periodic auto zero verification check. Automatic span verification check with standard gas . Up to 350 deg. C Transceiver unit suitable up to 90 deg.c Smart control unit suitable upto 60 deg. C In-situ Infra Red rays absorption Fully selectable from 0 50 m/s, m3/sec. Smart control unit accepts analog, serial, keypad input for temperature, pressure, moisture & oxygen/CO2 correction. 5 seconds +/_2% of measurement +/_1% of measurement +/_1% of measurement Selectable from 10 second to 1 Hr. Suitable for 0.5 15m duct size Manual zero & span verification check. Up to 850 deg. C
8.2.8.
Repeatability
8.2.9. 8.2.10. 8.2.11.
Averaging Path length Calibration
: : :
8.2.12. 8.2.13.
Flue Gas temperature Ambient temperature
: :
8.3. 8.3.1. 8.3.2. 8.3.3. 8.3.4.
GAS VELOCITY/FLOW Type Of Instrument Operating Principle Measuring Range Normalisation : : : :
8.3.5. 8.3.6. 8.3.7. 8.3.8. 8.3.9. 8.3.10. 8.3.11. 8.3.12.
Response time Accuracy Linearity Repeatability Averaging Path length Calibration Flue Gas temperature
: : : : : : : :
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8.3.13.
Ambient temperature
Detector units suitable up to 90 deg.c control unit suitable up to 60 deg. C In-situ
8.4. 8.4.1. 8.4.2. 8.4.3. 8.4.4. 8.4.5. 8.4.6. 8.4.7.
Online Oxygen Analyzer Type Of Instrument : : : : : : :
Range Accuracy Resolution Flue gas temperature Filters Reference air purging
0 - 25% +/_0.2% of measured value. 0.01% Oxygen above dew point to 760 deg.c standard depending on fuel type
YES
9.0 9.1
LIFT PERMANENT RACK AND PINION TYPE : LIFT COMPLETE FOR PERSONNEL INCLUDING CONDUIT RISERS AND NECESSARY CABLES REQUIRED LANDING LEVELS : ESSENTIAL FEATURES : : (a) CAGE WITH FRAME, GUIDE ROLLERS AND MECHANICAL SAFETY HOOKS. CAGE OF WELDED STEEL STRUCTURE WITH WIRE MESH COVERED WALLS, WITH ONE DOOR ELECTRICALLY AND MECHANICALLY INTERLOCKED. ELECTRICALLY AND MECHANICALLY INTERLOCKED TRAPPED DOOR IN CAGE ROOF, SAFETY RAILING ON TOP OF CAGE AND LADDER INSIDE CAGE.
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YES
9.2 9.3
(b)
(c)
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(d)
SHEET 254 of 267
SEMI-AUTOMATIC CONTROL SYSTEM FOR OPERATION OF LIFT FROM INSIDE THE CAGE AS WELL AS ON LANDING WITH AUTOMATIC STOP EQUIPMENT STOP NEXT LANDING. OVERSPEED GOVERNOR FOR CONTROLLING EXCESSIVE DESCENDING SPEED. AN EXTERNAL BRAKE RELEASE MECHANISM LOCATED INSIDE THE CAGE FOR DESCENDING CAGE IN CASE OF POWER FAILURE PROGRESSIVE TYPE POSITIVE ACTION SAFETY DEVICE DRIVEN BY A SEPARATE PINION ENGAGED IN THE ROCK (ALIMAK PATENTED OR EQUIVALENT) EMERGENCY ALARM SYSTEM
(e)
(f)
(g)
(h)
10.0 10.1 10.2 10.3
ELECTRICAL GROUNDING TERMINALS LIGHTING CONDUITS EARTHING ELECTRODES / LEADS : : : YES YES YES
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10.4
LIGHTING a) AVIATION WARNING BEACONS b) OBSTRUCTION LIGHTS / FLOOD LIGHTS c) SWITCH FUSE UNITS d) RECEPTACLES : : : : : : YES YES YES YES YES YES
10.5 10.6
CABLINMG LIGHTING PROTECTION
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1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA TECHNICAL SPECIFICATIONS PART I
SHEET 256 of 267
SECTION VI - TECHNICAL SPECIFICATIONS PART I - CODES, STANDARDS & REFERENCES 1.0 IS CODES AND REFERENCES
1.1
All the Indian Standards referred to shall be the latest revision (including all amendments issued thereto) on the date of opening of the price bid. Reference to only some of the codes in this document and various clauses of design criteria shall not limit or restrict the scope or applicability of other relevant codes. It shall be ensured that all other codes relevant to a specific job, in addition to those already mentioned, are followed wherever applicable. Where British / American / DIN or other codes and standards are referred to in this document, equivalent Indian Standards may be substituted if available. In case of any deviation / conflict between provisions of IS codes, Specification and the design criteria, the provisions that are more stringent shall be followed unless specifically directed otherwise. The Codes and Standards listed below are applicable for the design and construction of structures and buildings in general. Codes and Standards applicable for specific design and construction are listed elsewhere in reference sections. Not used. Field and laboratory testing procedures for materials follow Indian Standard Specifications unless stated otherwise. Not used. All materials, design, workmanship test and acceptance criteria etc., must conform to the latest edition of the Indian Codes and Standards or other Internationally accepted standards which ensure a quality equal to or higher than the Indian Standards unless otherwise specified in the EPC specification: 1. Indian Standards Different Indian Standard Codes (IS) Special Publications (SP) Indian Road Congress Standards (IRC National Building Codes (NBC) If any, standard/clauses of the standard contains a provision which is inconISSUE R0
1.2
1.3
1.4
1.5
1.6 1.7
1.8 1.9
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sistent with a provision in Indian Standard, the interpretation of the Owner shall prevail. All work shall be carried out on the basis of latest edition of applicable codes & standards mentioned.
2.0
LOADS IS: 875 Code of Practice for design loads (other than earthquake) for Buildings and structure (All parts) IS: 1911 IS: 1893 Schedule of unit weights of building materials Criteria for earthquake resistant design of structure
3.0
FOUNDATIONS IS: 1080 Code of Practice for design and construction of shallow foundations on soils ( other than raft, ring and shell ) IS: 1904 Code of Practice for design and construction of foundations in soils general requirement IS: 2911 Code of Practice for design and construction of pile foundations: ( All parts ) IS: 2950 IS: 2974 Code of Practice for design and construction of raft foundations Code of Practice for design and construction of machine foundations ( all parts ) IS: 4091 Code of Practice for design and construction of foundations for transmission line towers and poles IS: 8009 Code of Practice for calculation of settlement of foundations: ( All parts ) IS: 9556 Code of Practice for design and construction of diaphragm walls IS: 11089 IS: 13301 Code of Practice for design and construction of ring foundation Guidelines for vibration isolation for machine foundations
4.0
RCC IS: 456 IS: 458 Plain and Reinforced Concrete-Code of Practice Specification for pre cast concrete pipes
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IS: 3370
Code of Practice for concrete structures for the storage of liquids: ( All parts )
IS: 3414
Code of Practice for design and installation of joints in buildings
IS: 3935 IS: 4326
Code of Practice for composite construction Code of Practice for earthquake resistant design and construction of buildings
IS: 4995
Criteria for design of reinforced concrete bins for storage of granular ( all parts ) and powdery materials
IS: 4998 IS: 5525 IS: 1786
Criteria for design of reinforced concrete chimneys: ( All parts) Recommendation for detailing of reinforced concrete works Specification for high strength deformed steel bars and wires for concrete reinforcement
IS: 10262 IS: 11384
Recommended guidelines for concrete mix design Code of Practice for composite construction in structural steel and concrete
IS: 11504
Criteria for structural design of Reinforced concrete Natural Draft Cooling Tower
IS: 11682 IS: 13920
Criteria for design of RCC staging for overhead water tanks Code of Practice for ductile detailing of reinforced concrete structures subjected to seismic forces.
5.0
STRUCTURAL STEEL IS: 800 IS: 802 General construction in steel- Code of Practice Code of Practice for use of structural steel in overhead transmission line towers: (All parts) IS: 806 Code of Practice for use of steel tubes in general building construction IS: 808 Dimensions for hot rolled steel beam, column channel and angle section IS: 813 IS: 816 Scheme of symbols for welding Code of Practice for use of metal arc welding for general construction in mild steel
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IS: 1024
Code of Practice for use of welding in bridges and structures subjected to dynamic loading
IS: 1161 IS: 2062 IS: 4000 IS: 7215 IS: 8640
Steel tubes for structural purposes Hot rolled low, medium and high tensile Structural steel High Strength bolts in steel structures Code of Practice Tolerances for fabrication of steel structures Recommendations for dimensional parameters for industrial building
IS: 9178
Criteria for design of steel bins for storage of bulk material ( all parts )
IS: 9595
Recommendation for Metal arc welding of carbon and carbon manganese steel
IS: 12843 6.0
Tolerances for erection of steel structures
MISCELLANEOUS IS: 1038 IS: 1172 Specification for steel doors, windows and ventilators Code of basic requirements for water supply, drainage and sanitation IS: 1346 IS: 1742 IS: 1905 IS: 2210 Code of Practice for water proofing of roofs with bitumen felts Code of Practice for building drainage Code of Practice for structural use of unreinforced masonry Criteria for design of reinforced concrete shell structures and folded plates IS: 2470 ( part 1 ) ( part 2 ) IS : 2720 (part 7) Code of Practice for installation of septic tank: Design criteria and construction Secondary treatment and disposal of septic tank effluent Method of Test for Soils Determination of Dry density-water content relationship with light compaction IS: 3067 Code of Practice for general design details and preparatory works for damp proofing and water proofing of buildings IS: 10440 Code of Practice for construction of reinforced brick and reinforced brick concrete floors and roofs
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SP: 6 SP: 7 SP: 16 SP: 20 SP: 22
Handbook for structural engineers ( all parts ) National Building Code of India Design Aids for reinforced concrete to IS:456-1978 Handbook on masonry design and construction Explanatory handbook on codes for earthquake engineering ( IS:1982-1975 and IS:4326-1976 )
SP: 24
Explanatory handbook on Indian Standard code of Practice for plain and reinforced concrete
SP: 25 SP: 32 SP: 34 IRC: 37 IRC: 73
Handbook on causes and prevention of cracks in buildings Handbook on functional requirements of industrial buildings Handbook of concrete reinforcement and detailing (SCIP) Guidelines for design of flexible pavements Geometric design of roads Bridge rules of Government of India, Ministry of Railways ( Railway Board )
IRC: 109 BS: 4485
Guidelines for design of wet mix macadam (WMM) Structural design of Cooling Towers (part 4)
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SHEET 261 of 267
SECTION VI - TECHNICAL SPECIFICATIONS PART J TOWNSHIP
1.0
GENERAL OWNER has constructed a township to accommodate the employees for the existing 2X300MW DCRTPP, Yamunanagar. The OWNER intends to construct additional dwelling units along with associated infrastructures/facilities/utilities/systems to accommodate the employees of 1X660MW supercritical unit, DCRTPP, within the existing township. The scope of work, envisaged under this section intends to cover such requirements. Any other work necessary to accomplish all the functional and service requirement to the satisfaction of the OWNER shall be deemed to be considered by the bidder without any cost implication to the OWNER. The contractor shall take all necessary measures and precautions to the satisfaction of the OWNER, for safe working and to prevent damage to the existing buildings, installations, utilities etc. In case of damage, the same has to be rectified/reconstructed as per the direction of the OWNER without any extra cost. The contractor shall try to the best not to intervene/obstruct/disturb the existing utilities, installations, systems etc during his course of work. However, in case such becomes inevitable, the same shall be intimated to OWNER for prior approval. The contractor remains liable to restore/refurbish/remake all such works to the satisfaction of the ENGINEER In-charge without any extra cost. Any dismantling, shoring, strutting, dewatering, temporary works shall be deemed to have been considered by the bidder. SCOPE The works covered in this section consists of collection of all site related data, design, preparation of all construction drawings, supply of all labour & materials, construction, painting and testing where necessary, all architectural and associated works of all structures required for housing the OWNER`s employees. The Scope will cover but not limited to the following investigations/studies/buildings/structures / systems / facilities/utilities. a. Residential buildings comprising of types - II, III, IV, V, VI, VII, and VIII b. Roads Service road and approach to buildings. c. All internal and external electrification works to the buildings, illumination and road lighting. d. All internal Sewerage and Drainage system and internal water supply
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system.
SHEET 262 of 267
e. External water supply system and connection to the nearby water distribution system as directed by the ENGINEER In-charge. f. External sewerage and drainage system and connection to the nearby sewage disposal and drainage system as directed by the ENGINEER In-charge.
g. Surveying works for layout and construction of all the building and facilities/utilities. h. Local levelling, grading, dressing i. It is not the intent to specify completely herein all details of design and construction of works involved under this specification. However, the works shall conform in all respect to high standards of engineering, design and workmanship. Haryana Govt. Gazzete notification dated 29.07.05 regarding energy efficient design shall be followed. The construction water supply for Township work & electricity shall be arranged by the bidder at his own cost.
j.
k. Parking area shall be provided with 60mm thick factory made cement concrete interlocking paver blocks of minimum M20 grade with strong vibratory compaction and of approved size and design shape laid in required colour and pattern over 50mm thick compacted bed of fine sand over compacted eath to 90% of Proctor Density with adequate slope for drainage, filling the joints with fine sand etc all complete as per the direction of ENGINEER In-charge. 3.0 All civil and architectural specifications, design methodology and considerations shall be same as those of the existing township. However, an indicative details of work and specification are described hereunder for bidder`s guidance. For detail information, bidder may request the OWNER for specifications/drawings/Geo-technical investigation report/documents pertaining to the existing township. It is clarified that the area of staircase shall be additional to the above area up to Cat-VI. Covered parking for scooters shall be provided up to Cat-IV and covered car parking shall be provided for Cat-V and VI. For Cat-VII and Cat-VIII, garages shall be provided. Adequate sleeping terrace shall be provided for upper floors. Balconies shall be provided in such a way that each house is well lighted and ventilated and cooler/ ACs could be fixed in almost all windows through balconies/projections. R.C.C stairs shall be provided up to roof level. Single storey houses shall have soil, waste and rain water pipes embedISSUE R0
3.1 3.2
3.3 3.4
3.5 3.6
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3.7 3.8 3.9 3.10
ded in walls. The electric wirings shall be done in embedded conduit using copper wires. All materials and construction shall have Owners approval. Grills shall be provided in all windows and ventilators. Officers and Staff Quarters The details of quarters are as under: SL. No. Name of Category No. of Storey Covered Area of One dwelling unit 41 Sqm. 61.3 Sqm. 71.5 Sqm. 122.6 Sqm. 165 Sqm. 236 Sqm. 260 Sqm. Nos. Of block Nos. of dwelling unit in each block 24 24 4 1 Total No of DU
1 2 3 4 5 6 7
Cat II Cat III Cat IV Cat V Cat VI Cat VII Cat VIII
G+3 G+3 G+3 G+3 Duplex -do-do-
2 1 3 1 -
48 24 12 1 -
3.10.1
General Specifications of Cat-V, VI, VII, VIII Quarters: a) Flooring Flooring and skirting in all rooms except drawing / dining/lobby to be in terrazzo (in white and grey cement 70: 30) (marble). Flooring and skirting in drawing/ dining and lobby to be in vitrified tiles. Flooring in kitchen and toilets shall be in marble 20mm thick and kitchen working top shall of granite 20 mm thick. Kitchen and toilet dados shall be-in glazed tiles, 6mm thick minimum. For staircase kota stone with marble combination shall be provided. b) Joinery work 1.0 2.0 3.0 4.0 5.0 6.0 All chowkhats of doors, windows and cupboards shall in commercial hard wood hollock. All the wood work in shutters of doors and windows shall be in. commercial hard wood hollock. All doors shutters shall be panelled door in commercial hard wood hollock with commercial ply. Cupboard shutters shall be in common hard wood hollock with ply on both sides. All wood work shall have enamel paint Cupboard shelves shall be in RCC in all bed rooms and in wooden in
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dining room racks.
SHEET 264 of 267
c)
Good quality of approved make aluminium (powder coated) fittings shall be used for joinery work. All outer windows shall have grills and fly mesh shutter. All outer doors shall also have fly mesh shutters. All internal walls/ ceiling shall be plastered and walls to be painted with oil bound distemper, ceiling shall be white washed. External facade of the houses shall be designed properly and aesthetically with selected portion having cladding in brick tiles uniformly throughout township quarters. All these houses shall be preferably semi detached type of houses i.e. block of two houses each. Ground floor unit shall have boundary wall on three sides and lawn in front and court yard in the back side.
d)
e)
f)
g)
3.10.2
General Specifications of Cat II, III and IV quarters
a) Flooring
Flooring and skirting in all rooms veranda /bath and kit shall be in terrazzo. Flooring in staircase shall be kotah stone. Kitchen working top shall be in marble. In kitchen and toilets white glazed tiles shall be used on walls.
b) Joinery work
1. 2. 3. 4. 5. 6. c) All chowkhats of doors and windows shall be in wood. All the window shutters shall be in commercial hard wood hollock only. All doors shall be panelled door of hollock wood with 12 mm commply panel painted. All cupboard shutters shall be in commercial hard wood hollock with 4 mm ply on one side only. Chowkhats of cupboards shall be in common hard wood hollock. Cupboard shelves shall in RCC. Aluminium/Anodised iron fittings shall be used of approved standard make ISI mark or as per ISI specification for wood work. All outer windows shall have grills and fly mesh doors and all outer doors shall have fly mesh shutters.
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e)
All internal walls/ceiling shall be plastered and walls to be painted with oil bound distemper, ceiling shall be white washed. External facade of the houses shall be designed properly and aesthetically with selected portions having cladding in tiles uniformly throughout township quarters, and painted with water proof cement paint. These shall be in the shape of row housing. G Floors units shall have boundary wall and lawns in front and court yard in near side.
f)
g)
3.10.3
Service roads Service roads shall be having bituminous carpet width 5.00m & 1.50m wide shoulder on either side. Road work shall be carried out as per MOST specification.
3.10.4
Drainage System All drains & rain water drain pipe shall be as per existing township. All drain pipe / drain system shall be properly design for self cleansing velocity and shall be to nearby drainage system. Drain shall be provided on either side of road.
3.10.5
Sewerage System All internal sewerage line & external sewerage line shall be as per existing township & shall be designed for self cleansing velocity. Proper venting pipe & manholes shall be provided at suitable location. All sewerage water / sludge shall be collected for proper treatment at one point. External sewerage system shall be connected to the nearby sewage disposal system as directed by the ENGINEER In-charge.
3.10.6
Water Supply System All internal & external water supply system line shall be as per existing township. External water supply system shall be connected to the nearby water distribution system as directed by the ENGINEER In-charge.
4.0
Demobilisation On completion of work, the CONTRACTOR shall promptly demobilise from the site and leave the place in a manner as directed by the OWNER/ENGINEER-In-Charge, including cleaning of the area. CONTRACTOR shall start demobilisation only after the successful completion of the contract.
5.0
Exclusion
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a. b. c. d. e. f. g. h. i.
Geo-technical investigation Topography survey Electrical substation Overhead reservoir Landscaping and Garden, green belt development, parks Elevator Sewage treatment plant Township main boundary wall Rain water harvesting system
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HARYANA POWER GENERATION CORPORATION LIMITED

1 X 660 MW SUPERCRITICAL DCRTPP YAMUNANAGAR, HARYANA

CIVIL REQUIREMENTS VOLUME VI

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

ISSUE R0 TCE FORM NO. 329 R5

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

ISSUE R0 TCE FORM NO. 329 R5

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

STEAM GENERATOR AND AUXILIARIES C1 TCE-6417A-H-500-001 R0 STEAM GENERATOR & AUXILIARIES 73

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

CONDENSATE POLISHING UNIT C5 TCE.6417A-H-500-001 R0 CONDENSATE POLISHING UNIT 15

CONDENSATE POLISHING UNIT DATASHEET A A1 TCE.6417A-H-500-001 R0 DATA SHEET A1 5

CONDENSATE POLISHING UNIT DATAHSEET - B B1 TCE.6417A-H-500-001 R0 DATA SHEET B1 6

ISSUE R0 TCE FORM NO. 329 R5

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

EFFLUENT TREATMENT PLANT - A D5 TCE-6417A-H-500-001 R0 EFFLUENT TREATMENT PLANT 5

EFFLUENT TREATMENT PLANT - B D5 TCE-6417A-H-500-001 R0 EFFLUENT TREATMENT PLANT 9

FIRE PROTECTION SYSTEM D6 TCE-6417A-H-500-001 R0 WRITE UP ON FIRE PROTECTION SYSTEM 18

FIRE PROTECTION SYSTEM DATASHEET A D6 TCE-6417A-H-500-001 R0 FIRE PROTECTION SYSTEM 5

PIPING DATA SHEET-A ISSUE R0 TCE FORM NO. 329 R5

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

ASH HANDLING SYSTEM D9 TCE.6417A-H-500-001 R0 ASH HANDLING SYSTEM 25

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

COMPRESSED AIR SYSTEM D11 TCE.6417A-H-500-001 R0 COMPRESSED AIR SYSTEM 12

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

MILL REJECT SYSTEM D16 TCE.6417A-H-500-001 R0 MILL REJECT SYSTEM 12

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS

ELEVATORS DATASHEET A A1 A2 TCE.6417A-H-500-001 TCE.6417A-H-500-001 R0 R0 DATASHEET A1 ELEVATORS DATASHEET A2 ELEVATORS 3 1

ELEVATORS DATASHEET B B TCE.6417A-H-500-001 R0 DATASHEET B ELEVATORS 3

ELEVATORS DATASHEET C C TCE.6417A-H-500-001 R0 DATASHEET C - ELEVATORS 1

ISSUE R0 TCE FORM NO. 329 R5

TATA CONSULTING ENGINEERS LIMITED

1 X 660 MW SUPERCRITICAL UNIT AT DCRTPP YAMUNANAGAR, HARYANA CONTENTS