Volume - II

JHABUA POWER LIMITED 1 X 600+1 x 660MW JPL SEONI Project Specification for River Water Intake System
VOLUME II
TECHNICAL SPECIFICATION
Doc.No.3109142MESPC108-001-Rev 0 Volume II Technical Specification
Page 1 of 1 Separator Sheet
JHABUA POWER LIMITED 1X600MW + 1X660MW JPL SEONI Project Specification for River Water Intake System
TABLE OF CONTENTS
Section No.
Description
No. of pages
1 2 3 4 5 6 7 8 9 10
GENERAL TECHICAL SPECIFICATION................................................. 17 DETAILED TECHNICAL SPECIFICATION- CIVIL...250 DETAILED TECHNICAL SPECIFICATION- MECHANICAL ..79 DETAILED TECHNICAL SPECIFICATION- ELECTRICAL....76 DETAILED TECHNICAL SPECIFICATION- C&I.. 28 DETAILED TECHNICAL SPECIFICATION- PAINTING.. 26 LIST OF BID DRAWINGS TECHNICAL DATA SHEETS & SCHEDULES..... 10 66
QUALITY ASSURANCE PROGRAMME ... 27 LIST OF MANDATORY SPARES ............................................... 5
Doc.No.3109142MESPC108-001 Rev 0 Volume IITechnical Specification Table of Contents
Page 1 of 1
JHABUA POWER LIMITED 1X600MW + 1 x 660MW JPL SEONI Project Specification for River Water Intake System
VOLUME II SECTION - 1 GENERAL TECHNICAL SPECIFICATION
Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification
Section 1
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General Technical Specification
TABLE OF CONTENTS
1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0 9.0.0 10.0.0 11.0.0
GENERAL ............................................................................................................................ 3 SCOPE OF WORKS AND SERVICES ................................................................................. 4 TERMINAL POINTS ........................................................................................................... 11 OWNER SUPPLIED INPUTS ............................................................................................. 11 PERFORMANCE TEST ..................................................................................................... 12 SPARES ............................................................................................................................. 12 APPROVED SUB VENDORS/MAKES ............................................................................... 13 PAINTING AND CORROSION PROTECTION ................................................................... 13 QUALITY ASSURANCE, TESTING AND INSPECTION .................................................... 14 DRAWINGS/ DOCUMENTS TO BE FURNISHED BY THE BIDDER ALONG WITH BID ... 16 DRAWINGS / DOCUMENTS TO BE FURNISHED AFTER AWARD OF CONTRACT ....... 17
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VOLUME II SECTION 1 GENERAL TECHNICAL SPECIFICATION 1.0.0 GENERAL This specification covers the design, detailing, manufacture and assembly, inspection and testing at the Vendor's and/ or his sub-vendor's works, suitable painting and packing requirements for transportation, erection, construction, commissioning and testing at site of all materials and equipment inclusive of complete Civil construction, Electrical, Mechanical& Instrumentation works for the River water intake system complete with all accessories as specified hereinafter. The scope of work shall include design, engineering, manufacture, assembly / reassembly. Constructional features, test at manufacturers works, forwarding (duly packed for transportation), transportation delivery to site, unloading, handling storage and in plant transportation at site, complete execution of necessary and allied Civil / Mechanical / Electrical / Control & Instrumentation works, complete services of erection, testing at site, successful commissioning, operation and training to Jhabua Power Limited (JPL) personnel and handing over the plant in flawless operating condition to Owner of the River water intake system at the proposed 1x600 MW + 1 x 660MW JPL Seoni Project, near Jabalpur, Madhya Pradesh. The equipment and services to be provided under this specification shall be as detailed here below. Items though not specifically mentioned here but needed to make the system complete shall also be furnished, unless specifically mentioned under exclusions. 1.1.0 Source of Water Source of plant raw water will be from river Narmada. The plant raw water requirement will be met by pumping the surface water from the proposed intake well cum pump house in the Bargi Dam reservoir area. Topographic mapping Topographical survey along the proposed pipeline route between the intake point and the plant site & Bathymetric survey in the reservoir area at the proposed intake location have been done. Details of the investigation done are enclosed with Tender Documents. The bidder shall confirm all the data provided before starting the work. Geotechnical investigation Geotechnical Investigation at the proposed intake location, along the approach bridge and along the pipeline route has been carried out by the Owner and the report is enclosed as Annexure in the civil works specification. However, the bidder shall confirm the report to establish the data required to finalise the type of foundations and their design parameters based on the settlement and other criteria specified in the tender documents. Any claim by contractor for price / time increase shall not be entertained by owner on account of any variance in data supplied by owner and that actually met at site. Documents Provided by Owner for submission of bids VOLUME I - COMMERCIAL Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Notice Inviting Tender (NIT) Instructions To Bidders (ITB) General Conditions of Contract (GCC) General Technical Conditions (GTC) Erection Conditions of Contract (ECC) Forms & Formats
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1.2.0
1.3.0
1.4.0
VOLUME II TECHNICAL Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Section 10 General Technical Specification Detailed Technical Specification Civil Works Detailed Technical Specification Mechanical Detailed Technical Specification Electrical Detailed Technical Specification Control & Instrumentation Detailed Technical Specification Painting List of Bid drawings Technical Data sheets & Schedules Quality Assurance Programme List of Mandatory spares
2.0.0 2.1.0
SCOPE OF WORKS AND SERVICES Scope of Works The project is being implemented in two phases with first phase consisting of 1 x 600 MW unit based on subcritical technology and second phase consisting of 1x660MW unit based on supercritical technology. The time lag between the units would be about 8 to 12 months. The scope work covered under Phase-1 and Phase-2 are described below. Scope of Works (PHASE-I) The equipment and works to be provided under this specification shall be as detailed below. Scope of works include obtaining necessary approvals, materials, execution as per codes, specification, best engineering practices and to the satisfaction of the Owner for all Civil/ Structural, Mechanical, Electrical and Control & Instrumentation works. The scope shall include detailed design of the system, complete manufacture including testing, providing engineering drawings, data, operation manual etc for the owners approval, packing and transportation from the manufacturers works to the site, receipt storage preservation and conservation of equipment at the site, erection testing and commissioning of all the equipment, reliability tests, performance acceptance tests on completion of commissioning all the equipment & furnishing spares. The River water intake system shall consist of the following major components : a) b) c) d) e) f) g) h) i) River water intake well cum pump house. Approach bridge Onshore switch gear & Transformer yard River water intake pumps Valves & specialties, all piping and fittings from the River water intake well to plant reservoir. Rubber expansion joint Stop log gate and coarse screen with accessories EOT crane and hoist All electrical and control necessary for the system
The source of the water will be water body connected to reservoir of Rani Avanti Bai sagar (Bargi dam) Dam located on the Narmada River. The intake well is proposed at near Bagdari
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village, Gadaghat at distance of around 12.00 km (approximate) including approach bridge of 2.50 km length from the Power plant boundary. Bidder shall visit and apprise himself fully with existing site conditions including soil conditions, rainfall data, and availability of all construction materials including backfill, graded material etc. and other aspects for construction of plant, building structures etc. This specification covers requirements of following items which are included in Bidders scope for the Offshore River Water Intake System package. Drawings and data provided by the owner in the bid documents is the concept level minimum requirement and for bidders information and guidance. The design/ Equipment layout offered by bidder shall take into account Hydraulic Institute Standards & other statutory clearances. Bidders shall furnish all dimensional details along with their offer. Wherever necessary, obtaining permission for trenching and pipe laying, cabling, Transmission line works etc., from the NHAI / SH / PWD / Forest department / Local bodies shall be the responsibility of the successful bidder. However, during this process if any compensation such as reinstatement charges is required to be deposited to the concerned authorities, the Owner will make the payment after getting the relevant documents / letter from the authorities. 2.1.1 Civil works comprising the following shall be provided The scope of work will cover in general, but not limited to the following items of work The scope includes providing detailed Design and issue construction drawings including bar bending schedule/ detailed drawings for all works and getting them approved by the Owner/ Engineer Setting out from the reference provided by Owner and fixing the limits of working in Rani Avanti Bai Sagar Dam (Bargi Dam) on River Narmada, at Gadaghat in Seoni District of Madhya Pradesh. The scope includes providing detailed Design for intake structure including well & pump house, pipe supports, approach bridge & pipe protections from external load and issue construction drawings including bar bending schedule/ detailed drawings for all works and getting them approved by the Owner/ Engineer. An intake well of 10 m diameter ( EPC bidder shall decide and indicate all the dimensions in the bid satisfying Hydraulic Institute Standards(HIS) and shall be with the bid proposal) and pump house of required size to accommodate 3 numbers of pumpsets and control room with toilet facilities. An approach bridge of 6.70 m clear width for about 2.50 km long shall be constructed from the intake well to bank within the reservoir. Near the intake well the width shall be of 12 m for maneuvering of vehicles. Approach Bridge shall comply with the requirements of Rani Avanti Bai sagar (Bargi dam) Dam Authorities. Typical layout of intake well & approach bridge is indicated in the drawing. Coffer dam, if necessary shall be provided to facilitate construction on dry of some of the bridge piers. A Switch gear & transformer yard shall be provided on shore as indicated by the Owner. Arranging right of way for laying pipe line shall be part of the scope of the contractor. Bidder shall also consider all other allied and supporting structures for the pipe lines and bridges over river / nallah drainage are to be provided.
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RCC thrust blocks, air valve chamber, scour valve chambers etc., as required for the pipe line shall be provided. Necessary improvement works are to be carried out on river bed (if necessary) All construction work shall commence only after the design & construction drawings are checked and approved by the Owner/ Engineer. Submission of Field quality plans for owners approval in respect of construction, erection & commissioning within 4 weeks from NOA. The scope of work will also include providing & fixing of inserts/pipe sleeves etc. in concrete work, providing & fixing of steel connections like brackets etc., to the structural steelwork, providing & fixing of any other type of steel inserts as may be needed for completion of the job Supply and fixing of base plates, foundation plates, anchor bolts, sleeves, inserts, bolts and nuts for all equipment supplied. Any temporary inserts and openings required for construction / erection and closing of opening after complete of construction. Provision of Toilet and septic tank in the pump house Transformer foundations in the fenced area Providing necessary Gate and fencing arrangements to the Approach bridge near the shore area and the On shore Transformer yard. The scope also includes providing necessary labour, materials, scaffoldings, construction equipment, tools and plants, appliances, necessary supervision by competent Supervisors and execution of all incidental items not specified or indicated but implied or required to complete the work under this scope in all respects and in strict accordance with the specifications and drawings including their revisions and amendments made from time to time. Providing necessary shuttering with supports & bracings; bending, binding, fixing and placing of the reinforcement, including supplying and fabricating metal & steelwork. The scope of work will also include removing the formwork after concrete is sufficiently cured and as per instructions of the Owner/ Engineer and making the concrete surface smooth and rendered to the satisfaction of the Owner/ Engineer and as per technical specification. Any honeycomb or other defects as pointed out, by the Owner/ Engineer to be rectified to the satisfaction of the Owner/ Engineer without any extra cost to the Owner/ Engineer. Owner/ Engineer decision on this will be final and binding on the part of the Contractor.
2.1.2
Mechanical scope of supply and services comprising the following shall be provided
2.1.2.1 The scope of supply will cover in general, but not limited to the following:
3 a) Two (1W+1S) numbers of vertical turbine river water pumps of duty 3000m / hr x 167m head along with electrical motor drives & all accessories.
b) Laying of MS pipe of 1200mm diameter and 14mm thickness (minimum) satisfying the water hammer requirements (surge analysis) as per the specification and conforming to IS 3589 & AWWA-M 11 for about 12.0 km (approximate) long from intake pump house to plant boundary and additional length of pipeline from plant boundary to the raw water
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reservoir inside the plant, as required and also consider the buckling load for design the pipe thickness. c) Two (2) nos. of (i) Rubber expansion joints at pump discharge with limiting tie-rods, necessary split retaining rings stretcher plates, nuts and bolts, (ii) Electric motor actuated Butterfly Valve (iii) Dual Flap check valve at the discharge of pump. d) One (1) number of portable sludge & Dewatering pump capacity of 40m3 / hr x 35m head along with drives & all accessories. e) Required Air valve, sluice valve and fittings (DI Material) f) Required Vent with isolation valve g) Thrust block, as required h) Non-reverse ratchet for pump i) Foundation bolts, foundation inserts, base plates, sole plates, bolts, nuts, washers, supports, covers etc. Required Discharge piping from each pump up to the header along with all associated valves and fittings.
j)
k) Necessary supports l) Common header connecting all pumps and a recirculation line from the common header back to the river including all associated valves
m) Necessary lubrication water system & cooling arrangement considering the quality of the river water. n) One (1) number of Double girder EOT Crane with capacity of 1.2 times of handling the heaviest component of equipment in River water pump house. o) One (1) number of under slung type semi gantry crane with adequate capacity for handling gates and screen. p) Bidder shall carry out the surge analysis to the pipeline from the reputed institute considering various river water pump and pipeline operating possibilities. Power pack valves if required on the basis of surge analysis have to be supplied and installed. Surge protection devices along with required accessories. The procedure of water hammer analysis shall be included by the EPC bidder as a part of the bid proposal q) Stop log gate, Coarse Screen r) Ventilation fans and accessories, Air conditioning system & fire extinguishers with accessories etc.
s) Supply and application of paints, tape, coatings, corrosion protection on all piping and other equipment. t) Any other equipment/ item not specified above, but required to make the system complete. Supply of all consumables required for erection, commissioning, trial operation and performance test is included in the basic scope and same shall be supplied by Bidder. List of such item shall be identified & furnished with bid & finally included in the bill of material document. Supply of oil, lubricants and grease, dosing chemical for initial fill and first change of oil shall be included in the scope of supply.
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Supply of mandatory spares. Supply of all erection and commissioning spares. List of O&M recommended spares for 3 years trouble free operation of the equipment One (1) set of new special tools and tackle required for operation, maintenance, inspection and repair shall be supplied in neatly packed-in steel boxes complete with operating instructions for the equipment as necessary.
2.1.2.2 The scope of services will cover in general, but not limited to the following: a) Design & Engineering of Pumps, valves, fittings, cranes, Hoists, Surge protection devices, ventilation, fire extinguishers, auxiliaries and all accessories etc including complete electrical & C&I system. b) Water Hammer Analysis shall be carried out to ensure satisfactory working of the Surge protection Devices. c) Transportation of equipment and material to site from manufacturer's works, receiving at project site, handling, storage at site and transport to erection site. d) Complete erection, testing and commissioning at site. The bidder shall provide all instruments as required for performance testing. e) Pre-commissioning, testing, startup, and run tests, load test, performance guarantee and acceptance test. f) Submission of Erection, Operation and Maintenance instruction manuals.
g) Preparation and submission of drawings & documents for approval of Owner/ Consultant both in soft and hard form. h) Submission of Quality plans for owners approval, carrying out inspection and testing of equipment (witnessed by Owner or his representative), submission of test certificate. i) Submission of monthly progress report and participation in project review/ Technical Coordination meetings. Submission of complete design with all details required, layout drawings, detailed calculations etc., for checking and approval of the Owner/ Engineer. Training of Owner's personnel in operation and maintenance of the equipment
j)
k) 2.1.3
Electrical Works comprising the following shall be provided
2.1.3.1 The scope of work will cover in general, but not limited to the following terms of work: a) b) c) d) e) f) g) h) 11kV Switchgear. 2 nos. Service Transformers LT Switchgear. 11kV Isolator 11 kV capacitor banks Soft starter for 11 kV motors (if required) Local push button stations. HT & LT Motors
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i) j) k) l) m) n) o) p) q) r) s) t) u) v) w) x) y)
Electrical Actuators. 220 V DC Battery, Charger & DCDB. 240 V AC UPS & UPS DB. 11 kV double circuit transmission line. 11 kV Power Cables Power and Control Cables. Illumination system complete with Lighting panels, Lighting fixtures, lighting poles, receptacles, conduits, wires, switch boxes etc. Cabling system complete with cable trays, supports, conduits, glands, lugs etc. Installation of all the interconnecting cables (HT, LT & Control cables) between the equipments supplied by the Bidder. Fire sealing system for cable penetrations. Earthing system including buried earthmat and above ground earthing. Lightning protection system. Rubber mats, First aid box, Danger plate, etc. Erection components, Tools, Tackles, hardwares, etc. Erection & Commissioning spares O&M spares. Any other electrical equipment and accessories required to complete the River water intake System.
2.1.4
Control & Instrumentation Works comprising the following shall be provided Complete independent control and instrumentation system for the safe, efficient and reliable operation of the River Water Supply System but not limited to following:
2.1.4.1 All control system equipment including the PLC-based control system, HMI equipment consisting of 1 nos. operator-cum-engineering PC-based workstation with 22" LCD/TFT display, keyboard, mouse and other accessories, 132 column dot matrix printer and all associated networking equipment including cables, control desk and interfaces with electrical systems. 2.1.4.2 Hardwired back-up control panel for the manual operation of the Raw Water Supply pumps and discharge valves, complete with indicating lamp push buttons (ILPBs), hardwired annunciator and local/remote selection switch. The back-up panel shall be so designed that the basic monitoring and operation of the pump house shall be possible without the operator work station. 2.1.4.3 All necessary field instrumentation including level switches, HART compatible process transmitters for pressure, flow etc., confirming to applicable standards on hazardous area classifications and rated for installation in dusty environments. 2.1.4.4 Complete supply and installation of junction boxes, cable trays, cable glands, lugs, cable ties, pneumatic and process hook up hardware, instrumentation, control and special cables, data cables, vibration sensors with transmitters and other erection hardware and accessories integral to the control system. 2.1.4.5 The scope shall also include cabling and installation of local cable trays with all necessary accessories between any two equipments in Bidders scope. This shall include instrument and control cabling between field instruments, bearing RTDs, vibration sensors, reverse rotation sensors to field junction boxes and cables from field junction boxes to PLC cabinets. 2.1.4.6 Redundant Uninterruptible Power Supply (UPS) with SCVS along with power supply distribution for powering all control system equipment including HMI, network components, Hardwired Annunciation back-up panel, VMS cabinets, and reverse rotation sensors with
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Lead Acid Plante batteries (1 set) for backup. Redundant 415V, 3 phase feeders shall be envisaged as the power source for the UPS. 2.1.4.7 VMS cabinets with vibration probes/sensors and key phasor for Raw water intake pumps and motors, special cables, analyser modules, power supplies and necessary software applications. Machined surfaces on motor/pump body for mounting vibration sensors shall also be provided by the Bidder. 2.1.4.8 Pump reverse rotation monitor with probes, display units, associated cables and other accessories. Cabling from the reverse rotation sensor assemblies to their respective display units and then to the PLC cabinets shall be in Bidders scope. 2.1.4.9 PLC based control system shall be interfaced bidirectionally with unified PLC system in central control room via GPRS based redundant wireless communication system or by redundant FO cable (laid alongside the RW water pipe, on either side) from the RW pump house to the Main Plant and shall be through HDPE conduit via soft link as applicable. 2.1.4.10 Bidder shall follow KKS Tagging philosophy for instruments as provided by owners during detailed engineering. All the equipment in the P&IDs shall be assigned individual unique KKS codes from the block of numbers allotted by the owner. 2.1.4.11 Testing and inspection of the offered control system and all its components in line with approved FAT and SAT procedures. 2.1.4.12 Supply of necessary maintenance and calibration equipment. 2.1.4.13 Supply of all recommended, mandatory and commissioning spares. 2.1.4.14 Training of Owners personnel on the engineering of the hardware and software components as well as maintenance of the control system. 2.1.4.15 Drawing No. 30-3109142-I-168, Control System Configuration for River Water Intake System outlines the suggested configuration of the control system. 2.1.4.16 The minimum instrumentation requirement for the River water intake system shall be as per the bid flow diagram. However, for completeness of the River water intake system and its associated equipment, Bidder shall also provide all the necessary instruments even if it is not specifically indicated in the P&ID. 2.1.4.17 The instrumentation, operation and control philosophy proposed is specific to the plant design. Any improvement over the proposed typical control & instrumentation scheme shall be accepted so long as it does not deviate from the basic intent and general philosophy enumerated herein and elsewhere in this specification. 2.2.0 2.2.1 Scope of Works (PHASE II) Civil works comprising the following shall be provided Fixing of base plates, foundation plates, anchor bolts, sleeves, inserts, bolts and nuts and all other allied civil works for the installation of pumps and accessories. Mechanical works
3 a) One number of vertical turbine river water pump of duty 3000m / hr x 167m head along with electrical motor drives & all accessories.
2.2.2
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b) One (1) no. of (i) Rubber expansion joint at pump discharge with limiting tie-rods, necessary split retaining rings stretcher plates, nuts and bolts, (ii) Electric motor actuated Butterfly Valve (iii) Dual Flap check valve at the discharge of pump. c) Non-reverse ratchet for pump d) Supply of Foundation bolts, foundation inserts, base plates, sole plates, bolts, nuts, washers, supports, covers etc. e) Required Discharge piping from pump up to the header along with all associated valves and fittings. f) Supply and application of paints, tape, coatings, corrosion protection on equipment.
g) Any other equipment/ item not specified above, but required to make the system complete. 2.2.3 Electrical Works a) All allied electrical works related to the above mechanical work 2.2.4 Control & Instrumentation Works a) All allied control and instrumentation works for the above work 3.0.0 3.1.0 TERMINAL POINTS Mechanical Pipe line upto the raw water reservoir located within the Main plant site. 3.2.0 Electrical The Terminal Point for the Electrical shall be 11kV Isolator at the Power Plant Site. 3.3.0 Civil Approach bridge construction upto the Onshore of the Narmadha River 3.4.0 3.4.1 Control & Instrumentation For GPRS based wireless communication (option 1): Link PC of the unified PLC supervisory system. For Datalink (option 2): Unified PLC Supervisory system in Main plant Central Equipment Room at 17.0m. 3.4.2 Exclusions All instrument erection outside the battery limit. 4.0.0 OWNER SUPPLIED INPUTS Towards setting up the co-ordinates for starting the work at the River Narmada, Bagdari Village, Gadhagat reference co-ordinates are provided.
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5.0.0 5.1.0
PERFORMANCE TEST Guarantee requirements In addition to compliance with the requirements of the Specification, the Bidder shall meet the specific guarantees of performance as required and as stated in the Schedules of Guaranteed Data. All tests shall be carried out in accordance with the relevant international standards unless otherwise specified or approved by the Owner. Performance test will be carried out, within the appropriate time period as specified to demonstrate the achievement of guaranteed parameters.
5.2.0 5.2.1
Guarantee Test Procedure The performance tests shall be conducted by the Bidder to the satisfaction of the Owner/Engineer. The guaranteed performance figures mentioned in the bid documents shall be provided by the Bidder during these Performance and Guarantee Tests. Should the results of these tests show any decrease from the guaranteed values the Bidder shall modify the system as required to enable it to meet the guarantees. In such case, Performance and Guarantee Tests shall be repeated within one month, from the date the system is ready for retest and all cost for modifications including labour, materials and the cost of additional testing to prove that the system meets the guarantees shall be borne by the Bidder. However During the Performance Guarantee(PG) Test in case the Total guaranteed Power consumption at input terminal of Motor(For Pumps) exceeds beyond specified limit in Schedule of guaranteed parameter, LD shall be livable @ Rs. 94652 (Rupees ninety four lakhs six hundred and fifty two only) per KW or Part thereof. The equipment shall be guaranteed to meet performance requirements required by this specification and rectification shall be carried out until satisfactory results are obtained. The Owner reserves the right to reject the equipment should the performance values fall short of those indicated in the schedule of Technical data sheets. In case of such option of rejection being exercised by the Owner, the Bidder shall replace the equipment with new equipment which shall meet the guaranteed values.
5.2.2
5.2.3
The Bidder shall furnish a detailed performance test procedure and a program well in advance for approval by the Owner. SPARES Recommended Spare Parts Bidder shall furnish the list of O&M /recommended spare parts for three years trouble free operation along with their unit prices on ex-works basis valid for 12 (twelve months from the last date of submission of Bid. All the spares supplied shall be strictly interchangeable with the parts for which they are intended to replace and are to be tested and packed for long storage under the climatic conditions prevailing at the project location.
6.0.0 6.1.0
6.2.0
Mandatory Spares The Bidder shall supply mandatory spares as listed in Annex 1.2 and the Lumpsum price quoted shall include the price of mandatory spares also.
6.3.0
Erection & Commissioning Spares
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The Bidder shall also supply erection & commissioning spares along with his equipment as per his experience, for replacement of damaged or unserviceable ones during the execution of the project at site, to avoid delay in the project schedule. 7.0.0 APPROVED SUB VENDORS/MAKES The makes of all the equipment/ instruments under this specification shall be subject to Owners approval in the event of order. Bidder can propose additional list of makes/ subvendors/ sub-contractors along with his bid for Owners acceptance prior to award. Owner reserves the right to accept/ reject any make or sub-vendor or add new makes/ sub-vendors for the project, after award of contract. Approval, rejection or addition of makes shall not have any cost implication to the Owner after award of contract. 8.0.0 8.1.0 PAINTING AND CORROSION PROTECTION The painting and corrosion protection for the equipment and structures in bidders scope shall be suitable for particular atmospheric condition of the proposed site. The inside and outside of the equipment shall be thoroughly cleaned of all foreign matter, excessive oxide, weld spatter and flux. All fabricating scars and rough edges shall be repaired by welding and/or grinding. All surfaces shall be cleaned to a degree sufficient to maintain cleanliness. Except for the rotor assembly and other machined parts, all surfaces shall be grit blasted to remove all scale and oxides, and then protected against corrosion until start-up. Material used for grit blasting shall not contain silica or iron oxide. Grit blasting shall not be performed until all repairs and shop inspections are completed. The painting scheme for the cranes, Hoists shall be as follows: Before packing and dispatch, all structure/parts/equipment/ components shall be thoroughly cleaned by shot blasting or chemical cleaning methods to remove all dirt, grease, scale and rust and painted with two coat of zinc chromate primer at shop of 20 microns DFT each and two coats of finished paint (epoxy paint) of 50 microns DFT each after erection and testing at site. All moving parts, viz., crane bridge, trolley, hooks shall be painted with Golden Yellow colour with black stripes. All other mechanical/electrical equipment/ components shall be painted with two coats of finished paints with zinc chromate primer and Air Craft Grey colour. The painting scheme for the pumps, motors, valves and fittings shall be as follows: Surface preparation Primer : : grit blasting as per SISO55900 standard. Two coats of epoxy resin zinc chromate high build of 20 microns DFT each. Two coats of polyamide cured high build epoxy, each of 50 microns DFT. Sea green for pump and light grey for motor.
8.2.0
8.3.0 8.4.0
8.5.0 8.5.1
8.5.2
8.6.0
Finish painting
Finish colour
Finish colour for valves and fittings shall be finalized after award of contract. 8.7.0 No paint or filler shall be applied until all repairs, tests and final shop inspection are completed. Paint shall be applied prior to shipment.
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8.8.0
Necessary finish paints including touch-up paints, if not applied at shop, should be supplied in sealed containers for site application & applied by the Bidder. The bidder shall submit the painting scheme and the finish colour for all the equipment to owner for approval. QUALITY ASSURANCE, TESTING AND INSPECTION Quality Assurance Programme To ensure that the equipment and services under the scope of this Contract whether manufactured or performed within the Bidder's works or at his Sub-Vendor's premises or at the Owner's site or at any other place of work are in accordance with the specifications, the Bidder shall adopt suitable quality assurance programme to control such activities at all points necessary. Such programmes shall be outlined by the Bidder and shall be finally accepted by the Owner after discussions before the award of Contract. A quality assurance programme of the Bidder shall generally cover the following: a) Bidders organization structure for the management and implementation of proposed quality assurance programme, b) Qualification data of his key personnel, c) The procedure for purchase of materials, parts, components and selection of SubVendor's services including Vendor analysis, source inspection, incoming raw material inspection, verification of materials purchased, etc. d) System for shop manufacturing including process controls and fabrication and assembly controls, e) Inspection and test procedure both for manufacture and field activities, f) Control of calibration and testing of measuring and testing equipment,
8.7.0
9.0.0 9.1.0 9.1.1
g) System for indication and appraisal of inspection status, h) System for quality audits, i) j) System for handling, storage & delivery, System for authorizing release of manufactured product to the Owner,
k) System for maintenance of records, and l) A quality plan detailing out the specific quality control procedure adopted for controlling the quality characteristics relevant to each item of equipment/component furnished.
9.2.0 9.2.1
Quality Assurance Documents The Bidder shall be required to submit the following Quality Assurance Documents as required. a) All non-destructive examination procedures, stress relief and weld/repair procedure actually used during fabrication. b) Welder and welding operation qualification certificates. c) Welder identification list, listing welders and welding operator's qualification procedure and welding identification symbols. d) Material mill test reports on components as specified by the specification.
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e) The inspection plan with verification, inspection plan check points, verification sketches, if used, and method used to verify that the inspection and testing points, in the inspection plan were, performed satisfactorily. f) Sketches and drawings used for indicating the methods of traceability of the radiographs to the location on the equipment. g) Non-destructive examination result reports. h) Stress relief time temperature charts. Factory test results for testing required as per applicable codes and standards referred in the specification.
i)
9.2.2
The Owner shall be given reasonable notice of all tests and shall have the right to witness all tests, and shall have access to the works of Bidder and Sub-Vendor at all times for the purpose of carrying out system audits, conducting quality surveillance witnessing of tests and inspections etc.
9.2.3 The Owner or his authorized representative may periodically check the work and the Constructor's method of operation to assure that quality control practices are being followed. At the time of Owner's visit all quality documentation pertaining to test, qualifications, inspections etc., shall upon request be made readily available. 9.2.4 9.3.0 9.3.1 All reports of tests and inspections as per Quality Control Practices and Quality Plans shall be furnished to the Owner. General Requirements for Testing and Inspection All equipment covered under these specifications shall be subject to inspection and tests by the Owner/his authorized representative or third party during manufacture erection and commission. The approval of the Owner or passing of such inspection of test will not, however, prejudice the right of Owner to reject the equipment if it does not comply with specifications when erected or does not give complete satisfaction in service. The cost of all such tests as well as third party inspectors shall be borne by the Bidder. The Bidder shall furnish the quality plan for shop activities indicating stage wise all tests and inspections, procedures and acceptance norms to be adopted for each piece of equipment under this specification right from raw materials stage, manufacturing, assembly, performance and final inspection. Testing/ inspection procedures as detailed herein & in various Sections of this Tender document is to give a basic quality control programme to be followed by the Bidder and are in no way comprehensive and in no way form a complete quality assurance programme. Any other inspection stages not mentioned in these clauses but required as per the Bidder's quality assurance programme or the Owner shall be deemed to be included. Any tests necessary from operation, safety and reliability point of view shall also be included. Such quality plan shall be subject to the approval of the Owner. All fabrication, manufactured items (including any proprietary item), driven equipment, gears, fans, switches, etc., shall be subjected to stagewise inspections and tests as per the relevant standards at the manufacturer's works before dispatch. It shall, however, be the Bidder's responsibility to supply all the materials as per specification and standard herein mentioned. All the items shall be subjected to inspection at shop as well as at site. The cost of all inspection at shop & site as well as by other regulatory institutions shall be borne by Bidder and accordingly included in his lump sum price in the Bid. 9.3.5 The Owner, his duly authorised representative shall have access at all reasonable times to inspect and examine the materials and workmanship of the works during its manufacture or erection and if part of the works is being manufactured or assembled on other premises or works, the Bidder shall obtain for the Engineer in-charge and for his duly authorised
9.3.2
9.3.3
9.3.4
representative permission to inspect as if the Works were manufactured or assembled on the Bidder's own premises of works. 9.4.0 9.4.1 Shop Tests Shop tests shall include all tests to be carried out at Bidder's works, at Works of his subVendor and at works where raw material used for manufacture of the equipment is manufactured. Shop tests shall include electrical, mechanical, performance and hydraulic tests in accordance with relevant standards called for under these specifications to ensure that the equipment being supplied fulfills the requirement of the specifications. For equipment not covered by any approved standards, the tests to be carried out shall be in accordance with Bidder's quality control programme to be agreed to between the Bidder and the Owner. All material shall be of tested quality, supported with duly correlated test certificates. If the Owner is furnished with certificate particulars of tests which have been carried out by the Bidders of material, the Owner may, at his discretion, dispense with separate test, which he would witness. Non-destructive Examination All non-destructive examinations shall be performed in accordance with written procedure to meet ASME Sec. 1 and Sec. V code requirements. The personnel shall be qualified with Practice SNT-TC-1A of the American Society of Non-destructive Testing or equivalent. Each non-destructive examination shall be recorded in a report which summaries methods and equipment used results evaluation, date and identification of personnel employed. Welding Procedure All welding procedures adopted for performing welding work shall be qualified in accordance with the requirements of IS 2825/ 1969 (or latest revision), Section IX of ASME code. These welding procedures shall clearly state the type of material, thickness, the joint details, the preheat temperature maintained, the post-weld heat treatment given, the welding current and voltage used during qualification of welding procedures. All records of the welding procedures, the welders qualifications, tests and welders performance details for the work performed under these specifications shall be maintained by the Bidder and be made available to the Owner on request DRAWINGS/ DOCUMENTS TO BE FURNISHED BY THE BIDDER ALONG WITH BID General Completely filled up technical datasheet & schedules, bill of quantity, schedule of price as specified in tender documents. Preliminary outline drawings indicating the principal dimensions of the equipment offered and locations Bar chart indicating design, procurement, manufacture, testing, delivery, installation, site testing and commissioning. List of recommended spare parts for equipment offered including bought out components suitable for three (3) years operation of the equipment. Quality Assurance Plan Inspection and Test Plan (ITP)
9.4.2
9.4.3
9.5.0 9.5.1
9.6.0 9.6.1
9.6.2
9.6.3
10.0.0 10.1.0 10.1.1
10.1.2
10.1.3
10.1.4
10.1.5 10.1.6
Section 1
Page : 16 of 19
10.1.7
Complete descriptive and illustrated literature on each equipment and accessories being offered. The concept of working in the river bed, execution methodology and sequence to be followed during construction Mechanical Piping and Instrumentation Diagram Duly filled in Technical data sheets System description Preliminary outline drawings indicating the principal dimensions of the equipment offered and locations of pump suction and discharge connections. Performance curve for single and parallel operation along with family curve. Electrical load list Write up on pump lubrication system for thrust bearing and for shaft bearing. Brief write-up of hydraulic model study Control and Instrumentation Operation and control philosophy Codes and applicable standards followed for the project Clause-wise confirmation/deviation list with respect to C&I requirements outlined in this specification List of vendors for C&I items.
10.1.8
10.2.0 10.2.1 10.2.2 10.2.3 10.2.4
10.2.5 10.2.6 10.2.7 10.2.8 10.3.0 10.3.1 10.3.2 10.3.3
10.3.4
11.0.0 11.1.0
DRAWINGS / DOCUMENTS TO BE FURNISHED AFTER AWARD OF CONTRACT Foundation drawings with all design loads, direction and points of application. Loading data for thrust block, if provided, shall be indicated. Cross-section drawings indicating the assembly of pumps and major parts thereof with materials of construction and special features. Drawings indicating the desired sump dimensions minimum submergence and the clearances from suction bell for proper suction condition required for most efficient running of the pump. Characteristic curves of pumps showing effective head pump input power, efficiency, submergence, and NPSH, against capacity ranging from a shut-off condition to 115% and 145% of rated capacity. Speed Vs Torque curve of the pump corresponding to recommended mode of pump starting, super-imposed on Speed vs. Torque curves of the motor, corresponding to 80%, 90%, 100% rated voltage and also extending over Quadrant-I and Quadrant-II covering reverse flow conditions, if applicable.
11.2.0
11.3.0
11.4.0
Section 1
Page : 17 of 19
11.5.0
Homologous curves for all four quadrants for Flow vs. Head and Torque vs. Speed characteristics. Final version of all documents drawings submitted along with the offer General arrangement and sectional assembly drawings, detailed literature, material of construction details. Bidder to submit and obtain Owner's Engineer's approval of all drawings / documents design, detail engineering and construction before proceeding with construction and execution. A list of such drawings will be finalised at the time of Award and which will get updated as the detail engineering progresses. Control and Instrumentation Level-II PERT for C&I system Purchase specification for C&I equipment including UPS Control philosophy / Operation philosophy / Design philosophy Loop schematics Complete Input / Output list (I/O list) Instrument List Drive List / Solenoid valve list Annunciation List SOE List Technical Datasheets for all instruments P&IDs indicating all primary and secondary instruments and the functionality of the signals Marshalling & Cabling philosophy Junction Box Schedule Technical Catalogues and Specifications for all field instruments, JBs and cables, local cabinets, Uninterruptible Power Supply (UPS) etc. Installation sketches and isometric drawings Control schemes / Logic diagrams Factory Acceptance Test (FAT) procedure / Availability test procedure / PG test procedure for all C & I equipment Interconnection schedules and cable schedules for cables between field instruments, JBs, control panel and PLC cabinets. Wiring diagrams for back-up control panel, junction boxes, actuators etc. OGA & IGA drawings for PLC cabinets, back-up control panel, UPS List of logs with point assignment & format of logs and reports
11.6.0 11.7.0
11.8.0
11.9.0 11.9.1 11.9.2 11.9.3 11.9.4 11.9.5 11.9.6 11.9.7 11.9.8 11.9.9 11.9.10 11.9.11 11.9.12 11.9.13 11.9.14
11.9.15 11.9.16 11.9.17
11.9.18
11.9.19 11.9.20 11.9.21
Section 1
Page : 18 of 19
11.9.22 11.9.23 11.9.25
List of Set Points Heat load and power consumption data for UPS UPS and Battery Sizing Calculation.
11.9.24 Vibration Monitoring System (VMS) drawings 11.9.25 QAP for all field instruments, JBs and cables, control panel, Uninterruptible Power Supply (UPS) and all other components and accessories. Essential & start-up Spares list Equipment wise vendor details including address, contact person, telephone nos. etc. Complete system as built drawings Control system configuration indicating the GSM/GPRS router and its communication to the unified PLC supervisory system, HMI and peripherals, local control panel with hard wired annunciators, ILPBs etc. (if applicable) System Configuration and Write-up on the wireless communication set-up. (if applicable)
11.9.26 11.9.27
11.9.28
11.9.29
Section 1
Page : 19 of 19
JHABUA POWER LIMITED 1 x 600MW + 1 x 660MW JPL SEONI Project Specification for River Water Intake System
VOLUME II SECTION - 2 DETAILED TECHNICAL SPECIFICATION CIVIL WORKS
Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II Detailed Technical Specification Civil works
Section 2
VOLUME - II SECTION 2.0 DETAILED TECHNICAL SPECIFICATION - CIVIL WORKS Section - 2.0 Scope of Work & Design Requirements Section - 2.1 Technical Specification for Earthwork excavation & Backfilling Section - 2.2 Technical Specifications for Plain and Reinforced Concrete Work Section - 2.3 Technical Specifications for Miscellaneous Steel Work Section - 2.4 Technical Specifications for Masonry Works Section - 2.5 Technical Specifications for Waterproofing, Roof Insulation & Allied Works Section - 2.6 Technical Specifications for Doors, Windows, Louvers, Rolling Shutters & Glazing Section - 2.7 Technical Specifications for Painting, Colour Washing Etc. Section - 2.8 Technical Specifications for Floor and Floor Finishing Section - 2.9 Technical Specifications for Water Supply, Drainage and Sanitary Works Section - 2.10 Technical Specifications for Gate and Fencing Section - 2.11 Technical Specifications for Approach bridge. Annexure 2.1 Soil report for bore hole at intake well location & along the approach bridge Annexure 2.2 Trail pit details along the cross country pipe line alignment
Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II Detailed Technical Specification Civil works
Section 2
JHABUA POWER LIMITED 1x600MW + 1x660MW JPL SEONI Project Specification for River Water Intake System
VOLUME - II SECTION - 2.0 SCOPE OF WORK & DESIGN REQUIREMENTS 1.0.0 GENREAL REQUIREMENT This section of the specification covers the general requirements for design of Civil, Structural & Architectural works and execution including fabrication and erection of structural steel works. The work shall generally involve design of civil, structural & architectural works and structural steel fabrication and erection, sheeting all complete. The Works to be performed under this Specification shall include: a) Execution of the works according to fabrication drawings/ working drawings/ scheme drawings, etc. prepared by the contractor and approved by the Engineer, procurement of all bought out items as per approved data sheet, including providing all labour, supervision, materials, consumables, fuel, construction equipment, tools and plants, supplies, transportation, all sampling, testing and quality assurance, providing necessary facilities and equipment to Engineer for carrying out the inspection and quality check, setting out layout and levels, safety measures conforming the general environmental requirements, carrying out erection in a mechanized manner, storage, repair/ rectification/ maintenance until handing over, furnishing of design, working drawings, calculations, data sheets, records, etc. complying with statutory provisions and applicable laws etc. Covering all contingencies, overheads, levies, taxes, royalties, duties etc. Covering all incidental items not specifically mentioned but reasonably implied and necessary for successful completion of the work. Providing supervision by specialist agencies, wherever required.
b) c) d)
All work shall be performed in accordance with drawings released / approved by the Engineer, technical specifications, general conditions of contract, special conditions of contract, and directions of the Engineer. Item/ items of work though specified in the scope of work but for which detailed specifications are not given in the technical specifications, shall be performed as per the best available industry practice. In case of conflict between the stipulations contained in various sections of these specification and stipulations of Indian standards, codes etc. the more stringent requirements of the two stipulations shall prevail. Mobilizing of all manpower, construction material, tools, tackles, plants etc. The detailed design shall include, but not limited to: Generation of all data from, evaluation of foundation parameters available in the soil investigation report like modulus of deformation, bearing capacity, water table and dewatering requirements, permeability, liquefaction, slope stability etc, preparation and submission of design basis with criteria and information required for approval, for the completion of the River water intake system.
Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II Detailed Technical Specification
Section 2.0
Page : 1 of 26
Scope of Work & Design Requirements
Design and analysis of structures, buildings, bridges and their foundations, equipment supporting structures and their foundations, equipment foundations, cable trenches etc submission of design report with calculations for approval. Preparation and submission of all construction drawings (Layout, Architectural, Civil and Structural) required for the complete execution of civil works, material selection and material take off. SUFFICIENT DETAILING SHALL BE DONE IN ALL DRAWINGS SO THAT NO DIFFICULTY IS FACED BY SITE ENGINEERS DURING EXECUTION. Furnishing of quantities of all civil items involved like excavation, PCC, RCC, formwork, reinforcement etc. based on approved drawings. Handing over of all the documents in the editable format in compact disc along with a set of hard copies as mentioned elsewhere in the tender document. Submission of Quality Assurance Program for civil works
1.1.0
SCOPE OF WORK Broadly, the Scope of Civil Works covers the following in general, but not limited to only the following items of work The scope includes providing detailed Design and issue construction drawings including bar bending schedule/ detailed drawings for all works and getting them approved by the Owner/ Engineer Setting out from the reference provided by Owner and fixing the limits of working in Rani Avanti Bai Sagar Dam (Bargi Dam) on River Narmada, at Gadaghat in Seoni District of Madhya Pradesh. The scope includes providing detailed Design for intake structure including well & pump house, pipe supports, approach bridge & pipe protections from external load and issue construction drawings including bar bending schedule/ detailed drawings for all works and getting them approved by the Owner/ Engineer. An intake well of 10 m diameter ( EPC bidder shall decide and indicate all the dimensions in the bid satisfying Hydraulic Institute Standards(HIS) and shall be with the bid proposal) and pump house of required size to accommodate 3 numbers of pumpsets and control room with toilet facilities. An approach bridge of 6.70 m clear width for about 2.50 km long shall be constructed from the intake well to bank within the reservoir. Near the intake well the width shall be of 12 m for maneuvering of vehicles. Approach Bridge shall comply with the requirements of Rani Avanti Bai Sagar (Bargi dam) Dam Authorities. Typical layout of intake well & approach bridge is indicated in the drawing. Coffer dam, if necessary shall be provided to facilitate construction on dry of some of the bridge piers and intake well. A Switch gear &Transformer yard shall be provided onshore as indicated by the Owner. Arranging right of way for laying pipe line shall be part of the scope of the contractor. Bidder shall also consider all other allied and supporting structures for the pipeline and bridges over river / nallah drainage are to be provided. Geotechnical & Topographical survey conducted by the owner is provided for reference and the bidder shall confirm and shall carryout additional geotechnical & topographical survey if necessary.
Section 2.0 Page : 2 of 26
RCC thrust blocks, air valve chamber, scour valve chambers etc., as required for the pipe line shall be provided. Necessary improvement works are to be carried out on river bed (if necessary) All construction work shall commence only after the design & construction drawings are checked and approved by the Owner/ Engineer. Submission of Field quality plans for owners approval in respect of construction, erection & commissioning within 4 weeks from NOA. The scope of work will also include providing & fixing of inserts/pipe sleeves etc. in concrete work, providing & fixing of steel connections like brackets etc., to the structural steelwork, providing & fixing of any other type of steel inserts as may be needed for completion of the job Supply and fixing of base plates, foundation plates, anchor bolts, sleeves, inserts, bolts and nuts for all equipment supplied. Any temporary inserts and openings required for construction / erection and closing of opening after complete of construction. Provision of Toilet and septic tank Transformer foundations in the fenced area Providing necessary Gate and fencing arrangements to the Approach bridge near the shore area and the On shore Transformer yard. The scope also includes providing necessary labour, materials, scaffoldings, construction equipment, tools and plants, appliances, necessary supervision by competent Supervisors and execution of all incidental items not specified or indicated but implied or required to complete the work under this scope in all respects and in strict accordance with the specifications and drawings including their revisions and amendments made from time to time. Providing necessary shuttering with supports & bracings; bending, binding, fixing and placing of the reinforcement, including supplying and fabricating metal & steelwork. The scope of work will also include removing the formwork after concrete is sufficiently cured and as per instructions of the Owner/ Engineer and making the concrete surface smooth and rendered to the satisfaction of the Owner/ Engineer and as per technical specification. Any honeycomb or other defects as pointed out, by the Owner/ Engineer to be rectified to the satisfaction of the Owner/ Engineer without any extra cost to the Owner/ Engineer. Owner/ Engineer decision on this will be final and binding on the part of the Contractor
1.2.0
General Description of the System The River Narmadha is a perennial river with erosion of the banks and caries substantial silt and meanders at its high flow. Detailed Hydro-geological studies were taken up to decide the concept of drawing water.
1.3.0
IS CODES All the Indian Standards referred to shall be the latest revision (including all amendments issued thereto at the time of execution.
Section 2.0
Page : 3 of 26
Reference of 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. In case of any deviation/ conflict between provisions of IS codes 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. Specifications for materials supplied from India follow the Indian Standard Specifications. Field and laboratory testing procedures for materials follow Indian Standard Specifications. Working stress design can be used as alternative but the approval of owner is a prerequisite. 1.4.0 LOADS IS:875 IS:1911 IS:1893 1.5.0 FOUNDATIONS IS:1080 IS:1904 IS:2911 (Part-1) (Part-4) IS:2950 IS:2974 IS:8009 (Part-1) (Part-2) IS:11089 IS:13301 1.6.0 RCC IS:456 IS:3370 Code of Practice for Plain and Reinforced Concrete Code of Practice for Concrete Structures for the Storage of liquids
Section 2.0 Page : 4 of 26 Scope of Work & Design Requirements
Code of Practice for design loads (other than earthquake) for buildings (all parts) and structure Schedule of unit weights of building materials Criteria for earthquake resistant design of structure
Code of Practice for design and construction of shallow foundations on soils (other than raft, ring and shell) Code of Practice for design and construction of foundations in soils : General requirement Code of Practice for design and construction of pile foundations : Concrete piles Load test on piles Code of Practice for design and construction of raft foundations Code of Practice for design and construction of machine foundations (all parts) Code of Practice for calculation of settlement of foundations : Shallow foundations subject to symmetrical static vertical loads Deep foundations subjected to symmetrical static vertical loading Code of Practice for design and construction of ring foundation Guidelines for vibration isolation for machine foundations
(Part 1) (Part 2) (Part 4) IS:3414 IS:4326 IS:5525 IS:11682 IS: 13920 1.7.0
General Requirements Reinforced Concrete Structures Design tables Code of Practice for design and installation of joints in buildings Code of Practice for earthquake resistant design and construction of buildings Recommendation for detailing of reinforced concrete works Criteria for design of RCC staging for overhead water tanks Code of Practice for ductile detailing of reinforced concrete structures subjected to seismic forces
STRUCTURAL STEEL IS: 800 IS:808 IS:813 IS:816 IS:9595 Code of Practice for general construction in steel Dimensions for hot rolled steel beam, column channel and angle section Scheme of symbols for welding Code of Practice for use of metal arc welding for general construction in mild steel Recommendation for Metal arc welding of carbon and carbon manganese steel
1.8.0
MISCELLANEOUS IS:1172 IS:1742 IS:1905 IS:2210 IS:2470 Code of basic requirements for water supply, drainage and sanitation 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 Code of Practice for installation of septic tank (Part 1) Design criteria and construction (Part 2) Secondary treatment and disposal of septic tank effluent Code of Practice for general design details and preparatory works for damp proofing and water proofing of buildings 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 onm codes for earthquake engineering
IS:3067 SP:6 SP:7 SP:16 SP:20 SP:22
(IS:1982-1975 and IS:4326-1976) SP:24 SP:25 SP:32 SP:34 IRC:37 IRC:73 2.0.0 2.1.0 Explanatory handbook on Indian Standard Code of Pracrtice for plain and reinforced concrete Handbook on causes and prevention of cracks in buildings Handbook on functional requirements of industrial buildings Handbook of concrete reinforcement & detailing (SCIP) Guidelines for design of flexible pavements Geometric design of roads
DESIGN CRITERIA - LOADS AND LOAD COMBINATIONS GENERAL All structures shall be designed for the most critical combinations of dead loads, imposed loads, equipment loads, crane loads, piping (static & dynamic) and other piping loads, wind loads, seismic loads, temperature loads, loads and any other loading conditions which can occur during the design life of the facility. The applicable loads for the design shall be as listed below:
2.2.0 2.2.1
DEAD LOADS (DL) Dead loads consist of the weights of the structure complete 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 stabilizing load for uplift. The following unit weight of material shall be considered for computation of loads:
2.2.2
2.2.3
Materials
Plain Cement Concrete Reinforced Cement Concrete Structural Steel Brick work Cement Plaster Roof Treatment (7 course bituminous) Floor Finish 2.3.0 EQUIPMENT LOADS (EL)
Unit Weight
24 kN/m 25 kN/m 78.5 kN/m 19 kN/m 21 kN/m 0.3 kN/m 24 kN/m
Static and dynamic loads of major equipments shall be based on the manufacturer's data of the specified equipments. However, 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.
Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II Detailed Technical Specification Section 2.0 Page : 6 of 26 Scope of Work & Design Requirements
All equipments, tank and piping design loading shall include hydraulic testing loads. The weight of equipments, ducts, tanks, pipes and conduits etc., supported by structure shall include maximum possible loading conditions i.e. flooded material contents and associated impacts, test loading, anchorage and constraint effects. 2.4.0 2.4.1 IMPOSED LOADS (LL) General Imposed loads in different areas shall include live loads, minor equipment loads, cable trays, small pipe racks/ hangers, erection loads, operation/ maintenance loads etc. The loads considered shall not less than that specified in IS: 875 (Part II). The loads listed hereunder are minimum live 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. 2.4.2 Roofs a. Flat Roof 1.5 kN/sq.m for accessible roofs 0.75 kN/sqm for non-accessible roofs 5.0 kN/sqm for accessible roofs with HVAC equipment etc. As per IS: 875
b. Sloped Roof 2.4.3
Electrical Bay and other electrical buildings a. Control Room Floor b. MCC Room c. Cable Vault Floor d. Battery Rooms e. AHU, AC & Ventilation plant floors f. Switchgear room g. PLCC, relay room h. Cable tray loads i. Minimum live load 10 kN/sqm 12 kN/sqm 5 kN/sqm 20 KN/sqm 10 kN/sqm 15 kN/sqm 12 kN/sqm 1.0 kN/m per tray 5 kN/sqm
2.4.4
Pump Houses a. Operating floor slab 15 kN/sqm or as required by equipment supplier whichever is higher 5 kN/sqm for offices, laboratories, conference rooms and general floors 5 kN/sqm The gratings/chequerrd plates shall be designed for minimum live load of 7.5 kN/sq.m for minimising deflection. However, the supporting member shall designed for a live load of 5 kN/sq.m d. Walkways 3 kN/sqm
2.4.5
Other Areas a. RCC Floors b. Stairs and balconies c. Chequered Plate/ gratings be
e. Toilet rooms 2.5.0 2.5.1
2 kN/sqm
CRANE& MONORAIL LOADS (CRL & MRL) Crane girders and supporting columns shall be designed for vertical and horizontal forces (including impact forces) as per crane vendor's 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 (Part 2). The minimum impact factors to be used in design shall be as follows:
2.5.2
2.5.3
Crane Loads a. b. For vertical force, an impact factor of 25% of the maximum static loads. A lateral crane surge of 10% of the weight of the crab plus lifted load applied at the top of crane rail acting on any one crane track rail. For frame analysis, this force shall be applied on one side of the frame at a time in either direction. A longitudinal surge of 5% of the maximum static wheel loads of the crane applied at the top of the rail.
c. 2.5.4
Monorail Loads a. b. Impact factor of 10% of lifted load of hoist for monorail and support design Impact factor of 25% of lifted load for electrical pulley and support design
* - CRL (E) - Refers to Crane Load without Lift. 2.6.0 TEMPERATURE LOAD (TL) 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). 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 the 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 total temperature variation. Co-efficient of thermal expansion for steel shall be taken as = 1.2 E-05/C per unit length. Co-efficient of thermal expansion for concrete shall be taken as per IS: 456. 2.7.0 WIND LOAD (WL) Wind loads 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. Basic Wind Speed K1 factor K2 factor
= = =
47 m/s 1.07 shall be corresponding to Terrain

Category 2 K3 factor
1.0
In design of structures, wind force on equipments supported on frame including all fixtures, piping, staircases, ladders, handrails etc. shall also be considered. 2.8.0 SEISMIC LOAD (SL) Seismic forces shall be as per IS: 1893-2002. As per IS: 1893-2002, the site falls in Zone III. Zone Factor (Z) Response Reduction factor (R) = = = 0.16 4 (for steel structures) 5 (for concrete structures)
For the following structures, the design methods listed below shall be used: Pump House/ Other Buildings Pseudo static Method / Response spectrum method
The importance factor for all buildings and structures shall be considered for computation of forces as per IS: 1893. Ductile detailing as per IS: 13920 shall be adopted for all RCC structures. 2.9.0 EARTH PRESSURE LOAD (SP & SCL) Earth pressure for all underground structures shall be calculated using co-efficient of earth pressure at rest, co-efficient of active or passive earth pressure (whichever is applicable). In addition to earth pressure and ground water pressure etc. a minimum surcharge load of 20kN/m shall also be considered for the design of all underground structures including channels, sumps, cable & pipe trenches etc. for the vehicular traffic in the vicinity of the structure. The underground structures shall be subjected to sub surface water pressures. Calculations shall be based on the buoyant weight of the soil plus full hydrostatic pressure. The full upward pressure of water below base raft shall be taken over the entire area. 2.10.0 HYDROSTATIC PRESSURE LOAD (HP) Ground water level for calculation of shall be considered at 1.0 m below finished grade level. 2.11.0 LOAD COMBINATIONS 2.11.1 Building / Structures The individual members of the frame shall be designed for the 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. Load factors shall be based on the factors given in the relevant codes of practice in general, all loads, which are variable (including earth and ground water pressure), shall be treated as live loads for purpose of determining the load factor. Criticality of erection / maintenance loads shall also be checked separately in combination with other simultaneously occurring loads for possible design loading. Lifted load of crane / monorail shall not be considered during seismic condition.
Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II Detailed Technical Specification Section 2.0 Page : 9 of 26
2.11.2 Underground Structures Following loading conditions shall be considered in addition to the loading from super structure for the design of substructure of pump house, channels, sumps, tanks, reservoirs, trenches and other underground structures. a. Only liquid pressure from inside and no earth pressure & ground water pressure and surcharge pressure from outside (applicable only to structures which are liable to be filled up with water or any other liquid). b. Earth pressure, surcharge pressure and ground water pressure from outside and no water pressure from inside. c. Base slab of the sump 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 are designed considering water on one side only and the other side being empty for maintenance.
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. The ground water level shall be considered to be at FGL for design. 3.0.0 3.1.0 DESIGN CRITERIA - REINFORCED CONCRETE STRUCTURES AND FOUNDATIONS GENERAL All structures, building foundations, machines/ equipment foundations, water retaining structures, trenches, pits etc. shall be designed as per IS relevant Codes in general. 3.2.0 3.2.1 DESIGN METHODOLOGY General RC Structures 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. Ductile detailing of RC structures shall be as per IS: 13920. For reinforcement detailing IS: 5525 and SP: 34 shall be followed. The walls shall be provided with reinforcement on both faces for sections 200 mm or more, even if not required from design consideration. Approach Bridge in the reservoir area shall satisfy relevant IRC standards. 3.2.2 3.2.3 Foundations and Underground Structures Sub-soil Conditions As furnished in the Soil Report conducted for the area under the scope of this specification 3.2.4 Liquid Retaining Structure RCC water retaining structure like storage tanks, reservoirs, Sump, etc. shall be leak proof and designed as uncracked section. The design of intake well cum pump house shall conform to the working stress method of IS: 3370-2009- Part II (liquid retaining structures).
Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II Detailed Technical Specification Section 2.0 Page : 10 of 26 Scope of Work & Design Requirements
All water retaining/ storage structures shall be designed assuming liquid upto the full height of wall irrespective of provision of any over flow arrangement. 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. Minimum thickness for water retaining structures to be 200mm 3.2.5 3.2.6 All block foundations resting on soil shall be analyzed considering dynamic properties of soil. The mass of the RCC block shall not be less than the three times the mass of the machine. For the foundations supporting minor equipments weighting 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. All such foundations shall be separated from adjoining part of building and other foundations. Joints at floor/ slab shall be suitably sealed. All appendages to such foundations shall be reinforced suitably to ensure integral action. 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. An increase of 25% is permissible for combination when DL and LL are combined with Temperature load. Bearing capacity of soil / pile shall be allowed to increase by 25% under seismic / wind load condition. 3.3.0 MINIMUM THICKNESS OF STRUCTURAL ELEMENTS The following minimum thickness shall be followed : a. b. c. d. e. f. g. h. i. j. k. Suspended floor slab/ roof slab/ walkways/ canopy slabs etc. Ground floor slab (non - suspended) Water Retaining Slab / Walls Cable / Pipe Trenches / Underground pit / Launder walls and base slab All footings (including raft foundations) Tapered footings (Min. at edges) Parapets / Chajjas Precast louvers / fins Precast trench cover slabs / floor slabs/ louvers Basement walls and base slab Underground reservoir Below ground water table Above ground water table 200mm 150mm 200 mm 125 mm 50 mm 100 mm 250 mm 150 mm 150 mm 200 mm 125 mm 125 mm
3.2.7
3.2.8
Section 2.0
Page : 11 of 26
3.4.0 3.4.1
MINIMUM HEIGHTS FOR PEDESTALS OF STEEL COLUMNS Pedestals to Steel columns for building structures In case the top of pedestal is kept at a lower level so that the column base plates together with gussets and stiffeners remain below finished floor level (FFL), the column bases as well as column sections shall be encased in concrete upto FFL:
3.4.2
Pedestals to Steel columns for outdoor structures Top of pedestal shall be 300 mm above surrounding Finished Ground level(FGL)
3.5.0
CONCRETE MIX The following minimum grades of concrete as per IS : 456 / IS 3370 shall generally be used for the type of structures noted against each grade. Ordinary Portland Cement (OPC) of Grade 53 as per IS:12269 mixed with flyash shall be used for all underground structures and for all above ground structures. Plinth level shall be cutoff level for underground structures Mix ( 1 : 3 : 6 ) PCC below foundations, trenches and underground structures. Minimum thickness of the layer shall be 75 mm. PCC for plinth protection work Pavement around buildings including plinth protection work, damp proof course below brickwork etc. Base plate encasement, grade slab, work. Precast concrete and encasement of steel column basis All RCC members in foundations & substructure All RCC members in superstructure & water retaining structures Intermixing of different grades of concrete, if required, in the same structure shall be clearly indicated with the extent of usage.
Mix (1 :2 : 4) Grade M20
Grade M25 Grade M30
3.6.0 3.6.1
REINFORCEMENTS Reinforcement bars shall be as per the following codes: All reinforcement shall be TMT-Fe500 from primary manufacturer (TISCON/SAIL/RINL) and conform to IS: 1786-2008 & IS 432-1982
3.7.0
GROUTING Non-shrink flowable grout shall be used for under pinning work below base plate of columns. For grouting of base of machine foundation high flowable strength ready mixed non-shrink grout shall be used. Minimum grade of grout shall be M25. Nominal thickness of grouting shall be atleast 50 mm for building columns and pedestals of major equipments. For secondary posts, stair and ladder base etc. Grouting shall not be less than 25 mm thick.
Section 2.0
Page : 12 of 26
3.8.0
MINIMUM COVER TO FOUNDATION BOLTS Minimum distance from the centreline of foundation/ anchor bolt to edge of pedestal shall be the maximum of the following: a. Clear distance from the edge of the base plate/ base frame to the outer edge of the pedestal shall be minimum 50 mm. b. Clear distance from the face of pocket to the outer edge of the pedestal shall be 75 mm. c. Clear distance from the edge of the sleeve or anchor plate to the edge of pedestal shall be 75 mm.
3.9.0
MINIMUM COVER TO REINFORCEMENT The minimum cover to the main reinforcement for all the structures, unless otherwise specified, shall be as follows : Slabs (roof and floors, canopies, : 25 mm or dia of bar chajjas, waist slab in stair etc.) whichever is more 35 mm or dia of bar whichever is more 50 mm 50 mm 50 mm 50 mm 40 mm 40 mm 50 mm
Beams, Lintels Columns Pedestals Dry pits/ retaining walls i. ii. i. ii. Footing i. ii. Sides and top Bottom Face in contact with earth Free face Face in contact with liquid with earth
: : : : : : :
Water/ Liquid retaining structures Away from liquid but in contact :
: :
50 mm 75 mm
3.10.0 DEFLECTION CRITERIA Generally deflection Criteria shall be in accordance with IS: 456. 3.11.0 Foundation System 3.11.1 General Requirements (a) (b) All equipment/ structures shall be supported either on suitable open foundations or on pile foundations as required. The roads, ground floor slabs, trenches, channels and other lightly loaded structures with foundation intensities less than 5.0 t/sq.m may be supported on open/shallow foundation resting on virgin/controlled compacted filled up soil (cohesive non-swelling soil). All foundations shall be designed in accordance with provisions of the relevant parts of the latest revisions of Indian Standards.
(c) (d) (e)
No major foundation shall rest in the filled up ground/soil. A combination of open and pile foundations shall not be permitted under the same equipment/ structure/ building. Foundations shall be designed to resist all loads, including those due to wind or seismic, construction loads, and any other load as applicable and as specified elsewhere in the specification. Foundation shall be designed for worst combination of loads as described elsewhere in the specification. For identifying the subsoil for founding purposes, the Bidder shall depute/ post an experienced qualified geologist/ geotechnical engineer so that the specified strata as conceived in the design is reached.
(f) (g)
3.11.2 Open Foundations In case, open foundations are adopted following shall be adhered to: (a) (b) (c) (d) Minimum width of foundation shall be 1.0 m. Minimum depth of foundation shall be 1.0 m below NGL. It shall be ensured that all foundations of a particular structure/ buildings/ facility shall rest on one bearing stratum, i.e. either overburden or rock. Wherever the intended bearing structure is weathered rock but the actual stratum encountered during foundation excavation consists of both overburden soil and weathered rock at founding level, under such cases either the foundation shall be lowered completely into the weathered rock or the overburden soil upto the weathered rock level shall be removed and built up through PCC up to designed foundation level. The net allowable bearing pressure values to be adopted for design upon Owners approval shall correspond to total permissible settlement as mentioned under para permissible settlement of foundations or the permissible settlement from functional requirement, which ever is more stringent. Permissible settlement of foundations: The total permissible settlement and differential settlement shall be governed by IS: 1904 and IS: 13063 and from functional requirements, whichever is more stringent. However, total settlement shall be restricted to the following: (i) (ii) (iii) (iv) (v) All facilities in Main Plant area, ducts, equipment foundation All foundations in switchyard, control room Building including, isolated/strip continuous/raft foundation Other footings of width upto 6m Other footings of width greater than 6.0 m (raft) Footings on rock 25 mm 40 mm 40 mm 75 mm 12 mm
(e)
(f)
In case the total permissible settlement is to be restricted to less than as above specified from functional requirements, then the net allowable bearing pressure shall be reduced/ reviewed accordingly in consultation with Employer.
3.11.3
Pile Foundations In case piles are adopted, following shall be adhered to: (a) The piles foundation shall be of RCC, Cast-in-situ bored piles as per IS: 2911. Piles shall be installed by using rotary hydraulic rig. Three-stage flushing of pile bore shall be ensured, by airlift technique. The minimum diameter of pile shall be 600mm. The uplift and lateral load capacity shall be respectively restricted to 20% and 5% of the allowable load capacity in vertical compression. However, the pile capacities to be adopted shall be the least of the estimated design values and that obtained from the initial pile load tests. Only straight shaft piles shall be used. Minimum cast length of pile above cutoff level shall be 1.0 m. The bidder shall furnish design of piles (in terms of rated capacity, length, diameter, termination criteria to locate the founding level for construction of pile in terms of measurable parameter like SPT & SCPT value, reinforcement for job as well as test piles, etc.) for Owners approval. The piling work shall be carried out in accordance with IS: 2911 (Relevant part) and accepted construction methodology. The construction methodology shall be submitted by the Bidder for Owners approval. Number of initial load tests to be performed for each diameter and rated capacity of pile shall be as under: Vertical } Lateral } Uplift } ----------Minimum of 3 No. in each mode.
(b)
(c) (d)
(e)
(f)
The initial pile load test shall be conducted with test load upto three times the estimated pile capacity. In case of compression test the method of loading shall be cyclic as per (IS: 2911 (relevant part) (g) Number of routine pile load tests to be performed for each diameter/allowable capacity of pile shall be as under: (i) Vertical (ii) Lateral 0.5% of the total number of piles provided. 0.5% of the total number of piles provided.
The routine tests on piles shall be conducted upto test load of one and half times the allowable pile capacity. The Employer shall approve piles for routine load tests. Routine load tests may be done by conventional method as per IS: 2911 (Part-4) or by means of high strain dynamic pile load testing method as per ASTM D4945. If high strain dynamic pile load testing is adopted, site specific correlation vis--vis conventional test shall be established as approved by Employer. 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 the Bidder shall install additional pile(s) as required and the pile cap design shall accordingly be reviewed and modified, if required, without additional cost to the Employer. (h) Testing of piles and interpretation of pile load test results shall be carried out as per IS: 2911 (Part-4). Contractor shall ensure that all the measuring equipment and instruments are properly calibrated at a reputed laboratory/ institute prior to their use. Additional measurement for pile movement shall also be done.
(i)
Low Strain Pile Integrity test shall be conducted on all test piles and job piles. This test shall be used to identify the piles for routine load test.
3.11.4
Other Requirements (i) In case of high ground water table, for excavations comprehensive dewatering arrangement shall be required. Scheme for dewatering and design with all computations and back-up data of dewatering and sheet pilling shall be submitted for Owners information. The founding level for trenches/ channels shall be decided as per functional requirement. The bottom of excavation shall be properly compacted prior to casting of bottom slab of trenches/ channels. Excavation for open foundations shall be covered with PCC immediately after reaching the founding level. In case of any local loosening of soil at founding level during excavation, the same shall be removed and compensated by PCC. The foundation pits shall be maintained dry during the complete construction period by means of suitable dewatering systems. Backfilling, around foundations and bottom of pipes, thrust blocks, etc. shall be carried out with approved material in layers not exceeding 30 cm thickness and each layer shall be compacted to 90% standard proctor density for cohesive soil and to 75% of relative density for non-cohesive soils.
(ii)
(iii)
(iv)
Excess/ surplus excavated material shall be disposed off by the Bidder as per the instructions of the Enginee-in-charger upto a lead of about 5 km. 4.0.0 4.1.0. DESIGN CRITERIA STEEL STRUCTURES GENERAL STEEL STRUCTURES Design of structural steel work shall include generally but not be limited to the steel constructions listed below: a. b. c. d. e. 4.2.0 4.2.1 Steel building structure and open structures. This shall include beams, columns, bracings, supporting structure for floors, roof slabs, cladding etc. Crane gantry girders, monorails Platforms and walkways Ladders, staircases, handrails etc Pipe racks and cable racks.
FRAMING All steel - framed structures shall generally be of "rigid frame" in the generally transverse direction and braced frame in the longitudinal direction bracing confined to selected bays. Lateral forces shall be resisted by stiff jointed moment connections in rigid frame design. The column bases shall generally be fixed to concrete foundation pedestal by providing moment resistant base detail.
4.2.2
Pipe rack consist of rigid cum braced (braced below pipe tier) main frame in transverse direction spaced longitudinally as required. In longitudinal direction, pipe rack shall be divided in sections of suitable length with an anchor bay. The main transverse frames shall be connected with longitudinal beams, which will transmit horizontal forces to braced anchor
bays. Longitudinal beams on one side of anchor bay shall be connected by means of sliding joints. 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. 4.2.3 Concrete floors shall be considered to provide continuous lateral support to the top (compression) flange of the support beams by usage of shear connectors. Removable grating 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 for floors with grating /chequered plate 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. 4.2.4 Columns shall be designed to support the load combination that produces the maximum interaction ratio. Exterior columns shall be designed to resist wind moments between braced elevations as appropriate. 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 IS: 2062. Chequered plates shall conform to IS: 3502. All gratings shall be pressure locked type (preferably Electro-forged) manufactured in accordance with applicable Indian Standard. Pipes for handrail shall be as per medium grade of IS: 1161. Crane rails shall conform to IS: 3443. CONNECTIONS Welding shall be used for shop fabrication as well as for site connection. However, for site connections, HT Bolts can also be used where welding is not possible. For shear connections of lighter members or removable beam connections, bolted joints may be adopted e.g. purloins, side girts etc. A minimum of two bolts per connection shall be used. IS: 816 and IS: 9595 shall be followed for welding of structures. Electrodes of approved makes shall be used. For High Strength Friction Grip (HSFG) bolt connections, IS: 4000 shall be followed. High strength friction grip bolts shall be of property class 8.8, shall conform to IS: 3757 and shall not be less than 20 mm in diameter unless designated otherwise. High strength bolts shall be installed as bearing type joint except where loads are reversible. All other (other than HSFG) bolted connections shall have bolts of minimum 16 mm dia. The connections of stairs and hand railing shall be made with 16 mm diameter threaded fasteners conforming to IS: 1363. Erection bolts shall be black bolts of minimum 12 mm dia. All bolts and nuts have properly 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. 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 crane girders, 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.
4.3.0 4.3.1 4.3.2
4.4.0 4.4.1
4.4.2 4.4.3
4.4.4
4.4.5
4.4.6 4.4.7
4.4.8
The work point of the bracing connection shall be the centre of column and girder to which it connects, where practical. The connections of gusset plates to column and girders shall be made to include provisions for eccentricity in connection. The double angle back-to-back with gusset plates in between shall not be used in dust-laden areas. Where double angles are not adequate, beam sections with web in the plane of bracing are used. Horizontal bracings shall be angle/ tee section located at the bottom of framing beams. Field welding of bracing at the underside of beam as required to meet slenderness requirement of bracing member shall be indicated on the drawings. Horizontal bracing shall be arranged to avoid framing into the beams at columns locations. DESIGN METHODOLOGY The design of steel structures shall be done by working stress method in accordance with the provisions of IS: 800 and other relevant IS codes as applicable to specific structures. Crane gantry girders shall be single web plate girder or 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/ monorail beams ISMB sections shall be preferred and the bottom flange of all beams shall be checked separately for distortion and reinforced suitably if required. Permissible stresses for different members shall not be allowed to exceed by 331/3% under wind and seismic conditions. However, permissible stresses in bolts and welds shall be allowed to exceed upto 25% only. For design which requires the use of the minimum column load (such as, uplift on anchor bolts, column axial tension etc.) 90% of Dead Load along with uplift forces if applicable shall be considered. Base plates shall be placed on foundation pedestal with grouting. For large base plates necessary grout holes shall be provided. Generally anchor bolts for fastening steel columns on foundation shall be embedded in foundation during concreting itself. No anchor pockets in foundation shall be allowed for anchor bolts in tension. Design of base plates shall be based on design pressure on foundation, which shall not exceed the appropriate bearing values given in IS : 456. 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 co-efficient 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 shear may be transmitted through bolts or shear keys. 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. Necessary recesses shall be kept in the foundation concrete for shear lugs. The following criteria shall be followed for noticing loads on the design drawings. For vertical beam reactions, the load shall be noted whenever the value exceeds the maximum allowable uniformly distributed load. For axial loads in floor beams, the actual horizontal load which the beam end connection must resist shall be noted for each end of the beam. Note that this value may be different for opposite end of the same beam. For truss members, only one member force shall be noted for each member.
4.4.9
4.5.0 4.5.1 4.5.2
4.5.3
4.5.4
4.5.5
4.5.6
4.5.7
4.6.0
PERMISSIBLE DEFLECTIONS The permissible deflection of various steel members under normal loading conditions shall be as specified below. For calculation of deflections in structures and individual members
Section 2.0
Page : 18 of 26
dynamic effects shall not be considered, unless specified otherwise. Also, no increase in deflection limits shall be allowed when wind or seismic loads are acting concurrent with normal loading conditions. 4.6.1 Vertical Deflection For beams supporting dynamic Equipment For beams supporting floors / masonry For beams supporting pipes (pipe rack) For roofing and cladding components For gratings and chequered plates span / 500 Span / 325 Span / 400 Span / 250 Span 200 subject to a maximum of 6 mm
4.6.1.1 a. b. c. d. e.
4.6.1.2 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 : a. b. For manually operated cranes & monorails For electric overhead cranes i. ii. 4.6.2 Upto 50 t capacity Above 50 t capacity Span / 750 Span / 1000 Span / 500
Horizontal deflections The permissible horizontal deflections shall be as per following unless specified otherwise: a. b. c. d. Single storey building (without crane load) Multistoried building (without crane load) Pipe rack columns Open structures Height/ 325 Height/ 500 Height/ 200 Height/ 200
4.6.3
Provisions of IS: 800 and relevant IS codes shall be followed for checking 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. Structural steel members exposed to marked corrosive environment shall be increased suitably in thickness or suitably protected otherwise as per good practice and sound engineering judgement in each instance. a. b. c. d. e. Trusses, purlins, girts and bracing Columns and beams Gussets Stiffeners Base plates : : : : : 6 mm 8 mm 8 mm 8 mm 10 mm & above
4.7.0 4.7.1
f. g. h.
Chequered plates Grating flats
: :
6 mm o/p & above 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.
4.7.2
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.
4.8.0 4.8.1 4.8.2
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 general guide. a. b. c. d. e. Truss Rolled beams and girders for ordinary floors and rafters Supporting floor beams for vibrating machinery / equipments Roof purlins and girts Gable columns 1/10 1/24 1/15 1/45 1/30
5.0.0 5.1.0
DESIGN CRITERIA FINISHING REQUIREMENTS GENERAL The finishing schedule shall be as given below:
5.2.0 5.2.1
FLOORING Air conditioned areas like : Control Rooms Unloading bays, Mezzanine Floor, Maintenance & workshop floors, Operating floor of pump houses, Switchgear rooms Battery rooms, Any other area coming in contact with acid / alkali vapours / fumes PVC - 2 mm thick (antistatic) as per IS:3462 Laid as per IS:5318 Total thickness of flooring - 50 mm Metallic Hardener topping 12 mm thick topping Total thickness of flooring - 50 mm Acid / Alkali resisting tiles Ceramic unglazed vitreous acid / alkali tiles conforming to IS:4457 - minimum 20 mm thick or Bedding shall comprise of potassium silicate mortar conforming to IS:4832 (Part-I) and resin based mortar like epoxy etc. for jointing Total thickness of flooring - 50 mm Cast-in-situ Terrazzo Using white cement / ordinary cement with colouring pigment
5.2.2
5.2.3
5.2.4
Risers & treads of staircases
5.2.5 WC & Urinals
Total thickness of flooring - 50 mm Laid as per IS:2114
Anti-slip tiles Total thickness of flooring - 50 mm Sunken RCC slab for toilets areas, Canteen, Terrazzo tiles 250 x 250 x 20 mm thick precast Mosaic tiles Total thickness of flooring - 50 mm Integral Floor finish to concrete base As per IS:2571 Plinth Protection shall be 1000 mm wide, 150 mm thick M20 concrete paving on well prepared subgrade
5.2.6
General circulation Office areas etc. Cable vaults
5.2.7 5.2.8
All buildings except mentioned otherwise
5.2.9
Aluminium / MS angle nosing with minimum 50 x 25 x 3 mm angle shall be provided for edge protection in RCC stairs.
5.2.10 Angles 50 x 50 x 6 mm (minimum) with lugs shall be provided for edge protection all round cut-outs / openings in floor slab, edge of drains supporting grating covers, edges of RCC cable / pipe trenches supporting covers, edges of manhole supporting covers, supporting edges of precast covers and any other plate where breakage of corners of concrete is expected. 5.2.11 Floor of switchgear room shall have embedded channel suitable for easy movement of breaker panels. 5.2.12 Ground floor slab shall be in RCC. Grade slab shall be laid over a base course and sub base course. 5.3.0 5.3.1 SKIRTING / DADO All areas except mentioned otherwise Skirting 150 mm high Matching with floor finish Glazed tile dado Glazed tiles of minimum 5 mm thickness upto 2.2 m height Acid / Alkali resistant dado Ceramic unglazed vitreous acid / alkali resistant tiles conforming to IS:4457 of 20 mm thickness upto minimum height of 1.0 m Bedding shall comprise of potassium silicate mortar conforming to IS:4832 (part-I) and jointing shall be done with resin bonded mortar like epoxy etc.
5.3.2
WC & Urinals
5.3.3
Battery room, any other area coming in contact with acid / alkali
5.4.0
WALLS
Section 2.0
Page : 21 of 26
5.4.1
All walls shall be non-load bearing infilled panel walls. External walls of all buildings shall be 230 mm thick brick masonry. All internal walls shall be 230 mm or 115 mm thick brick masonry. 50 mm thick DPC (1:1.5:3) with water proofing shall be provided at plinth level before starting masonry work. Minimum 75 kg/sq.cm. compressive strength brick shall be used in brickwork. Cement sand mortar 1:6 for one brick thick wall and 1:4 for half brick thick wall shall be used. IS: 1905 and IS: 2212 shall be followed for brick work design and construction. Type, thickness and height of external walling facing the transformer yard to take care of fire accidents in transformer yard shall be according to the requirements of Tariff Advisory Committee. PLASTERING External Walls: All buildings unless otherwise noted. Cement Sand Plaster 18 mm thick cement sand with under layer of 12 mm thick in (CM 1:6) and top layer 6 mm thick in (CM 1:4) on outer face. 12 mm thick cement sand plaster (1:6) on inner face Cement Sand Plaster 12 mm thick cement sand plaster (1:6) Cement Sand Plaster 6 mm thick cement sand plaster (1:4) Plaster of Paris over Plastered Surface Inside surface of walls shall be provided with 2 mm thick plaster of Paris punning over the plastered surface.
5.4.2 5.4.3
5.4.4
5.5.0 5.5.1
5.5.2 5.5.3
Internal Walls : All buildings unless otherwise noted Ceiling : All buildings unless otherwise noted (except in cable vaults and over false ceilings) a. b. Office areas, Entrance lobby, Corridors etc. Control equipment room, UPS room and other air-conditioned areas
5.5.4
5.5.5 5.6.0 5.6.1
IS:1661 shall be followed for all plastering work PAINTING External face - All buildings. unless otherwise noted (other than those specified for decorative finish) a. Inside walls - Control Room and Control equipment room, UPS room and Air-conditioned areas like conference room, entrance lobby etc. Inside walls - All areas unless otherwise noted. Water Proof Cement Paint finish As per IS:5410
5.6.2
Acrylic Emulsion Paint As per IS:5411 (Part-I)
b. 5.6.3
Oil bound distemper As per IS:428 White Washing Suitable white washing
All ceilings
5.6.4
Battery rooms and other areas coming in contact with acid / alkali fumes All woodwork in Fire Phone areas
Chlorinated Rubber Paint As specified Fire Resisting Transparent Paint Shall be as per IS:162 To be provided over French Polish (as per IS: 348) or flat oil paint (as per IS: 137). Brolac or equivalent water proof paint Synthetic Enamel Paint P.O. Red / Signal Red All fire exits shall be painted in P.O. red / signal red shade Shall not be used anywhere else except to indicate emergency or safety measure
5.6.5
5.6.6 5.6.7
All woodwork All Fire Exits
5.6.8 5.6.9
All
structural steel galvanized steel)
(other
than
As per Technical Specification for painting.
For painting on concrete, masonry and plastered surface, IS:2395 (Part-I and II) shall be followed. For painting on steel work and ferrous metals, IS:1477 (Part-I and II) shall be followed. For painting on wood works, IS:2338 (Part-I and II) shall be followed. ROOF All buildings unless otherwise noted Cast-in-situ RCC slab
5.7.0
5.8.0 5.8.1 5.8.2
ROOF DRAINAGE AND WATER PROOFING All roofs shall have elastomeric waterproofing membrane as water proofing treatment. In addition to the membrane, electrical and control buildings shall be provided with the following: a. 50 mm thick foam concrete as per IS:6598 for thermal insulation. b. 12 mm thick cement sand plaster (1:4) over foam concrete.
5.8.3 5.8.4 5.8.5
Cement concrete tiles shall be provided over water proofing treatment in areas where movement of personnel and handling of equipment is envisaged. For efficient disposal of rain water, the runoff gradient for the roof shall not be less than 1:100. Gradient shall be provided using screed concrete 1:2:4 (using 12.5 mm coarse aggregate) and / or cement mortar (1:3). However, if underbed thickness exceeds 25 mm, only screed concrete shall be used. PVC pipes shall be used to drain off rain water from roof. They shall be suitably concealed with masonry work or cement concrete. Number and size of downcomers shall be governed by IS:1742 and IS:2527.
5.8.6
Section 2.0
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5.9.0 5.9.1
DOORS & WINDOWS All doors, windows & ventilators of Control Room Aluminium Doors, Windows, Ventilators and Partitions With 15 micron thick anodising Main entrance of control room and control equipment room shall be provided with air-locked lobby with provision of double doors. Door shall be double swing type. Single glazed panels with aluminium framework shall be provided between two AC areas wherever clear view is necessary.
5.9.2
a. Doors - Office areas, WC & Urinals b. Doors - Fire Exit Points
Wooden Paneled doors Wooden panelled door as per IS:1003 (Part-I) Fire Proof Doors Fire proof doors shall be provided at all fire exit points as per recommendations of TAC and as per IS:3614 (I & III) Fire rating shall be as per TAC but not less than 2 hours. Doors shall be double cover plated type with mineral wool insulation Steel Doors Shall consist of double plate flush door shutter Steel Windows / Ventilators As per IS:1038 Rolling Shutters As required to facilitate operations Suitable operating arrangement i.e., manual / electric (as per IS:6248) according to size.
c. Doors - All other doors unless otherwise noted 5.9.3 Windows / Ventilators - All windows / ventilators other than those specified above (unless otherwise noted) Rolling Shutters
5.9.4
5.10.0 GLAZING 5.10.1 a. Windows & Ventilators located at higher elevation where frequent replacement is not feasible Wired Glass Of minimum 6 mm thickness and conforming to IS:5437 Ground Glass Minimum 4 mm thick Float / Flat Transparent Sheet Glass Minimum 4 mm thick and conforming to IS:2835
5.10.2 In toilets 5.10.3 All areas unless otherwise noted
5.10.4 For glazing work IS:1083 and IS:3548 shall be followed
Section 2.0
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5.11.0 FALSE CEILING & UNDERDECK INSULATION 5.11.1 Plant control room Galvanized Steel Ceiling System Suspended ceiling shall be of 84 mm wide and 16 mm deep panels roll from 0.45 mm TCT coil coated galvanized steel fixed on carriers and suspended from roof by anchors Underdeck Insulation Shall comprise of 25 mm thick resin bond mineral wool insulation material conforming to IS:8183. 5.12.0 WATER SUPPLY & SANITATION 5.12.1 Water Supply - All building, Pump Houses as required 5.12.2 Toilets Galvanized MS pipe of medium class conforming to IS:1239 shall be used for internal piping works for potable water supply Toilet with all facilities shall be provided in the Control building Number of toilets and the facilities provided therein shall depend on total number of users and as per IS:1172, IS:2064 and IS:2065.
5.12.3 Each toilet shall generally have the following facilities : i. WC Orissa pattern (580 x 440 mm) as per IS:2556(3) with all fittings for separate toilet block including CI cistern of 10 litres capacity as per IS:774 WC western 390 mm high as per IS:2556(2) with toilet paper roll holder and all fittings for attached toilets including chromium plated flush pipe Urinal (430 x 260 x 350) with all fittings Wash basin (550 x 440 mm) with CP pillar cocks, chromium plated P-traps and other fittings are as per IS:2556(4) Bathroom mirror (600 x 450 x 5.5 mm thick) CP Brass towel rail (600 x 20 mm) Soap holder and liquid soap dispenser Rotating type chromium plated shower rose with extension arm and inlet size Ventilation shaft, Exhaust fans
ii. iii. iv. v. vi. vii. viii. ix.
5.12.4 C.I. pipes with rubber gasket joints conforming to IS: 3114 shall be used for sanitary works above ground level. 5.12.5 IS: 1172, IS: 2064 & IS: 2065 shall be followed for water supply, drainage and sanitation works.
5.13
OTHERS Doors and windows on external walls of buildings shall be provided with RCC sunshade over the openings with 300 mm projection on either side of the opening. Projection of sunshade from the wall shall be minimum 600 mm over window and 1000 mm over door openings as per the functional requirements.
Section 2.0
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VOLUME II
SECTION 2.1 TECHNICAL SPECIFICATION FOR EARTHWORK IN EXCAVATION & BACKFILLING
Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Detailed Technical Specification
Section 2.1
Page : 1 of 15
Earthwork in Excavation & Backfilling
SECTION 2.1 TECHNICAL SPECIFICATION FOR EARTHWORK IN EXCAVATION & BACKFILLING CONTENTS
CLAUSE NO.
DESCRIPTION
PAGE NO.
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0
SCOPE .................................................................................................. 3 CODES AND STANDARDS................................................................... 3 SETTING OUT....................................................................................... 4 INITIAL LEVELS .................................................................................... 4 CLEARING AND GRUBBING ETC. ....................................................... 4 EXCAVATION AND CUTTING .............................................................. 4 EXCAVATION IN ROCK ........................................................................ 5 VARIATION IN EXCAVATION ............................................................. 12 KEEPING WORKS SITE FREE FROM WATER .................................. 12 PROTECTION OF WORK ................................................................... 13 SHORING AND STRUTTING .............................................................. 13 DISPOSAL ........................................................................................... 13 BACKFILLING AND FILLING IN PLINTH ............................................ 14 TESTING AND ACCEPTANCE CRITERIA .......................................... 14
Section 2.1
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SECTION 2.1 TECHNICAL SPECIFICATION FOR EARTHWORK IN EXCAVATION & BACKFILLING 1.0.0 SCOPE This specification covers the requirement of site clearing, excavation, conveyance, disposal & backfilling in all types of soil for foundations, basements, trenches, drains, culverts including necessary shoring, dewatering, protective fencing etc. The work to be provided for by the contractor unless otherwise specified shall include providing all labour, supervision, services, materials, scaffolds, equipment, tools and plants transportation etc. GENERAL The area of various building and structures shall be excavated to the dimensions as shown in the excavation drawings prepared by the contractor & approved by the Engineer. Earthwork shall consist of all works involved in site grading, filling around foundations, as directed by Engineer and such other relevant items. The areas to be excavated or filled with the excavated materials shall be clearly demarcated in the field by the Contractor The earthwork shall also include, wherever required temporary sheet piling or sheathing, bracing and shoring to maintain excavations, maintenance without interruptions to service of all cables, ducts, banks, pipe lines etc., encountered within the area of excavation or within reasonable distance of excavations and also furnishing, erecting and maintaining of substantial barricades around excavated areas and also "Red" lamps in the night for ensuring safety. All excavation work shall be inspected and approved by the Engineer before any further works in the excavated areas are allowed to commence. It is imperative that the Contractor uses earth excavating, handling, transporting and compacting machinery for site grading to complete the work in time. This would primarily involve bulldozers, scrapers, graders, dumpers smooth wheeled and vibratory rollers pneumatic equipment for rock breaking etc. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards shall govern in respect of design, workmanship, quality and properties of materials and method of testing. Some of the relevant available codes are listed hereunder: IS:1200 Part 1 - Method of Measurement of building and engineering works - Earth work Classification and identification of soils for general engineering purposes Methods of test for soils (Relevant Part) Excavation works - Code of safety Safety code for blasting and related drilling operations Guidelines for dewatering during construction Handbook of Method of Measurement of Building Works
IS:1498 IS:2720 IS:3764 IS:4081 IS:9759 SP-27
Section 2.1
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3.0.0
SETTING OUT Contractor shall prepare and submit for approval, design and working drawings showing the approaches, slopes, berms, shoring, sheet piling, sumps for de-watering, space for temporary stacking of soils, disposal area, fencing etc. as may be requested by the Engineer. The work shall be set out to exact dimensions as shown on the drawings and shall be checked and approved by the Engineer before commencement of excavation. In firm soil, the sides of excavation in foundations shall be kept vertical up to a depth of 1.5 m from the bottom and for greater depths the sides shall be widened by forming steps of 300 mm on either side after every 1.5m from the bottom. Where soil is soft, loose or slushy, the width of steps shall be suitably increased or the side sloped or shored up, as directed by the Engineer. Working space shall be approved by the Engineer. In case of excavation for pipes, the authorized width of excavation shall be 600 mm plus outer diameter of pipe or the width of bedding as shown in the drawing whichever is higher, upto a depth of 1.5 m. For higher depths, the width shall be widened by forming steps of 300 mm on either side after every 1.5 m from the bottom.
4.0.0
INITIAL LEVELS Initial levels either in a definite grid pattern or as directed by the Engineer shall be taken by the Contractor jointly with the Engineer over the original ground prior to starting actual excavation work and after setting out. These initial levels will be used for preparing cross-section for volume measurement or for cross-checking the depths obtained from tape measurements. Under no circumstances shall the Contractor remove or disturb any permanent bench marks/ reference pillars installed by Owner/ Engineer. The Contractor shall carefully maintain and protect all bench marks and reference pillars and shall lay out all his works by accurate reference thereto.
5.0.0
CLEARING AND GRUBBING ETC. All the areas upon which the construction is to be carried out and over which site filling is to be done and areas which are required by the Contractor for his construction facilities are to be cleared of all rubbish, stumps, roots, bush, vegetation, existing structures etc. and any other objectionable matter. Stumps, roots shall be removed for their full depth wherever possible but at least 450 mm below original ground level. Trees, if any, shall not be uprooted or cut without the prior approval of the Engineer. All spoils and unserviceable materials and rubbish shall be burnt at locations away from the work site in a manner directed by the Engineer or removed from the Site. Care shall be taken to see that unsuitable waste materials are disposed off in such manner that there is no likelihood of these getting mixed up with the materials meant for construction. Useful materials, saleable timber, firewood etc., shall be stacked properly at the work site in a manner directed by the Engineer and finally handed over to Owner/ Engineer.
6.0.0
EXCAVATION AND CUTTING The Contractor shall excavate, remove materials of any nature or description which may be encountered and excavate to depths, widths and inclinations as shown on the drawings and/ or as directed. The bed of the excavation shall be made level and firm by watering and ramming. The Contractor shall not remove any tree without permission. Undercutting shall not be permitted; Sides of excavation shall be cut sharp true to line. While carrying out excavation for drain work, the sides and bottom shall be cut to the exact shape, slope and gradient as shown on the drawings. The surface shall be properly dressed. Excavated material shall not be placed within 1.5 m from the edge of any excavation or half of trench depth whichever is more.
Section 2.1
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7.0.0
EXCAVATION IN ROCK Blasting where permitted shall be carried out as specified in IS: 4081. Where blasting is prohibited, rock excavation shall be by chiseling, wedging or any other approved method.
7.0.1
BLASTING GENERAL A valid blasting license shall be obtained by the Contractor from authorities concerned for starting any blasting work. The Contractor shall employ a competent and experienced supervisor and licensed blaster in charge of each set of operation who shall be held personally responsible to ensure that all safety regulations are followed. Before any blasting is carried out, the Contractor shall intimate the Engineer and obtain his approval in writing for resorting to blasting operations. He shall intimate the hours of firing charges, the nature of explosions, and extent to be used and precautions to be taken for general safety. The Contractor shall ensure that all workmen and the personnel at Site are evacuated from the unsafe area to be determined by the Engineer at least 15 minutes before firing time by sounding warning siren. The area shall be encircled by red flags. The Contractor shall be responsible for any accident to workmen, public or property due to blasting operation.
7.1.0
CONTROLLED BLASTING Following methods of controlled blasting are proposed to be adopted for reducing overbreak and for preventing damage to rock beyond limits of excavation
7.1.1
LINE DRILLING Where shown on the approved drawings or specified by the Engineer vertical faces of excavations shall be formed by line drilling. The diameter of the holes for line drilling shall be 50 mm or more and the maximum spacing of line drilling shall be 150 mm when the diameter of the hole is 60 mm or less. When the line drilled holes are greater than 60 mm in diameter, the spacing of the holes may be increased on the approval of the Engineer. All vertical faces shall be line drilled to prevent damage to the rock beyond the limits of the excavation. Final trimming shall be completed by chiseling wedging, splitting & barring. Prior to blasting, the Contractor shall carry out a test program to confirm the amount of explosives required in blast holes to remove the perimeter rock. The blast holes directly adjacent to the line drilled holes shall be generally loaded lighter and shall be closely spaced than other holes in the primary pattern. The distance between the line drilled holes and the directly adjacent blast holes shall be 50 to 75 per cent of the normal burden. Contractor shall construct and maintain magazine of adequate capacity adhering standard safety norms for storing of explosives required for blasting work.
7.1.2
PERIMETER DRILLING AND PRE-SHEARING Where shown on the approved drawings or specified by the Engineer, vertical faces of excavation shall be formed by perimeter drilling and pre-shearing to the dimensions shown on the approved drawings. The Contractor shall carry out a test program prior to commencing actual perimeter drilling and pre-shearing to determine the correct spacing of the drill holes and amount of explosives required per hole to permit the rock to shear between the holes. The Contractor shall experiment with the spacing of the test holes which may vary from 300 mm to 600 mm depending on the rock characteristics and the amount and type of explosives placed in the holes, so that the rock will break cleanly between the holes with a minimum of shattering of rock on the exterior faces of the excavation.
Section 2.1
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All pre-shearing of vertical faces shall be carried out by the Contractor prior to blasting the interior pattern holes of the excavation so that a sheared line will be established on all vertical faces around the perimeter of the excavation Perimeter drilling and pre-shearing shall be carried out to the full depth of the vertical faces of the excavation, provided the depth of the excavation does not exceed 6 m. If the depth of excavation exceeds 6 m, the pre-shearing shall be staged with the second stage of the pre-shearing carried out after the first stage of the excavation is completed. 7.1.3 BLASTING BY OTHER PROTECTIVE MEASURES Whenever required by the Engineer, the rock blasting shall be carefully controlled so that vibrations generated during the blasting do not cause damage to the buildings and installation around Similarly, the rock pieces should not fly off the pits and thus endanger the buildings and installations around. Apart from the general precautions mentioned in the preceding paragraphs, following protective measures and limits for use of explosives are suggested as guidelines. Tenderer is advised to carefully check the Site conditions and submit the details of the scheme they propose to adopt for controlling the blast. 7.2.0 PROTECTIVE MEASURES Following protective measures shall be adopted while carrying out blasting operations. a) b) c) d) e) The hole shall be covered with 0.6 to 1.0 sq.m. mild steel plate of minimum 6 mm thick. Reinforcement rod mesh not less than 2.0 mm diameter at 150 mm centers in both directions shall be placed over the steel plates. Steel plate and reinforcement shall be inspected after every blasting operation and all twists shall be removed before reuse to the satisfaction of the Engineer. Sand filled bags shall be placed over the mesh suitably covering the whole region under blasting operation. The thickness of covering plate and the kind of dead weight is to be duly approved by the Engineer.
7.3.0
BLASTING OPERATIONS In dry weather and normal dry excavation, ordinary low explosive gun powder may be used on specified approval only. In damp rock, high explosive like gelatin with detonator and fuse wire may be used. In under-water or excavation with substantial seepage causing accumulation, an electric detonation shall be used. Holes for charging explosives shall be drilled with pneumatic drills, the drilling pattern being so planned that rock pieces after blasting will be suitable for handling without secondary blasting Pattern of drill holes should be got approved by the Engineer. The ingredient of the gunpowder shall be of best available quality. The composition shall be as per manufacturer's specification meant specifically for rock-blasting. The same shall be of best make and approved by the Engineer before actual use. Quantity of charge initially 75-80 mm of charge fill shall be used and observations made whether blasting is under full control. If necessary the charge may be gradually increased to 150 mm. Depth of hole Diameter of hole Embedment of fuse inside charge - 1500 to 6000 mm - 30 to 100 mm - Fuse end shall be embedded to a depth of to 1/3 of the depth of the charge. Distance of firing end of the fuse from the charge 15 m to 30m. - 120 Seconds to 150 Seconds - 1.2 m to 1.8 m apart both ways.
Time of blast firing the fuse Disposition of holes

Inclination
- Inclination of the hole to be pointed towards the nondeveloped side of the Site
Number of holes to be taken up per blast - minimum - 8, maximum - 20 or as decided by the Engineer. The holes shall be charged as per following procedure: a) b) c) d) Bottom 50 to 75 mm of the hole shall be filled with dry powder Then the gunpowder shall be fed into the hole to the desired length and lightly tamped with a wooden rod. The fuse wire shall then be inserted to a depth of 1/2 to 2/3 of the depth of the charge. The rest of the hole shall now be filled with dry brick powder or dry murrum.
When the drilled hole encounters water, the charge shall be fed into a steel tube or a plastic tube and inserted to the bottom of the hole. The explosive shall be exploded by means of a primer which shall be fired by a fuse instantaneous detonator (FID.) or other approved cables. The detonators with F.I.D. shall be connected by special nippers When excavation almost reaches the level, hand trimming by barring and chiseling shall have to be done for dressing the surface to the desired level. In case barring and chiseling is not resorted to for the last layer, the Contractor may resort to controlled blasting with the permission of the Engineer However, in this case over break beyond the specified limits, the Contractor should fill it up with the same type and class of material as is proposed to be laid over the excavated portions at his own cost. 7.4.0 CONTROL IN BLASTING In order to safeguard the existing civil structures and the operating power stations/units of Department of Atomic Energy (DAE), the following limitations shall be taken note of by the Contractor while planning for excavation in hard rock. a) b) c) Peak particle velocity of 10 mm per second shall not be exceeded. Peak particle velocity of 3mm per second is prescribed as a safe vibration level for buildings with electrical and electronic equipment installed at the basement. Delay detonators of 500 millisecond are recommended to be used for excavation
When excavation almost reaches the desired level, to dress the surface required level, hand trimming by barring and chiseling shall be resorted to. In case barring and chiseling is not resorted to for the last layer, Contractor may resort to controlled blasting with the permission of Engineer. However, in case of over-break beyond the specified limits Contractor shall fill it up with the same type and class of concrete proposed to be laid over the excavated portions at his own cost. 7.5.0 ELECTRIC BLASTING The Contractor shall resort only to electric blasting unless otherwise specially approved by the Engineer. Only the Supervisor in-charge shall posses the key of the firing apparatus and he shall keep it always with himself. Special apparatus such as capacitor discharge blasting machine shall be used as a source of current for the blasting operations. Power lines shall not be tapped for the purpose. Only approved make firing apparatus can be used on the job. The detonators shall be checked before use. For blasting in series only detonators of the same manufacture and of the same group of electrical resistance shall be used. Such of the electrical lines as could constitute danger for the work of charging, shall be removed from the site or shall be switched off. The firing shall be done with a proper insulating cover so as to avoid short circuiting due to contact with water, metallic parts or rock etc. The use of earth as a return line
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shall not be permitted. The firing cable shall be connected to the source of power only when nobody is in the area of blasting. Before blasting the circuit shall be checked by suitable apparatus such as blasting multimeter of low output. After firing, whether with or without an actual blast, the contact between the firing cable and the source of current shall be cut-off before people are allowed to leave the shelter. During storms, charging with electrical detonators shall be suspended. The charges already placed in the holes shall be blasted as soon as possible, but taking all safety precautions, and giving necessary warning signals. If this is not possible, the Site shall be evacuated till the storm has passed. 7.6.0 PRECAUTIONS AFTER BLASTING After the blast, the supervisor must carefully inspect the work and satisfy himself that all the charges have exploded. After the blast takes place in underground works, the workman shall not be allowed to go to the place till all toxic gases have disappeared from the place. If it is suspected that part of the blast has failed to fire or is delayed, sufficient time shall be allowed to elapse before entering the danger zone. When fuse and blasting caps are used, a safe time should be allowed and then the supervisor alone shall leave the shelter to inspect the blasting zone. None of the drillers are to work near the misfired hole until one of the two following operations have been carried out by the Supervisor Either (i) the Supervisor should very carefully (when the tamping is of damp clay) extract the tamping with a wooden scraper or jet of water or compressed air (using a pipe of soft material), and withdraw the fuse with primer and a fresh detonator with fuse should be placed in this holes and fired out, or (ii) the hole may be cleared of 30 cm of tamping and the direction then be ascertained by placing a stick in the hole. Another hole may thru be drilled at least 60 cm away and parallel to it and about 30 cm less in depth; this hole shall than be charged and fired. The balance of the cartridges and detonators found in the muck shall he removed. Before leaving his work, the Supervisor shall inform the Supervisor of the relieving shift of any case of misfires and should point out the position with a red cross denoting the same and also stating what action, if any, he has taken in the matter. The Supervisor should also at once report at the office of the Contractor and the Engineer all cases of misfire, the cause of the same and what steps were taken in connection with these. The name of the day and night shift Supervisors must be noted daily in the Contractor's office. If a misfire has been found to be due to a defective detonator or dynamite the whole quantity or box from which the defective article was taken, must be thoroughly inspected by the Contractor and if needed isolated Drilling in holes not completely exploded by blasting shall not be permitted. 7.7.0 LIMITATIONS Within 15 meters from existing structures no blasting shall be done without prior approval of the Engineer in writing Contractor shall submit his scheme with charges and delays he proposes to use for blasting for approval of the Engineer. Contractor has to make experiments for the above delay in the presence of Engineer to verify whether the charges and delays lie proposes to use are suitable for the type of work. When blasting is necessary adjacent to partially or completely built structures the contractor shall take all the precautions necessary to prevent flying rock from causing damage to the structures. The Contractor shall be responsible for all damage caused by blasting and shall replace or repair the structures at his own cost. All major blasting shall be completed prior to starting concrete work on site.
Section 2.1
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7.8.0
EXPLOSIVES The Contractor shall acquaint himself with all the laws, and regulations concerning transporting, storing, handling and the use of explosives. All such laws, regulations, rules and safety codes, etc. as are current from time to time shall be binding on the Contractor. The provisions detailed in this specification are supplementary to the above laws, rules and regulations. Further, the Engineer may issue modifications, alterations, and new instructions from time to time. All materials such as explosives, detonators, fuses, tamping materials etc. that are proposed to be used in the blasting operations shall have the prior approval of the Engineer. The Engineer may render necessary help to the Contractor to obtain license for explosives. However, it is the Contractor's responsibility to obtain the license, paying the necessary fees etc. Gun powder, gelatin and other safe explosives only shall be used wherever possible Explosives with nitroglycerine shall be used only under exceptional circumstances with prior approval of the Engineer. The Contractor shall clearly indicate the type and grades of explosive he proposes to use for blasting for different type of work under different conditions and the same shall be approved by the Engineer before commencement of work. However, for the purpose of guidelines in dry weather and normal dry excavation, ordinary low explosives may be used. In damp rock, high explosives like special gelatin shall be used. Special gelatin 80% and opencast gelignite are the explosives recommended for most type of excavation. Where especially hard rock is encountered or exceptionally good fragmentation is required special Gelatin 90% may be used. For initiation, plain detonators and safety fuse, electric detonators (instantaneous and short delay) 'Cordtex' Detonating Fuse and detonating relays may be used Electric short firing is preferred. The use of a fuse with only protective coat is prohibited. The fuse shall be sufficiently water resistant as to be unaffected when immersed in water for thirty minutes. The rate of burning of the fuse shall be uniform and not less than 4 seconds per 25 mm of length with 10% tolerance on either side. Before use, the fuse shall be inspected, and moist, damaged or broken ones, discarded the rate of burning of all new types of fuses, or fuses kept in stock for long, shall be tested before use. The detonators used shall be capable of giving effective blasting of the explosives. All the damaged detonators shall be discarded. The explosives shall be exploded by means of a primer which shall be fired by a fuse instantaneous detonator (FID) or other approved cables. The detonators with FID shall be connected by special nippers.
7.9.0
PERSONNEL Excavation by blasting will be permitted only under the competent and licensed blasters and trained workmen. All supervisors and workmen in charge of make up handling, storage and blasting work shall be adequately insured by the Contractor. Storage shall be in charge of a very reliable person approved by the Engineer, who may, if necessary conduct police inquiries as to his reliability, antecedents etc. The Contractor shall have to produce a security for the person in-charge of the explosives, if and when required by the Engineer, or the civil authorities of the district.
Section 2.1
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The Contractor shall make sure that his supervisors and workmen are fully conversant with all the rules to be observed in storing, handling and use of the explosives. It shall be ensured that the supervisor in charge is thoroughly acquainted with the details of the handling of explosives and blasting operations. 7.10.0 STORAGE OF EXPLOSIVES The Contractor shall have to make necessary storage facilities for the explosives as rules of the local authorities and the Govt. of India. The Contractor shall build a magazine for storing the explosives. The site of the magazine, its capacity and design shall be subject to the approval of the Engineer and the Inspector of Explosives before the construction is taken up. As a rule, the explosives shall be stored in a clean dry, well ventilated, bullet-proof and fire-proof building at an isolated site as approved by the Engineer/ Inspector of explosives. The explosives, detonators and fuses shall each be separately stored in accordance with relevant Govt. rules. 7.11.0 MAINTENANCE OF EXPLOSIVE MAGAZINE A careful and day to day account of the use of explosives shall be kept by the Contractor in an approved register and in an approved manner. The register shall be produced by the Contractor for inspection of the Engineer whenever so required by the latter. The Engineer may also pay surprise visits to the storage magazine. In case of any unaccountable shortage of the explosives or if the account is not found to have been maintained in a manner prescribed by the Engineer, the Contractor shall be liable to be penalized. The action taken under this clause shall be in addition to that which might be taken by the competent civil authorities in a court of law. The magazine shall be at all times be kept scrupulously clean. No unauthorized person should at any time be admitted inside the magazine. The magazine shall, when not in use by authorized person, be kept well and securely locked and guarded. The magazine shall on no account be opened during or on the approach of thunder storm and no person shall remain in the vicinity of the magazine during such periods. Magazine shoes without nails shall, at all times be kept in the magazine and a cement trough 30 cm high and 45 cm. in diameter, filled with water shall be kept near the door of the magazine. Persons entering the magazine must put on magazine shoes, which shall be provided by the Contractor for the purpose. They will also 1 2 3 Not put their feet on the clean floor unless they have the magazine shoes on Not allow the magazine shoes to touch the ground outside the clean floor, and Not allow any din or grit to fall on the clean floor
Person with bare feet, shall before entering the magazine dip their feet in water and then step direct from the tub over the barrier (if there be one) on the clean floor A brush or broom shall be kept in the lobby of the magazine, for cleaning out the magazine on each occasion it is opened, for the receipt, delivery or inspection of explosives. Matches, lighters or inflammable material shall not be allowed in the magazine Light shall be obtained from an electric storage battery lantern. No person having articles of steel or iron on him shall be allowed to enter the magazine. Oily cotton rags waste and articles liable to spontaneous ignition shall not be allowed inside the magazine.
Workmen shall be examined before they enter the magazine to see that they have none of the prohibited articles on their person. No tools or implements other than those of copper, brass, gunmetal, or wood shall be allowed inside the magazine. All tools shall be used with extreme gentleness and care. Boxes of explosives shall not be thrown down or dragged along the floor, and shall be stacked on wooden trestles: where there are white ants, the legs of the trestles should rest in shallow copper, lead or brass bowls containing water. Open boxes of dynamite shall never be exposed to the direct rays of the sun. Empty boxes or loose packing material shall not be kept inside the magazine. The magazine shall have a lightning conductor which shall be got tested at least once in six months by an officer authorized by the Engineer. The Contractor shall within 15 days comply with all recommendations made by the officer testing the lightning conductor. A notice shall be hung in the lobby of the magazine, prohibiting entrance of unauthorized people. The following shall be hung in the lobby of the magazine ; a) A copy of rules both in English, Hindi & in the language which the workers concerned are familiar with. A statement showing the stock in the magazine at the particular time. The certificate showing the last date of testing of the lightning conductor, and A notice that smoking is strictly prohibited.
b) c) d)
The magazine shall be inspected at least twice a year by an officer representing the Engineer, who shall see that all the rules are strictly complied with. He shall notify all omissions to the Contractor who shall rectify the defects within a period of 15 days from the date of receipt of the notice. 7.12.0 TRANSPORT OF EXPLOSIVES For the transport of the explosives and detonators between the store and the site, closed and strong containers made of soft materials such as timber zinc, copper, leather and the like shall be used. 7.13.0 DISPOSAL OF DETERIORATED EXPLOSIVES All deteriorated explosives shall be disposed of in an approved manner. The quantity of the deteriorated explosives to be disposed off shall be intimated to the Engineer, prior to its disposal. 7.14.0 PREPARATION OF PRIMER The primers shall not be prepared near open flames or fifes. The work of preparation of primers shall always be entrusted to the same personnel. Primers shall be used as soon as possible after they are ready. 7.15.0 CHARGING OF HOLES Holes for charging explosive shall be drilled with pneumatic drills, the drilling pattern being so planned that rock muck produced due to blasting can be handled without necessity of secondary blasting. Pattern of drill holes shall be got approved by the Engineer. The work of charging shall not commence before all the drilling work at the site is completed, and the supervisor has satisfied himself to that effect by actual inspection. While charging, open/naked lamps shall be kept away.
Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Detailed Technical Specification Section 2.1 Page : 11 of 15 Earthwork in Excavation & Backfilling
Only wooden tamping rods, without any kind of metal on them, shall be allowed to be used. The tamping rods shall have cylindrical ends. Bore holes must be of such a size that the cartridge can easily pass down the hole. Only one cartridge shall be inserted at a time and gently pressed home with tamping rod -sand or clay or other tamping material used for filling the hole completely shall not be tamped too hard. 8.0.0 8.1.0 VARIATION IN EXCAVATION Bad Soil Should the bottom of any excavation at design depth appear to be soft, unsound or unstable, the Contractor shall report the matter to the Engineer and if the Engineer so directs, shall excavate the same to indicated depths. The extra depth shall be filled up with concrete or such other materials as the Engineer shall direct. Such extra excavation and filling shall be paid for at appropriate item rate. 8.2.0 Excavation Too Deep If the Contractor excavates to levels deeper than those shown on drawings for any reason other than those stated in Clause 8.1.0, he shall fill it up at his own expense to the proper level with lean concrete 1:4:8 or sand filling as directed. No payment will be made for excavation taken down to depths more than those shown on the drawings or for the filling carried out as directed. 8.3.0 Slips and Falls Every precaution shall be taken against slips and falls of earth, clay, sand or other materials in the excavations, but in the event of any such occurring, the Contractor shall at his own expense make good the space affected by slips or falls even if the affected area is outside the dimension of the work ordered. The Engineer will determine in each case whether such affected area is to be filled up in whole or in part with concrete, brickwork or masonry of the quality used in the adjoining work or where only a part is to be so filled, the materials to be used for this remaining part. The methods of excavation shall be in every case be subject to the approval of the Engineer and the Contractor shall ensure the stability and safety of the excavations, adjacent structures, services and the works. If in the opinion of the Engineer there is a possibility of the newly constructed work having been damaged or disturbed by such collapse, the work shall be laid bare at the expense of the Contractor for inspection. Any damage caused shall be made good by the Contractor, at his own expense. 8.4.0 Soil/Sub-soil Water Condition Boring and sub surface data regarding the nature of soil, sub-soil water furnished to the Contractor shall be taken as guidance only and variation there from shall not affect the terms of Contract. The Contractor must satisfy himself regarding the character and volume of all work under this item and expected surface, and/or sub-soil water to be encountered. 9.0.0 KEEPING WORKS SITE FREE FROM WATER Dewatering The Contractor shall ensure that the excavation and the structure are free from water at all stages of construction and shall take all necessary precautions and measures to exclude ground water and water from other sources such as underground streams, aquifers, springs, artisans,
precipitation or infiltration from the surface flows etc. so as to enable the works to be carried out in dry condition in accordance with the construction schedule. The contractor shall dewater and maintain reasonably dry at all times the excavated pits by use of suitable pumps to baling out water or other approved means for all the structures within the scope of work. Dewatering shall also done for all other areas of the site where buildup of water in the opinion of the purchase obstructs the progress of work, leads to unsanitary conditions by stagnation, retards the speed of construction, is detrimental to the safety of men, materials, structures, equipment and such other causes. Pumping The Contractor shall provide and operate pumps and all other equipment necessary to drain the sub-soil water, rain water etc. to the nearest sewer or drain through properly laid pipes or channels and keep excavation pits, trenches etc. free from water at all times during excavation, backfilling and the continuance of the contract. Adequate care shall be taken to prevent movement of water through freshly laid concrete or masonry work. Sumps made for dewatering shall be kept clear of the foundation. Method of dewatering shall be approved by the Engineer but in no case the pumping arrangement shall be such that there is any movement of sub-soil or blowing-in due to differential head of water during pumping. 10.0.0 PROTECTION OF WORK The Contractor shall support and maintain adjoining and abutting property and structures to render work safe to persons and property. The Contractor shall provide necessary decking, guard, fencing, planking with red flags and red lights at night to maintain safe pedestrian and vehicular traffic near all open excavations. The contractor shall provide and maintain proper approaches for workmen and for inspection. The roads and approaches around the excavated pits should be kept clear at all times so that, there is no hindrance to the movement of men and materials and equipment of other agencies connected with the project. 11.0.0 SHORING AND STRUTTING Shoring and strutting shall be used as directed when excavation is to be carried out in soft or slushy soil which is likely to collapse during the excavation of the work. The shoring shall be either open or close boarded type depending on the nature of the soil and depth of excavation and the type adopted shall be as directed by the Engineer. While excavating in very unstable ground requiring support throughout the period of excavation, runners shall be used and shall be driven always in advance of the excavation. The size and spacing of different members to be used in shoring shall be as directed by the Engineer, depending on the site conditions. If however slips do occur, the same shall be removed by him and backfilled later by him at his own expense. The withdrawal of shoring & shoring material shall be done very carefully to prevent the collapse of pit or trench. No claim shall be entertained for any material which cannot be removed and is lost or buried. Necessary side slope as per the soil investigation report and horizontal berm at suitable intervals shall be provided to avoid the shoring and strutting based on the availability of space in the site. 12.0.0 DISPOSAL The excavated earth shall be disposed off in the following manner or as directed by the Engineer:
i)
By keeping separately the materials suitable for backfilling/ area filling and material not suitable at areas to be designated by the Engineer but within the stipulated lead. The excess material remaining after back-filling/ area filling shall be spread evenly so as to allow natural flow of water in the area. BACKFILLING AND FILLING IN PLINTH Earth used for filling shall be free from organic and other objectionable matter. As far as possible, materials obtained from excavation in foundation shall be used. The earth shall be basically CNS soil (Cohesive Non-Swelling Soil). All clods of earth shall be broken or removed. Where excavated material is mostly rock, the boulders shall be broken into pieces not bigger than 150 mm in size and mixed with fine materials consisting of decomposed rock, moorum or earth and the mixture shall be used for filling. Highly expansive soils like black cotton soil shall not be used for filling. Sand if used for filling shall be free from dust, organic and other objectionable matter and shall not contain more than 10% of clay. Fill materials shall not be dropped directly upon or against any structure or facility where there is danger of displacement or damage. Filling shall be started after the concrete / masonry has fully set and shall be carried out in such a manner so as not to cause any undue lateral thrust on any part of the structure. All space between foundation (concrete or masonry) and the sides of excavation shall be filled to the original surface after making allowance for settlement. Fill shall be placed in horizontal layers not exceeding 200 mm loose thickness. Each layer shall be watered and compacted with proper moisture content and with such equipment as may be required to obtain a compaction/ density as specified. Trucks or heavy equipment for depositing or compacting fill shall not be used within 1.5 meters of building walls, piers, or other facilities which may be damaged by their weight or operation. The methods of compaction shall be subject to the approval of the Engineer. Pushing of earth for filling shall not be adopted under any circumstances. Fill adjacent to pipes shall be free of stones, concrete etc. When filling has reached the appropriate level, the area shall be flooded with water for a minimum period of 24 hours to allow the fill to settle. The filling shall be allowed to dry and then compacted and dressed to the required level. All filling work shall be finished with a top earth cushion consisting of locally available soil/ excavated earth of specified thickness overlying the ash/ earth fill. Filling in trenches for pipes shall be commenced as soon as the joints of pipes have been tested and passed. Filling of trenches shall be carried out simultaneously on both sides of pipes to avoid unequal pressure on the pipe. The earth shall be spread on the sides and top of the pipes in layers not exceeding 200 mm (uncompacted thickness), watered, rammed and consolidated, taking care that no damage is caused to the pipe below.
ii)
13.0.0
14.0.0 14.1.0
TESTING AND ACCEPTANCE CRITERIA Excavation On completion of excavation, the dimensions of the pits will be checked as per drawings after the pits are completely dewatered. The work will be accepted after all under-cuts are set right all over excavations are filled with lean concrete or compacted earth as directed and all necessary shoring strutting done, all temporary approaches to the bottom of trenches provided, all to the satisfaction of the Engineer.
14.2.0
Backfilling /Plinth Filling The plinth shall be filled with earth as described herein-before in layers not exceeding 15 cm, watered and consolidated with approved compaction machine or manually if specifically permitted by the Engineer, where mechanical compaction is not possible in the opinion of the
Section 2.1
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Engineer. When the filling reaches the finished level, the surface shall be flooded with water for at least 24 hours allowed to dry and then rammed and consolidated in order to avoid settlement at a later stage. The finished level of the filling shall be trimmed to slope intended to be given to the floor All filling shall be done to the compaction specified in schedule of items. The backfilling work will be accepted only after the Engineer is satisfied with the degree of compaction. 14.2.1 CONTROLLED BACKFILLING In Areas shown by the Engineer, controlled backfilling shall be done using selected material. Prior to backfilling, modified Proctor Density tests shall be conducted on the material to be used for backfilling. The material shall be spread in un-compacted layers (after removing/breaking clods, etc.) of thickness 200 mm and rolled by sheep-foot roller or any other mechanical methods approved by the Engineer. Adequate number of passes will be made such that the dry density is not less than 95% of modified proctor dry density. At least one field density test by sand replacement method as per IS 2720 Part XXVIH shall be conducted on every alternate layers per 100 sq. meter area, to check the effectiveness of compaction, or as directed by the Engineer.
Section 2.1
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VOLUME II SECTION 2.2 TECHNICAL SPECIFICATION FOR PLAIN AND REINFORCED CONCRETE WORK
Section 2.2
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Plain and Reinforced Concrete Work
SECTION 2.2 TECHNICAL SPECIFICATION FOR PLAIN AND REINFORCED CONCRETE WORK
CONTENTS
CLAUSE NO. 1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0 9.0.0 10.0.0 11.0.0 12.0.0 13.0.0 14.0.0 15.0.0 16.0.0 17.0.0 18.0.0 19.0.0 20.0.0 21.0.0
DESCRIPTION
PAGE NO.
SCOPE .............................................................................................. 3 CODES AND STANDARDS ............................................................... 3 MATERIALS ....................................................................................... 5 GRADES AND PROPORTIONING .................................................... 6 MIXING .............................................................................................. 6 PLACING ........................................................................................... 6 COMPACTION ................................................................................... 7 CONSTRUCTION JOINTS ................................................................. 7 CURING AND PROTECTING ............................................................ 8 FINISHING ......................................................................................... 8 FORMWORK & CENTERING ............................................................ 8 REINFORCEMENT .......................................................................... 13 STEEL EMBEDMENTS .................................................................... 14 EXPANSION & ISOLATION JOINTS ............................................... 14 PRECAST CONCRETE ................................................................... 17 WATERPROOFING OF CONCRETE TO STRUCTURES ............... 18 TESTING.......................................................................................... 20 ACCEPTANCE CRITERIA ............................................................... 21 STORAGE AND HANDLING OF MATERIALS ................................. 24 PILING WORKS ............................................................................... 26 ROCK ANCHORS ............................................................................ 30
Section 2.2
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SECTION 2.2 TECHNICAL SPECIFICATION FOR PLAIN AND REINFORCED CONCRETE WORK 1.0.0 SCOPE This specification covers the requirement in respect of materials, workmanship and quality for plain and reinforced concrete for all types of structures in foundation and superstructure. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and methods of testing. Some of the relevant available codes are listed hereunder: Cement IS: 269 IS: 4032 IS: 6452 IS: 8041 IS: 8112 IS: 12330 IS : 455 Aggregate IS: 383 IS: 2386 IS: 2430 Coarse and fine aggregates from natural sources for concrete Methods of test for aggregates for concrete Methods of sampling of aggregates for concrete Ordinary and low heat Portland cement Method of chemical analysis of hydraulic cement. High alumina cement for structural use Rapid hardening Portland cement High strength ordinary Portland cement Sulphate resisting Portland cement Blast furnace slag cement
Concrete Plain and Reinforced IS: 456 IS: 460 IS: 516 IS: 1199 IS: 1607 IS: 1834 IS: 2645 IS: 2750 IS: 2974 IS: 3370 Code of practice for plain and reinforced concrete Test sieves Methods of test for strength of concrete Methods of sampling and analysis of concrete Methods for test sieving Hot applied sealing compounds for joints in concrete Integral cement water proofing compounds Steel scaffolding Code of practice for design and construction of machine foundations Code of practice for concrete structures for the storage of liquids
IS: 9013
Method of making, curing and determining compressive strength of accelerated cured concrete test specimens.
IS: 9103 IS: 9893 IS: 10262 IS: 10297
Admixtures for concrete Precast concrete lintels and sills Recommended guidelines for concrete mix design. Code of practice for design and construction of floors/roofs using pre-cast reinforced/pre-stressed concrete ribbed or cored slab units.
IS: 10566
Methods of tests for pre-formed fillers for expansion joints in concrete paving and structural construction
IS: 10790 Steel IS: 432
Methods of sampling of steel for pre-stressed and reinforced concrete.
Mild steel and medium tensile steel bars and hard-drawn steel wire for concrete reinforcement
IS: 1566 IS: 1568 IS: 1786 IS: 2502 IS: 2751
Hard-drawn steel wire fabric for concrete reinforcement Wire cloth for general purposes High strength deformed steel bars and wires for concrete reinforcement Code of practice for bending and fixing of bars for concrete reinforcement Code of practice for welding of mild steel plain and deformed bars used for reinforced concrete construction.
ASTM STANDARDS ASTM C-33 ASTM C-94 ASTM C-295 ASTM C-494 Specification for Concrete Aggregates. Specification for Ready Mixed Concrete Guide for Petrographic Examination of Aggregates for Concrete Specification for chemical admixtures for concrete.
ASTM C1202 Test method for electrical indication of concrete ability to resist chloride ion penetration. ASTM C-1240 Specification for use of silica fume as a Mineral Admixture in HydraulicCement concrete, Mortar and Grout. ASTM C1260 Standard test method for Potential Alkali Reactivity of Aggregate (Mortar Bar Method) ASTM D75 Sampling of Aggregates
ASTM D1411 Test methods for Water Soluble chlorides present as admixtures in graded aggregate road mixes. ACI / ASME CODES AND SPECIFICATIONS ACI 211.1 Standard Practice for selecting proportions for normal, Heavy Weight and mass concrete.
ACI 304.1R.
Guide for the use of Preplaced Aggregate Concrete for Structural and Mass concrete Applications.
ACI 304.2 ACI 318
R Placing Concrete by Pumping Methods. Building code requirements for structural concrete and commentary.
OTHER STANDARDS a) b) c) d) Railway Specifications Tests for chloride and sulphate content of aggregates. The European guidelines for Self Compacting Concrete Specification, Production and Use (EFNARC Publication). DIN-1048 Specification for water permeability of concrete. Concrete library of JSCE No. 36 Recommendations for construction of concrete containing ash as a mineral admixture JSCE Concrete engineering series 31-Recommendation for self-compacting concrete BS6699-Specifications for Ground Granulated Blast Furnace Slag for use with Portland cement
e)
f)
3.0.0
MATERIALS All materials that shall be used for works covered under this specification shall conform to following standards / specification. 1. Aggregate 2. Cement 3. Reinforcement Machine crushed blue granite conforming to IS: 383 Blast furnace Slag cement conforming to IS 455 Sulphate Resisting Portland Cement conforming to IS: 12330 High strength deformed steel bars (Fe 500) Conforming to IS: 1786 / IS: 1566 Conforming to IS: 2062 18 SWG annealed iron wire Approved non extruding, resilient fillers River or pit sand conforming to IS: 2116 PVC/Rubber/Metallic - GI, Aluminum, copper Conforming to IS: 9103 Clean, potable conforming to IS: 456.
4. Embedded plates5. Binding wire 6. Joint filler 7. Sand 8. Water stops 9. Admixtures 10. Water -
Source of coarse & fine aggregate shall be approved by the Engineer. Admixtures shall be used only after getting permission from the Engineer and as per the instruction of the manufacturer.
Section 2.2
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4.0.0
GRADES AND PROPORTIONING Any grades of concrete designated in IS: 456 as shown on the drawings or as per the Engineer's instructions shall be used. As far as possible design mix concrete shall be used on all concrete work. That is, the concrete mix shall be designed with preliminary tests. The mix shall be designed as per "Handbook on concrete mixers", SP: 23, BSI while designing the mix, the strength, durability, minimum cement content, maximum water ratio allowed and work ability necessary for the job by most economical use of the various ingredients shall be considered by the Contractor. The water cement ratio, coarse aggregates and grading for each mix shall be predetermined from the results of cube tests of trial mixes. The mix proportions determined thus shall be followed at site and shall in no way relieve the Contractor of his responsibility as regards the prescribed strength mix. The theoretical consumption of cement will be calculated based on cement per cubic metre of concrete as per design mix. In case, the Contractor has to use more than the minimum cement content specified, no increase in rate is payable due to the extra cement consumed and the extra cement consumed will be deducted at specified issue rates. The mix proportions, however, shall be revised if the results of the cube tests during the construction show consistently lower than the prescribed one. No claim to alter the rates of concrete work will be entertained due to such changes in mix designs, as the Contractor will be responsible to produce the concrete of required grade. The aggregates may be measured by volume. The maximum size of aggregates used shall be as indicated in IS: 456 or in Schedule of Items. Nominal mix concrete in accordance with IS: 456 for grade M 30 or lower may the used if shown on drawings or approved by the Engineer. In all cases the proportioning of ingredients and works control shall be in accordance with IS: 456 and shall be adopted for use after the Engineer is satisfied regarding its adequacy and after obtaining his approval in writing.
5.0.0
MIXING Mixing should be carried out in mechanical mixers. Hand mixing can however be permitted by Engineer in special cases subject to additional 10% extra cement without extra cost. When hand mixing is permitted, it shall be carried out on a clean, hard and water tight platform. Water cement ratio shall be rigidly controlled during mixing. Mixers shall be fitted with automatic devices to discharge measured quantity of water to the mixing pan. The water shall not be admitted to the drum until all the cement and aggregate constituting the batch are thoroughly mixed. Mixing shall continue until the concrete is uniform in colour and not less than 2 minutes and forty (40) revolutions after all the material and water are in the drum. Regular checks on mixer efficiency shall be carried out as directed by the Engineer. Only those mixers whose efficiencies are within the tolerances specified in IS: 1791 will be allowed to be employed. Batching plant where used shall conform to IS: 4925. The entire content of the drum shall be discharged before the ingredients for next batch are fed into the drum. No partly set or remixed or excessively wet concrete shall be used. Such concrete shall be immediately removed from site. Each time the work stops the mixer shall be thoroughly cleaned and when the next mixing commences, the first batch shall have 10% additional cement at no extra cost to the Owner to allow for loss in the drum.
6.0.0
PLACING Concrete shall be transported from the mixing plant to the forms as rapidly as possible by means which will prevent segregation, consolidation or drying out in hot weather. Concrete shall be placed within thirty (30) minutes after commencement of mixing. At the
Section 2.2
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time of placing concrete in very hot weather, care shall be taken to see that the o temperature of wet concrete does not exceed 38 C. Before placing concrete, all formwork, embedments and reinforcement shall be checked for completeness, location, dimension. It should also be square and plumb. All chips and saw dust or other foul matter shall be removed from within the forms. The base surface shall be well moistened and puddles wiped up. Earth foundation on which direct placement of concrete is allowed will be rammed and consolidated as directed by the Engineer such that it does not crumble and get mixed up with the concrete during or after placement, before it has sufficiently set and hardened. Concrete will always be placed against moist surface but never on pools of water. In case the foundation cannot be dewatered completely, special procedure and pre-caution, as directed by the Engineer will have to be adopted. A layer of mortar of thickness between 12 mm to 25 mm as directed, of the same or less W/C ratio and the same proportion as that of concrete being placed and /or cement slurry will be spread thoroughly on the foundation or construction joint just prior to placement of concrete. The cost of application of such cement slurry and/or mortar will be deemed to be included in the unit rate of concrete. Placing equipment and accessories shall be kept clean and free of partially set grout and concrete, and maintained in proper working order. Walking on reinforcement layers is not permissible. Walkways of wooden planks or similar can be placed with removal supports and should be independent of reinforcement. In general, placing shall be direct, by transporting buckets. Where it is necessary to deposit the concrete at level differences of more than 1.5 m, short chutes shall be used. Short chutes and hoppers shall be so designed and installed that segregation will not take place. In cases where chutes are impracticable due to excessive drop to placing level, hoppers and sectional tubes (elephant trunks) shall be used. After the concrete has been placed, it shall be spread, if necessary and thoroughly worked around reinforcement or other embedded fixtures into concrete form and shape. Vibrators shall not be used for pushing the concrete into the adjoining areas. Care must be taken to ensure that the inserts, fixtures, reinforcement and formwork are not displaced during or immediately after the placement and bring the concrete surface out of the alignment beyond tolerance limits, the Engineer may direct to remove the portion and reconstruct or repair the same at the Contractor's expense. The rate of placement of concrete shall be such that no cold joint is formed and fresh concrete is placed always against green concrete which is still plastic and workable. No concrete shall be placed in open, while it rains. During rainy season, no placement in open is to be attempted unless sufficient tarpaulins or other similar protective arrangement for complete covering the still green concrete from rain is kept at the site of placement. If there has been any sign of washing of cement and sand, the entire affected concrete shall be removed immediately. 7.0.0 COMPACTION Concrete in general shall be consolidated by vibration using high frequency mechanically driven vibrators. Concrete shall be placed in layers at least 300 mm deep in walls and approximately 450 mm in mass pouring. Vibrators shall not penetrate more than 50 mm into the surface of previously placed layers but shall completely vibrate the working layer. Care shall be taken not to over-vibrate any concrete and especially those with higher slumps. Under no circumstances vibrators shall be attached to or allowed to touch reinforcement. Spare vibrators in good operating condition shall be on hand during placing operations. 8.0.0 CONSTRUCTION JOINTS In general, construction joints shall be limited to those indicated on the drawings. In mass concrete, construction joints may not be indicated in the drawings but shall be made at
breaks, offsets or other convenient levels as controlled by volume, plant capacity and time factors. Such construction joints shall be so located that they do not impair the strength of the structure. In walls and columns, height of each lift shall not generally exceed 1.5 m unless otherwise specified in the drawings or directed by the Engineer. Method of forming all construction joints shall conform to the provisions of IS: 456. All construction joints shall be cleaned with wire brush and water to remove all laitance and loose material to expose the aggregates. Immediately before placing fresh concrete, the surface of previously placed concrete shall be coated with a thin coat of cement mortar slurry of the same proportion as that of concrete. Where locations of the joints are not specified, it will be in accordance with the following: a. In a column, the joint shall be formed 75 mm below the soffit of the beam or the edge of the anchored bars of the beam framing into it whichever is lower. The Contractor shall refer to the beam reinforcement drawing before deciding on the location of the joint at column-beam junction. Concrete in a beam shall preferably be placed without a joint, but if provision of a joint is unavoidable, the joint shall be vertical and at the middle one third of the span, clearing the cross beam location, if any. A joint in a suspended floor slabs shall be vertical and at the middle one third of the span and at right angles to the principal reinforcement. In general, construction joints shall be located preferably in a low shear stress zone and at right angles to the direction of the principal stress. Any deviation from the above shall be approved by the Engineer.
b.
c.
d.
As soon as the concrete has hardened sufficiently, hardened it shall be covered either with sand, Hessian, canvas or similar materials and kept continuously wet for at least seven (7) days after final setting. Curing by continuous sprinkling of water will be allowed if the Engineer is satisfied with the adequacy of arrangements made by the Contractor. 9.0.0 CURING AND PROTECTING Curing of concrete with water shall comply with IS: 456. Curing compound shall be used subject to approval by the Engineer. Finished floors shall be protected carefully until completely set. Protection of concrete against extreme weather conditions shall comply with the code. 10.0.0 FINISHING No touching-up will be permitted to the concrete after removal of formwork. Where damages, honey-combing or other unsatisfactory finishes have occurred to the concrete surfaces, they shall be rectified in a manner as directed by the Engineer, at no extra cost. If in the opinion of the Engineer the concreting is unsatisfactory, demolition of the entire concrete work and reconstruction of the same shall be carried out by the Contractor, as directed by the Engineer at his own cost. 11.0.0 FORMWORK & CENTERING Form work in general shall conform to IS: 456. For complicated work, the contractor shall submit his proposal of formwork before starting the work for approval of the Engineer. The number of props, their sizes and dispositions shall be such as to be able to safely carry the full dead load and constructional loads.
However, approval of the Engineer to this effect shall not relieve the contractor of his responsibility for proper work and safety. All forms of beams, slabs and members shall be so designed and erected that the sides can be removed without disturbing the soffit shutter and supports there to. Beam soffit shall be provided with an upward, camber of 6mm for each 3M of horizontal span or as directed by the Engineer. Vertical props shall be supported on wedges or sole plates or other measures where by the props can be gently lowered while commencing to remove the shuttering. Columns shuttering shall not be over 1.5 M in height a piece. Before removal of the shuttering the concrete shall be examined and its removal order taken from the Engineer. In no circumstance shall forms be struck until the concrete reaches strength of at least twice the stress to which the concrete may be subjected at the time of striking. Shuttering shall not be removed until the number of clear days specified in IS: 456 have elapsed since the last day of placing concrete in the member concerned. All formwork shall be removed without such shock or vibration as would damage the reinforced concrete. Before the soffits and struts are removed, the concrete surface shall be exposed, where necessary, in order to ascertain that the concrete has sufficiently hardened. The specified period may be extended if desired by the Engineer on account of delayed hardening caused by low atmospheric temperature. 11.1.0 Quality Assurance A. Requirements: All formwork shall be constructed of sheet metal or other approved material. It shall be firmly supported, adequately strutted, braced and tied to withstand the placing and vibrating of concrete and the effects of weather. Design of structures shown on the Engineers drawings does not include any allowance or consideration for imposed construction loads. One copy of the contractors shoring and formwork drawings shall be submitted to the Owner for record purpose only and not for review or approval. Forms, shoring and false work shall be adequate for imposed live and dead loads including equipment and men, height of concrete drop, concrete and foundation pressures and stresses, wind pressures, lateral stability, and other safety factors during construction. The Contractor shall be held solely responsible for any failure and for the safety of work and workmen. He shall pay necessary compensation, if need be, for damages to work, property and injuries to persons. The scaffolding, hoisting arrangements and ladders shall have easy approach to work spot and afford easy inspection. B. Standards and Tolerances: All formwork shall be fabricated in compliance with the best modern practice, so that the finished surface is even, unblemished, free of fins and true to line, level and shape as shown by the drawings. The forms shall comply with the requirements of IS: 4562000. i. Faces of formwork in contact with concrete shall be free from adhering foreign matter, projecting nails and the like, splits or other defects and all form work shall be clean and free from standing water, dirt, shavings, chippings or other foreign matter. Joints shall be watertight to prevent the escape of mortar and cement slurry or the formation of fins or other blemishes on the face of the concrete. Openings for inspection of the inside of the formwork and for the removal of water used for washing down shall be provided. Before placing concrete all bolts, pipes
ii.
or any other fixtures which are to be built in shall be fixed in their correct positions and cores and other devices for forming holes shall be held fast by fixing to the formwork or otherwise. C. Formwork Coating: The coating on all formwork shall be of non-staining mould oil that will not leave residual matter on surface of concrete or adversely affect bonding to concrete of any subsequent paint, plaster, mortar or other applied materials. Coatings containing mineral oil, paraffins, waxes or other non-drying ingredients are not permitted. For concrete surfaces contacting potable stored water, the coatings and form release agents shall be completely non-toxic. Care shall be taken to prevent the coating from coming into contact with reinforcement or with concrete at construction joints. 11.2.0 Materials Timber Timber shuttering shall be fabricated from partially seasoned timber, which shall not warp under the effects of the ambient temperature and humidity. Boards shall be strong enough to withstand the stresses imposed on the shuttering without flexing. The planks shall be sawed straight and all edges and planes shall be straight and free from warp. Joints All joints shall be bonded to prevent loss of grout during concerning. Plywood Plywood shall conform to IS:4990-1993 and shall be braced as necessary. Wooden forms shall be lined with plywood. Metal Forms Metal forms shall be true to detail, in good condition, clean, free from dents, bends, rust and mineral oils. They shall be of adequate gauge with appropriate angle frames. Moulds For grooves, drips, rebates, profiles, chamfers, and similar items, smooth finished timber coated with specified form coating shall be used. 11.3.0 11.3.1 Execution Scaffolding Scaffolding required for facility of construction shall be provided by the Contractor at his cost. Scaffolding shall be double or single as warranted for the particular class of Masonry and other works. Scaffolding shall be created with steel sections or pipes, ballies or bamboos of adequate strength to satisfy construction operations. The Contractor shall take all measures to ensure the safety of the work and working people. Any instructions of the Engineer in this respect shall also be complied with. The Contractor shall be entirely responsible for any damage to property or injury to persons resulting from ill erected scaffolding, defective ladders and materials or otherwise arising out of his default in this respect. Proper scaffolding shall be provided to allow easy approach to every part of the work. Overhead work shall not be allowed. Holes shall be
Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Detailed Technical Specification Section 2.2 Page : 10 of 31 Plain and Reinforced Concrete Work
made good by stones to match the face works when scaffolding is removed after ensuring that all holes behind are solidly filled with cement concrete M20 before plastering. 11.3.2 Shoring on Trenches and False Work for Concrete The loads shall be properly distributed over base area on which shoring is erected, either concrete slabs or ground; if on ground, it shall be protected against undermining or settlement. The forms shall be constructed to produce in finished structure all lines, grades, and camber as required. Jacks, wedges, or similar means shall be used and firmly anchored to take any settlement in formwork which may be occur camber for beams and slabs shall be as indicated. Form Construction Forms shall be built to exact shapes, sizes, lines and dimensions as required obtaining accurate alignment, location and grades, and level and plumb work in finished structures. Provision shall be made for openings, offsets, keyways, recesses, mouldings, reglets, chamfers, blocking, joint screeds, bulkheads, anchorages, and other required features. Forms shall be made for easy removal without hammering or prying against concrete. Metal spreaders may be used to provide accurate spreading of forms. Construction of form shall be such that there will be no sagging, leakage, or displacement occurring during and after pouring of concrete. Forms shall be coated with specified coating material only prior to placement of reinforcing steel; and coating material shall not come into contact with reinforcing bars. A. Slopes: Formwork shall be provided for the top surfaces of sloping work where the slope exceeds fifteen degrees from the horizontal (except where such top surface is specified as spaded finish) and shall be anchored to enable the concrete to be properly compacted and to prevent floatation, care being taken to prevent air being trapped. B. Chamfers: All exterior horizontal angles on the finished concrete of 90 degrees or less along the tops of walls shall be given 20mm x 20 mm chamfers. C. Ties: No ties or bolts or other device shall be built into the concrete for the purpose of supporting formwork without the prior approval of the Engineer. No part remaining embedded in the concrete shall be nearer than 50 mm from the surface in the case of reinforced concrete and 150 mm in the case of Plain concrete. Holes left after removal of such supports shall be neatly filled with 1:3 dry-pack mortars, which shall contain just sufficient water to make it plastic. It shall be well rammed into the hole and finished flush. D. Form Windows: Windows shall be provided in the formwork wherever directed or necessary for access for concrete placement and vibration. Windows shall be of size adequate for tremies and vibrators, spaced at maximum 1.8 mm centres horizontally, and shall be tightly closed and sealed before placing higher concrete. E. Cleanouts and Cleaning: Temporary openings shall be provided in wall, column and slab formwork for cleaning and inspection. Prior to pouring, all forms and surfaces shall be cleaned and coated to receive concrete.
F. Re-Use: Form material shall be cleaned and reconditioned before re-use. 11.4.0 Field Quality Control A. Control during Concrete Placement: Required slab and beam cambers shall be checked and correctly maintained as concrete loads are applied on forms. Workmen shall be assigned to check forms during concrete placement and to promptly seal any mortar leaks. B. Defects in Formed Surfaces: Workmanship in formwork and concreting shall be such that concrete surfaces shall be perfectly compacted and smooth. If any blemishes are revealed after removal of formwork, the Engineers decisions concerning remedial measures shall be obtained immediately. These measures may include, but shall not be limited to the followings: i. Fins, pinhole bubbles, surface discolouration and minor defects may be rubbed down with sacking immediately after the formwork is removed. Abrupt and gradual irregularities may be rubbed down with carborundum and water after the concrete has been fully cured. These and any other defects shall be remedied by; methods approved by the Engineer, which may include using a suitable epoxy, resin or, where necessary, cutting out to a regular dovetailed shape at least 75 mm deep and refilling with concrete over steel mesh reinforcement sprung into the dovetail.
ii.
Removal of Forms and Shoring: Formwork shall be so designed as to permit easy removal without resorting to hammering or levering against the surface of the concrete. The periods of time elapsing between the placing of the concrete and the striking of the formwork shall be as approved by the Engineer after consideration of the loads likely to be imposed on the concrete and shall be in any case be not less than the periods shown below, depending on the ambient temperature. S.No. Location of Form Time for striking using ordinary Portland cement 16 to 24 hrs
a)
Vertical formwork to Column walls and beams Soffit form works to slabs (props to be re-fixed after removal of form work) Props to slab I) Spanning up to 4.5 m. ii) Spanning over 4.5 m.
b)
3 days
c)
7 days 14 days 7 days
d) e)
Beam soffit (Props left under) Removal of props under beams and arches i) Beam soffit up to 6 m.
14 days
S.No.
Location of Form
Time for striking using ordinary Portland cement 21 days
ii) Beam soffit over 6 m.
Sequence of striking formwork shall be approved by the Engineer in important structures. Notwithstanding the foregoing the Contractor shall be held responsible for any damage arising from removal of formwork before the structures is capable of carrying its own weight and any incidental loading. The Contractor shall be wholly responsible for repairing or reconstruction as directed by the Engineer the section of the Works so affected. 1. Shoring and False work Removal: In retaining wall construction shoring and false work shall not be removed until 21 days after concrete placement or until concrete has attained at least 90 percent of the 28 days design compressive strength. 2. Restriction: Construction equipment or permanent loads shall not be imposed on columns, supported slabs, or supported beams until concrete has attained the 28 days design compressive strength as demonstrated by control test cylinders. 3. Concrete Curing During Removals: Concrete shall be thoroughly wetted as soon as forms are first loosened and shall be kept wet during the removal operations and until curing media or sacking is applied. Potable water supply with hoses or buckets shall be ready at each removal location before removal operations are commenced. 12.0.0 REINFORCEMENT The reinforcement bending shall be carried out as per the approved bar bending schedule prepared based on design drawing and availability of reinforcing bar in Owner's stores. Workmanship shall conform to IS: 2502. All reinforcement shall be free from loose mill scale, rust, oil, grease and paint. Reinforcement shall not be bent or straightened in a manner that will injure the materials and all bars shall preferably be bent cold. Hot bending shall not be permitted for bars whose strength has been increased by cold working. Reinforcement bars shall be placed and maintained accurately in positions as shown in the drawings. The correct cover to the reinforcement shall be maintained by use of precast concrete blocks. All intersections of longitudinal and transverse bars or stirrups and all laps shall be securely tied together with approved binding wire. The binding wire shall be so placed that it touches all the four corners of the intersection and the two ends shall be looped with pliers and the ends shall be turned into the body of the concrete. The cost of the binding wire and spacer/ cover blocks shall be included by the Contractor in his rate for reinforcement work. Welded joints may be used but in all cases of important connections, tests shall be made to prove that the joints are of the full strength of bars connected. Welding shall be done in accordance with IS: 2751 and special precautions shall be adopted for cold worked bars. Butt welding between the ends of a rod in line, whereby stress is transferred across the
section may be adopted only for mild steel bars. In case of tack welding for fixing reinforcements in their position, no special precaution need be taken. 13.0.0 STEEL EMBEDMENTS All embedments shall be accurately set, rigidly fastened and suitably anchored by welding lugs. Anchor bolts shall be set to template and firmly secured in vertical and horizontal line and required positions. Exposed surfaces of embedded materials are to be painted with one coat of red oxide zinc chrome and/ or bituminous paint. Correct location and alignment as per drawings/instruction of all anchor bolts, anchor sleeves, inserts, hangers, conduit pipes and other embedded fixtures shall be entirely the responsibility of the Contractor. 14.0.0 14.1.0 EXPANSION & ISOLATION JOINTS General Expansion and isolation joints in concrete structures shall be provided at specified places, as per details indicated on the drawings. The materials and types of joints shall be as specified hereinafter. In case of liquid retaining structures, additional precautions shall be taken to prevent leakage of liquids as may be specified on the drawings or as directed by the Engineer. All materials are to be procured from reliable manufacturers and must have the approval of the Engineer. Where it is the responsibility of the Contractor to supply the material, the Engineer may demand test certificates for the materials and/or instruct the Contractor to get them tested in an approved laboratory free of cost to the Owner. Approved samples of the material to be incorporated in the works shall be with the Engineer. Joints shall be formed true to line, level, shape, dimension and quality as per drawings and specifications. Prior approval of the method of forming the joints should be obtained from the Engineer before starting the work. 14.2.0 Bitumen Board/ Expanded Polystyrene Board Bitumen Board Bitumen impregnated fibre board of approved manufacturer as per IS: 1838 may be used as fillers for expansion joints. It must be durable and water proof. It shall be compressible and possess a high degree of rebound. The dimensions of the board should be equal to that of the joint being formed. It should, preferably be manufactured in one piece, matching the dimension of the joint and not prepared by cutting to size smaller pieces from larger boards at site. At the exposed end, the joint shall be sealed with approved sealing compound to a depth of at least 25 mm after application of an approved primer. The sealing compound and the primer shall be applied as specified by the manufacturer. Fixing of Joint Filler The concrete surface shall be made clean, smooth and free from dirt or loose particles. When the surface is completely dry, a coat of hot blow bitumen conforming to IS: 702 of grade 85/25 shall be given with brush or spray. When the bitumen is still hot the premolded joint filler fibre board shall be pressed against the surface and held in position till the time it takes to adhere. When more than one layer of filler are specified each layer shall be made to adhere to the preceding layer with a few patches of bitumen between the two layers. After placing the filler in position, the surface of the filler against which further concreting is to be done is given a coat of bitumen.
Section 2.2
Page : 14 of 31
Filling of joint sealing compound Sealing compound shall be of Grade A conforming to IS: 1834. Bitumen shall conform to IS: 3384. Before application of the sealing compound the sides of the joint are sprayed or brushed with bitumen primer. The primer is then allowed to dry out thoroughly for at least 24 hours and then filled with a mix of 30 % fine sand and 70 % sealing compound by weight. Expanded Polystyrene Boards If required, commercial quality of expanded polystyrene products commonly used for thermal insulations may also be used as filler material in expansion joints. The thickness may vary from 12 mm to 50 mm. The material will have to be procured from reliable manufacturers as approved by the Engineer. The method of installations will be similar to that recommended by the manufacturers for fixing on cold storage walls. A coat of bitumen paint may have to be applied on the board against which concrete will be placed. 14.3.0 Joint Sealing Strips Joint sealing strips may be provided at the construction, expansion and isolation joints as a continuous diaphragm to contain the filler material and/or to exclude passage of water or any other material into or out of the structure. The sealing strips will be either metallic like G.I., Aluminium or copper, of non-metallic like rubber or P.V.C. Sealing strips will not have any longitudinal joint and will be procured and installed in largest practicable lengths having a minimum number of transverse joints. The material is to be procured from reputed manufacturers having proven records of satisfactory supply of joint strips of similar make and shape for the jobs. The jointing procedure shall be as per the manufacturer's recommendations, revised if necessary, by the Engineer. The Contractor is to supply all labour and material for installation including the material and tools required for jointing, testing, protection, etc. If desired by the Engineer, joints in rubber seals may have to be vulcanized. Metal Sealing Strips Metal sealing strips shall be either G.I., Aluminium or Copper and formed straight, U shaped, Z shaped or any other shape and of thickness as indicated in the drawing and Schedule of Items and/ or as instructed by the Engineer. The transverse joints will be gas welded using brass rods and approved flux and will be tested by an approved method to establish that it is leak proof. In case it is found that the joints cannot be made leak proof, longer lap length and different method of brazing which will render it leak proof, will be adopted by the Contractor without any additional cost to the Owner. The edges shall be neatly crimped and bent to ensure proper bond with the concrete. a) G.I. Strips: G.I Strips shall be minimum 1.5 mm thick and 150 mm in width unless specified otherwise. The standard of Galvanizing shall be as per relevant Indian Standards for heavy duty work. The strips shall be strong, durable, without any rust or crease. At the joints, the over-lapping should be for a minimum length of 50 mm.
Section 2.2
Page : 15 of 31
b) Aluminium Strips: Aluminium strips shall be minimum 18 swg. thick and 300 mm wide unless specified other wise and shall conform to IS: 737 of 19000 grade or 31000 grade (Designation as per IS: 6051). A minimum lap of 50 mm length is required at the joints. c) Copper Strips: The Copper strips shall be minimum 18 swg. In thickness and 300 mm width unless specified otherwise and shall conform to the relevant Indian Standards. It should be cleaned thoroughly before use to expose fresh surface, without any reduction in gauge. A minimum lap of 50 mm is length is required at the joints. Non-metallic Sealing Strips These will be normally in Rubber or P.V.C. Rubber or P.V.C. joint seals can be of shape having any combination of the following features: a. b. c. d. e. Plain Central bulb Dumb-bell or flattened ends Ribbed and Corrugated Wings V - shaped
As these types of seals can be easily handled in very large lengths unlike metal strips, transverse joints will be allowed only under unavoidable circumstances and without the specific approval of the Engineer. The method of forming these joints, laps etc. shall be specified by the Manufacturer and/ or as approved by the Engineer taking particular care to match the central bulbs and the edges accurately. d) Rubber Sealing Strips: The minimum thickness of rubber sealing strips shall be 3 mm and the minimum width 100 mm. The actual size and shape will be as shown in drawings/Schedule of Items and/ or as directed by the Engineer. The material will be natural rubber and the resistant to corrosion, abrasion and tear and also to attacks from the acids, alkalies and chemicals normally encountered in service. The physical properties will be generally as follows. The actual requirements may be slightly different as decided by the Engineer. Sp. Gr. Shore Hardness Tensile Strength Max. Safe continuous Temperature Ultimate Elongation e) P.V.C. Sealing Strips: The minimum thickness of P.V.C sealing strips will be 3 mm and the minimum width 100 mm. The actual size and shape will be as shown in drawings/Schedule of Items and/or as directed by the Engineer. The material should be of good quality Polyvinyl Chloride highly resistant to tearing, abrasion and corrosion as well as to chemicals likely to come in contact with during use. The physical properties will generally be as follows. The actual requirements, which will be directed by the Engineer, may vary slightly.
: 1.1 to 1.15 : 65 A to 75 A : 25 - 30 N/mm : 75C : Not less than 350%
Sp. Gr. Shore Hardness Tensile Strength Maximum Safe Continuous Temperature Ultimate Elongation 14.4.0 Bitumen Compound
: 1.3 to 1.35 : 60 A to 80 A : 10 - 15 N/mm2 : 70 deg C : Not less than 275%
When directed, the gap in expansion joints shall be thoroughly cleaned and bitumen compound laid as per manufacturer's specifications. The compound to be used shall be of approved manufacturer and shall conform to the requirements of IS: 1834. 14.5.0 Isolation Joints Strong and tough alkathene sheet or equivalent, about 1 mm in thickness and as approved by the Engineer shall be used in Isolation Joints. It shall be fixed by an approved adhesive compound on the cleaned surface on the already set concrete, to cover it fully. Fresh concrete shall be laid against the sheet, care being taken not to damage the sheet in any way. 14.6.0 Rubber Pad Hard foundation quality rubber pads of required thickness and shapes are put below machine or other foundation as shown on the drawing or as directed by the Engineer. The rubber shall have a unit weight of 930 Kg/m3, shore hardness - 65 A to 70 A and be of best quality of approved manufacture, durable, capable of absorbing vibration and must be chemically inert in contact with moist or dry earth or any other deleterious material expected under normal conditions. 15.0.0 PRECAST CONCRETE All concrete for pre-cast concrete work shall comply with specifications for general concrete work and with the following requirements:All precast work shall be carried out in a yard for the purpose. This yard shall be dry, properly leveled and having a hard and even surface. If the ground is to be used as a soffit former of the units, it shall be paved with concrete or masonry and provided with a layer of cement plaster with smooth neat cement finish or a layer of M.S. sheeting. Where directed by the Engineer, casting will have to be done on suitable vibrating table. The yard, lifting equipment, curing tank, finished material storage space etc. shall be designed such that the units are not lifted from the mould before seven (7) days of curing and can be removed for erection after twenty eight (28) days of curing. The moulds shall preferably be of steel or of timber lined with G.I. sheet metal. The yard shall preferably be fenced. Lifting hooks, where necessary or as directed by the Engineer, shall be embedded in correct position of the units to facilitate erection, even though they may not be shown on the drawings, and shall be removed and the hooks finished after erection if directed by the Engineer. Precast concrete units, when ready, shall be transported to site by suitable means approved by the Engineer. Care shall be taken to ensure that no damage occurs during transportation. All adjustments, leveling and plumbing shall be done as per instructions of the Engineer. The Contractor shall render all help with instruments, materials and men to the Engineer for checking the proper erection of the precast units. Chipped or cracked or otherwise damaged pre-cast elements will be rejected.
After erection and alignment, the joints shall be filled with grout or concrete as directed by the Engineer. If centering have to be used for supporting the precast units, they shall not be removed until the joints have attained sufficient strength and in no case before fourteen (14) days. The joint between precast roof planks shall be pointed with 1:2 cement : sand mortar where called for in the drawings. 16.0.0 16.1.0 WATERPROOFING OF CONCRETE TO STRUCTURES General Waterproofing of concrete structures shall be done by either suitable extraneous treatments like applying paints, fixing bitumen felts etc. installing water bars at the joints. The design, material and workmanship shall conform to the relevant I.S. codes where applicable. The Engineer's approval of the materials shall be obtained by the Contractor before procurement. If desired by the Engineer, test certificates for the materials and samples shall be submitted by the Contractor free of charge. The materials shall be best quality available indigenously, fresh clean and suitable for the duties called upon. 16.2.0 Water Bar/ Seal Water bearing structures and underground structures may have water bar/seals installed at the joints. They may be either metallic, rubber or P.V.C. the material and installation will be as described under clause 14.3.0. 16.3.0 Waterproofing Admixtures a) In Concrete The admixture shall be procured from reliable and reputed manufacturers and approved by the Engineer. The method of application and other details shall conform to the manufacturer's specification and/or as instructed by the Engineer. The Contractor shall have the service of the manufacturer's supervisor at no extra cost to the Owner to supervise the work, if desired by the Engineer. The cost of the admixture used shall be paid to the Contractor if the addition of the admixture is stated in the drawing/Schedule of Items. b) In Plaster The concrete surface, to be plastered, shall be hacked to Engineer's satisfaction, cleaned thoroughly and kept wetted for 24 hours. The plaster shall be in cement sand mortar mixed is proportion varying from 1:1 to 1:4 by volume along with the approved waterproofing admixture and laid in appropriate thickness and in layer not exceeding 15 mm or as per manufacturer's specification. The additive shall be of quality and type approved by the Engineer. If desired by the Engineer, the Contractor shall have the work supervised by the manufacturer's supervisor at no extra cost to the Owner. On completion, the plastered surface shall be cured continuously for a minimum period of fourteen (14) days like concrete. 16.4.0 WATER-PROOFING OF UNDERGROUND STRUCTURES CBT AND INJECTION GROUTING STRUCTURES Underground structures shall be treated with waterproofing treatment as described herein under. This treatment shall also apply to other areas of work if required as per detailed design. The Contractor shall ensure that the waterproofing treatment renders the structures completely watertight and does not allow any leakage / seepage of water in any direction over a specified period. The structures shall be in bonedry condition. The
waterproofing treatment shall be proven system by reputed organizations. The Contractor shall enlist the works carried out by him for his waterproofing treatment. METHOD CBT TREATMENT Raft - Cement based treatment shall be applied over PCC (Mud-mat). The top surface of PCC shall be finished smooth with wooden trowel. Before laying the waterproofing treatment, the top surface of PCC shall be cleared of timber, spoils, laitance, scum or loose concrete. Thereafter cement based treatment (CBT) shall be laid over PCC as per manufacturer's recommendations. Over CBT, RC raft will be concreted as early as possible. CBT shall be cured by spraying water over it till construction of RC raft during concreting of RC raft, 25 mm dia G.I. grout pipes shall be placed at suitable locations (2 meters to 3 meters spacing) and inclination as per expert's accepted practice. Along construction joints extra care shall be taken while deciding on spacing of G.l grout pipes to ensure that grouting around water stops is done satisfactorily. Construction joints shall be hacked to expose aggregates and shall be treated with rich cement slurry. The Contractor shall specifically note that deformed bars anchors which pierce the CBT shall be completely treated by injection grouting or as recommended by water proofing agency. The Contractor shall clearly indicate his process of waterproofing including material and application he proposes to use. Walls - CBT shall be applied or external faces of wall as per manufacturers specifications. Construction joints in walls shall be treated as mentioned in preceding paragraphs. To ensure water-tightness of walls, Contractor shall place grout pipes at construction joints. Contractor shall place these pipes before concreting of walls with approval of Engineer. WATERPROOFING TREATMENT (BY GROUTING) After curing of raft and waits is completed, inject cement grout of correct consistency shall be injected through G.I. pipes in raft and walls under low pressure by means of hand-pump or other approved system. The low pressure grouting shall be such that grout penetrates through all pores and crevices and fills all the voids in the concrete, thus blocking the passage of water through concrete. Contractor shall add correct amount of admixture to ensure satisfactory performance of the treatment. WATERPROOFING TREATMENT BY LIQUID WATERPROOFING MEMBRANE The Liquid waterproofing membrane treatment for the underground structures as well as for roofs where insulation requirements are not specified. The scope includes supply and application of the treatment in line with the specifications and drawings. The work shall be carried out with the best workmanship. The materials and the application shall be subjected to the qualification requirements and acceptance requirements in line with the specifications to the satisfaction of the Engineer. The work shall proceed only after the approval from the Engineer. The procedure for the treatment for underground structures shall be as follows: The entire surface on which the treatment is to be given shall be cleaned with wire brush to make it free from loose dust, dirt, etc. Apply first coat of liquid waterproofing membrane at the rate of 1.5 kg/sq. m. Apply second coat of liquid water proofing membrane at the rate of 1.5 kg/sq. m
To protect the liquid water proofing membrane from damage, provide 12 mm thick plaster in cement mortar 1:4.
The procedure for the treatment to the flat roof shall be as follows: Clean the entire surface with the help of wire brush so as to make it free from loose dust, dirt, etc, Apply a coat of bituminous primer of approved make at the rate of 0.2 kg/sq.m Lay 4mm thick polyester reinforced polymer modified bituminous membrane of approved make The joints shall be sealed properly. Apply a coat of bituminous aluminium paint on entire surface of the membrane (where roof is inaccessible) To protect polyester reinforced polymer modified bituminous membrane, provide 25mm thick plaster in cement mortar 1:4 with chicken wire mesh as reinforcement (where roof is accessible)
16.5.0
Bituminous or Tar Coating The surface to be waterproofed shall be rendered absolutely dry, clean and dust free. The surface shall be sand papered, cleaned and completely coated with hot coal tar pitch of approved manufacture and quality as per IS:216 (not heated above 375oF) using not less than 2 kg. per Esq.. or with hot asphalt i.e. bitumen according to IS:73 (not heated above 400oF) using not less than 1.5 kg per Esq.. When the first coat has completely dried up and approved by the Engineer, the second coat shall be applied in the same manner using not less than 1.25 Kg. per Esq., in case of coal tar and 1 kg per Esq.. in case of asphalt. Immediately after application of the second coat and before it is dried up, sand shall be spread on the surface to cover it completely. Sufficient time shall be allowed after spreading of sand before backfilling is done in order to allow the final coat to dry up completely.
17.0.0 17.1.0
TESTING Cement The Contractor shall submit to the Engineer the manufacturer's certificate for each consignment of cement procured if cement is supplied by him. If required by the Engineer, representative samples shall taken from each consignment and tests for fineness (by hand sieving), setting time and compressive strengths as per IS: 269 shall be carried out, free of charge by the Contractor. If the cement is procured by the Owner and issued to the Contractor, the Contractor shall satisfy himself at the time of taking delivery that the quality, quantity and freshness of cement and upto the specified standards. No complaint later on regarding the cement supplied by the Owner shall be entertained and all rectification work on this account shall be done by the Contractor at his own cost. Aggregates Coarse and fine aggregate and the grading shall be as per IS: 383. It shall be free from organic or clay coatings and other impurities, flaky particles, and any other material liable to affect the strength, durability or appearance of concrete. Washing of aggregates by approved means shall be carried out, if desired by the Engineer.
17.2.0
Section 2.2
Page : 20 of 31
The Contractor shall carry out any or all the tests on aggregates as may be required by the Engineer in accordance with IS: 2386. The acceptance criteria of samples tested shall be in accordance with the requirements of relevant Indian Standards. 17.3.0 17.3.1 Admixture Air Entraining Agents Initially, before starting to use Air Entraining Agents, relationship between percentage of air entrained and the cylinder tube crushing strength vis-a-vis quantity of Air Entraining Agents used for all types of concrete will be established by the Contractor free of charge by carrying out sufficiently large number of tests. After that, at regular intervals and whenever directed by the Engineer, the Contractor will check up free of charge, the actual percentage of air entrained and corresponding curing strengths to correlate with the earlier test results. 17.3.2 Other Admixture Tests for establishing the various properties of any other admixtures which may be required to be added shall be carried out by the Contractor free of charge to the Owner. 17.4.0 Concrete Sampling, making up, curing and testing of specimen will comply with IS:456, IS:516 and IS:1199. Unless otherwise instructed by the Engineer, frequency of works tests shall be as indicated below. The criteria for acceptance shall be in accordance with IS:456. Sampling procedure, shall generally conform to IS:456. Sampling frequency for each grade of concrete M15 and above shall be six (6) cubes for each 50 m3 or part thereof, or per day concreting volume, whichever is less. Out of each set of six (6) cubes, three (3) cubes shall be tested at seven (7) days and the remaining three (3) cubes at twenty eight (28) days. If there is a change in batch of cement, a separate set of samples consisting of six (6) cubes shall be taken for each batch. In case, the stripping time for shuttering needs to be reduced or early age strength is required to be known in specific cases, the Contractor shall carry out at short notice testing of cubes at one (1) day and three (3) days after accelerated curing as per IS:9013. The required number of additional samples for the same shall also be taken. To control the consistency of concrete from every mixing plant/machine, slump tests and/or compacting factor tests as per IS:1199 shall be carried out by the Contractor every two hours or as directed by the Engineer in addition to the slump measured when making test cubes. 18.0.0 18.1.0 ACCEPTANCE CRITERIA Structural Criteria Acceptance criteria of concrete shall be generally in accordance with Clause 15 of IS: 456. Immediately after stripping the formwork, all concrete shall be carefully inspected and any defective work or small defects either removed or made good before the concrete has thoroughly hardened. The acceptance criteria of concrete shall be in accordance with IS: 456. However, in exceptional circumstances, the Engineer may, at his discretion, accept a concrete of lower strength than specified and which is otherwise unacceptable according to IS: 456. Payment for such accepted concrete will be made only at reduced rate prorate to the strength obtained.
Concrete work found unsuitable for acceptance shall have to be dismantled and replacement is to be done as per specification by the Contractor. No payment for the dismantled concrete, the relevant formwork and reinforcement, embedded fixtures, etc. wasted in the dismantled portion shall be made. In the course of dismantling, if any damage is done to the embedded items or adjacent structures, the same shall be made good, free of charge by the Contractor, to the satisfaction of the Engineer. 18.2.0 Dimensional Criteria The permissible variation from dimension, lines given in the drawing shall be within tolerances specified in the relevant IS codes/ other applicable standards or as indicated by the Engineer. Generally the following tolerances shall be considered. Tolerances for R.C. Buildings: i) Variation from the plumb a. In the lines and surfaces of columns, piers, walls and in arises 5 mm per 2.5 m or 25 mm, whichever is less. b. For exposed corner columns and other conspicuous lines In any bay or 5 m max. In 10 m or more ii) 5 mm 10 mm
Variation from the level or from the grades indicated on the drawings a. In slab soffits, ceilings, beam soffit, and in arises In 2.5 m In any bay or 5 m max. In 10 m or more 5 mm 8 mm 15 mm
b. For exposed lintels, sills, parapets, horizontal grooves and other conspicuous lines In any bay or 5 m max. In 10 m or more 5 mm 10 mm
iii) Variation of the linear building lines from established position in plan and related position of columns, walls and partitions.
In any bay or 5 m max. In 10 m or more
10 mm 20 mm
iv) Variation in the size and locations of sleeves, openings in walls and floors - 5 mm except in the case of and for anchor bolts v) Variation in cross-sectional dimensions of columns and beams and in the thickness of slabs and walls Minus Plus vi) Footings a. Variation in dimension in plan
5 mm 10 mm
Minus Plus b. Misplacement or eccentricity
5 mm 50 mm
2% of footing width in the direction of misplacement but not more than 50 mm c. Reduction in thickness Minus 5% of specified thickness subject to a max. of 50mm
vii) Variation in steps a. In a flight of stairs Rise Tread b. In consecutive steps Rise Tread Tolerances in other Concrete Structures a. i. All structures Variation of the constructed linear outline from established position in plan In 5 m In 10 m or more ii. 10 mm 15 mm 1.5 mm 3.5 mm 3 mm 5 mm
Variations of dimensions to individual structure features from established positions In 20 m or more In buried construction 25 mm 50 mm
iii. Variation from plumb, from specified batter or from curved surfaces of all structures In 2.5 m In 5 m In 10 m or more In buried - construction 10 mm 15 mm 25 mm Twice the above amounts
iv. Variation from level or grade indicated on drawings in slab, beams, soffits, horizontal grooves and visible arises In 2.5 m In 7.5 m or more In buried construction v. 5 mm 10 mm Twice the above amounts
Variation in cross-sectional dimensions of columns beams, buttresses, piers and similar members Minus 5 mm
Section 2.2 Page : 23 of 31 Plain and Reinforced Concrete Work
Plus
10 mm
vi. Variation in thickness of slabs, walls, arch sections and similar members Minus Plus 5 mm 10 mm
b. Footing for columns, piers, walls, buttresses and similar members i. Variation of dimension in plan Minus Plus ii. Misplacement or eccentricity 5 mm 10 mm
2% of footing width in the direction of misplacement but not more than 50 mm iii. Reduction in thickness 5% of specified thickness subject to a max. of 50 mm Tolerances in other types of structures shall generally conform to those given in 2.4 of Recommended Practice for Concrete Formwork (ACI 347) Tolerances in fixing anchor bolts shall be as follows: i. ii. Anchor bolts without sleeves 1.5 mm in plan Anchor bolts with sleeves 5.0 mm in elevation a. For bolts upto and including 28 mm dia 5 mm in all directions b. For bolts 32 mm dia and above 3 mm in all directions iii. 19.0.0 Embedded parts - 5 mm in all directions
STORAGE AND HANDLING OF MATERIALS General a) The contractor shall make necessary arrangements, for safe storage and ensure prevention against deterioration of the materials. Cement, fly ash, GGBS, micro silica, super plasticizers, admixtures, retarders etc. shall, invariably, be stored in weather proof sheds of adequate capacity for storage of the material for at least 3 weeks of work. However, the contractor shall ensure that sufficient quantities of all materials are available for uninterrupted progress of the work. Cement and other construction materials shall be stored as per recommendations of Indian Standards and as per manufacturers recommendation. Storage silos shall be watertight. In the storage area, proper access and lighting shall be provided for inspection, identification and drawl of material. The material shall be stored batch wise with proper identification tag, indicating the quantity received, batch number and the date of receipt and issue. The consignments shall be used in the order of receipt at site, unless otherwise directed. In case of large concrete pours, the material to be used shall be identified and procured well in advance, taking the quantity required for a particular concrete pour into consideration. The cement shall be used within three months from the date of manufacture. However, in exceptional circumstances, if approved by the Engineer, the above stipulation may be relaxed subject to the
condition that the material shall be retested to ensure the conformity with the technical specifications. Normally, materials of different type or grade shall not be stored in the same godown. If materials of different type or different grade are stored in the same place, it shall be clearly demarcated and separated to avoid intermixing. b) The contractor shall prepare an elaborate procedure for the periodic inspection and testing of the materials to detect any deterioration and also for segregation of the deteriorated material. The above procedure shall be approved by the Engineer and implemented by the contractor. It is the responsibility of the contractor to provide all samples and other facilities to the Engineer for carrying out inspection and testing of materials both at the source and at the site of work at his own cost. The rejected materials shall be removed from the site within 48 hours. If the contractor fails to remove the rejected material within 48 hours, the right to get the materials removed from the site rests with the Engineer and all the expenditure incurred by the Engineer for such removal shall be borne by the Contractor. All storage arrangements, handling schemes shall be subject to the approval of the Engineer. If the storage arrangement is not to the satisfaction of the Engineer, he may direct the contractor to make such arrangements as he considers necessary and in the event of non-compliance, the Engineer reserves the right to make such arrangements as may be needed at the contractors risk and cost. A detailed record of receipt and issue of all materials with the associated test certificates shall be maintained by the contractor and shall at all times be available to the Engineer for his scrutiny.
c)
d)
19.1.0
Cement Cement shall be stored in easily countable stacks with consignment identification mark above ground level in perfectly dry and watertight sheds. Bulk cement shall be stored in air tight containers. Cement shall be stored in a manner so as to facilitate removal of firstin first-out basis. Any cement considered defective by the Engineer shall not be used by the Contractor and shall be removed from the site immediately. Cement that has been in store for six (6) months or more shall be tested for quality. Should at any time the Engineer have reasons to consider that any cement is defective, then irrespective of its origin, date of manufacture and manufacturer's test certificate, such cement shall be tested immediately at the Contractor's cost at an approved laboratory and until the test results are found satisfactory the cement shall not be used on any work. The Contractor is not entitled to any claim of any nature of this account.
19.2.0
Coarse and fine aggregate Aggregates shall be stored in easily measurable stacks on brick soling or an equivalent platform so that they do not come in contact with dirt, clay, grass or any other injurious substances at any stage. Aggregate of different size shall be kept in different stacks. If so desired by the Engineer, aggregate from different sources shall be stacked separately with proper care to prevent intermixing. Any aggregate delivered at site in a wet condition or becoming wet at site due to rain or any other means shall be kept in storage for atleast twenty four (24) hours to obtain adequate drainage before it is used for concreting or the water content of the mix must be suitably adjusted as directed by the Engineer.
Section 2.2
Page : 25 of 31
19.3.0
Reinforcement Reinforcement bars shall be stored off the ground and under cover if so desired by the Engineer. If necessary, a coat of cement wash shall be given to bars to guard against rusting. Reinforcing steel shall be stored consignment wise and diameter wise.
20.0.0 20.1.0
PILING WORKS General Piling work shall be carried out as per IS 2911 (latest addition). The pile shall be of Bored cast in situ, R.C.C. end bearing with suitable rock socketing.
20.2.0
WORKMANSHIP Bored cast-in-situ piles may be adopted by suitable choice of installation techniques; covering the manner of soil stabilization, that is use of casing and /or use of drilling mud; manner of concreting that is by use of tremie and choice of boring tools in order to permit a satisfactory installation of a pile at a given site.
20.3.0
CONTROL OF ALIGNMENT Piles shall be installed as accurately as possible as per the designs and drawings either vertically or to the specified batter. Greater care should be exercised in respect of installation of single pile or piles in two pile groups. As a guide, for vertical piles a deviation of 1.5 percent and for raker piles a deviation of 4 percent should not normally be exceeded although in special cases a closer tolerance may be necessary. Piles should not deviate more than 75mm or d/10 whichever is more in case of piles having diameter (d) more than 600mm from their designed positions at the working level of the piling rig. In the case of single pile in a column positional tolerance should not be more than 50mm (100mm in case of piles having diameter more than 600mm). Greater tolerance may be prescribed for piles driven over water and for raking piles. For Piles to be cut-off at a substantial depth, the design should provide for the worst combination of the above tolerance in position and inclination. In case of piles deviating beyond these limits and to such an extent that the resulting eccentricity cannot be taken care of by a redesign of the pile cap of pile ties, the piles should be replaced or supplemented by one or more additional piles. Any deviation from the designed location, alignment or load capacity of any pile shall be noted and adequate measures taken well before the concreting of the pile cap and plinth beam. A minimum length of one meter of temporary casing shall be increased in each bored piles unless other wise specifically desired. Additional length of temporary casing may be used depending on the condition of the strata, ground water level, etc., Drilling mud of suitable consistency may also be used instead of temporary casings for stabilizing sides of the holes. In case, a bored pile is stabilized by drilling mud or by maintaining water heads within the hole, the bottom of the hole shall be cleaned very carefully before concreting work is taken up. The cleaning of the hole may be ensured by careful operation of boring tool and/ or flushing of the drilling mud though the bottom of the hole. Flushing of bore holes before concreting with fresh drilling fluid/mud is preferred. In case of a hole is bored by use of drilling mud, the specific gravity of the mud suspension near about the bottom of the hole shall, whenever, practicable, be determined by suitable slurry sampler in a first few piles and at suitable interval of piles and recorded. Consistency of the drilling mud suspension shall be controlled throughout the boring as well as
Section 2.2
Page : 26 of 31
concreting operations in order to keep the hole stabilized as well as concreting operations in order to keep the hole stabilized as to avoid concrete getting mixed up with the thicker suspension of the mud. The concreting operations should not be taken up when specific gravity of bottom slurry is more than 1.2. Concreting shall be done by tremie method in all such cases. The slurry should be maintained at 1.5 m above the ground water level if casing is not used. Concreting under water may be done either with the use of tremie method or by the use of specially designed underwater placer to permit deposition of concrete in successive layers, without permitting the concrete with in the placer to fall through free water. 20.4.0 TREMIE METHOD In addition to the normal precautions to be taken in tremie concreting, the following requirements are particularly applicable to the use of tremie concrete in pipes. a. b. The concrete should be coherent, rich in cement (not less than 370 kg/m3) and of sump not less than 150mm When concreting is carried out under water a temporary casing should be installed to the full depth of the bore hole or 2 m into non-collapsible stratum, so that fragments of ground cannot drop from the sides of the hole into the concrete as it is placed. The temporary casing may not be required except near the top when concreting under drilling mud. The hopper and tremie should be a closed system embedded in the placed concrete, through which water cannot pass. The tremie should be large enough with due regard to the size of the aggregate. For 20 mm aggregate the tremie pile should be of dia meter not less than 200mm, aggregates more than 20mm shall not be used. The first charge of concrete should be placed with a sliding pushed down the tube a head of it or with a steel plate of adequate charge to prevent mixing of concrete and water. However, the plug should not be left in the concrete as a lump. The tremie pipe should always penetrate well into the concrete with an adequate margin if safety against accidental withdrawal of the pipe is surged to discharge the concrete. The pile should be concreted wholly by tremie and the method of deposition should not be changed part way up the pile, to prevent the laitance from being entrapped with in the pile. All tremie tubes should be scrupulously cleaned after use.
c. d.
e.
f.
g.
h.
Concreting of the piles should be uninterrupted. In the exceptional case of interruption of concreting, but which can be resumed with 1 or 2 hours, the tremie shall not be taken out of the concrete. Instead it shall be raised and lowered slowly, from time to time to prevent the concrete around the tremie from settling. Concreting should be resumed by introducing a little richer concrete with a slump of about 200mm for easy displacement of the partly set concrete. If the concreting cannot be resumed before final set up concrete already place, the pile so cast may be rejected or accepted with modifications. In case of withdrawal of tremie out of the concrete, wither accidentally or to remove a choke in the tremie, the tremie may be reintroduced in the following manner to prevent impregnation of laitance or scum laying on the top of the concrete already deposited in the bore. The top of concrete in a pile shall be brought above the cut-off level to permit removal of all laitance and weak concrete before capping and to ensure good concrete at the cut-off level for proper embedment into the pile cap.
Where cut-off level is less than 1.5 meter below the working level concrete shall be cast to a minimum of 300mm above cut-off level. For each additional, 0.3 m increase in cut off level below the working level additional coverage of 50mm minimum shall be allowed. Higher allowance may be necessary depending on the length of the pile. When concrete is placed by tremie method, concrete shall be cast to the piling platform level to permit overflow of concrete for visual inspection or to a minimum of one meter above cut-off level. In the circumstance where cut-off level is below ground water level the need to maintain a pressure on the unset concrete equal to or greater than water pressure should be observed and accordingly length of extra concrete above cut-off level shall be determined. 20.5.0 DEFECTIVE PILE In case, defective piles are formed, they shall be removed or left in place whichever is convenient without affecting, performance of the adjacent piles or the cap as a whole. Additional piles shall be provided to replace them as directed. Any deviation from the designed location alignment or load capacity of any pile shall be noted and adequate measures taken well before the concreting of the pile cap and plinth beam if the deviations are beyond the permissible limit. During chipping of the pile top manual chipping may be permitted after three days of pile casting, pneumatic tools for chipping shall not be used before seven days after pile casting. 20.6.0 RECORDING OF DATA A competent supervisor shall be deputed at site to record necessary information during installation of piles and data sheet shall be maintained. LOAD TEST ON PILES GENERAL Piles shall be tested for finding Ultimate load capacities and Safe load of the Pile. Load test on pile shall be carried out as per IS 2911 (Part-4 1985) TESTS:- Following tests shall be carried out for piles 1 Initial test --- at least one pile test shall be carried out from each block. 2. Routine test ---- The number of tests may be 2% of total no of pile in each block. General requirements 20.8.0 Pile test may be carried out on a single pile. Load application and deflection observation will be made at the pile top. The test should be carried out at cut-off level.
20.7.0
VERTICAL LOAD TEST (COMPRESSION) GENERAL In this type of test, compression load is applied to the pile top by means of a hydraulic jack against rolled steel joist or suitably positioned dial gauges record suitable load frame capable of providing reaction and the settlement. Maintained load method should be used for determination of safe load. However for specific requirements cyclic and CRP methods, which are alternate methods, may be used.
Section 2.2
Page : 28 of 31
PREPARATION OF PILE HEAD The pile head should be chipped off to natural horizontal plane till sound concrete is met. The projecting reinforcement should be cut off or bent suitably and the top finished smooth and level with plaster of Paris or similar synthetic material where required. A bearing plate with a hole at the center should be placed on the head of the pile for the jacks to rest. APPLICATION OF LOAD (Not applicable to CRP method) The test should be carried out by applying a series of vertical downward incremental load each increment bring of about 20 percent of safe load on the pile. For testing of racer piles it is essential that loading is along the axis. Reaction - The reaction may be obtained from the following:a. Kent ledge place on a platform supported clear of the test pile. In case of load test below under pinned structure he existing structure if having adequate weight and suitable construction may serve as Kent ledge. The center of gravity of the Kent ledge should be on the axis of the pile and the load applied by the jack should also be coaxial with this pile. Another piles with center-to center distance with the test pile not less than 3 times the test pile shaft diameter subject to minimum of 2m. IF the anchor piles are permanent working piles it should be ensured that their residual uplift is within limits. Care should be exercised to ensure that the datum bar supports are not affected by heaving up of the soil. Rock anchors with distance from the nearest edge of the piles at rock level being 2 times the test pile shaft diameter or 1.5 m whichever is greater. The reaction to be available for the test should be 25 percent more than the final test load proposed to be applied.
b.
c.
SETTLEMENT : (Not Applicable for CRP test.) Settlement shall be recorded with minimum 2 dial gauges for single pile and 4 dial gauges of 0.01 mm sensitivity for groups, each positioned at equal distance around the piles and normally held by datum bars testing on immovable supports at a distance of 3 D (subject to minimum of 1.5 m) from the edge of the piles, where D is the pile stem diameter of circular piles or diameter of the circumscribing circle in the case of square or non-circular piles. The safe load on single pile for the initial test should be least of the following: a Two-thirds of the final load at which the total displacement attains a value of 12 mm unless otherwise required in a given case on the basis of nature and type of structure in which case, the safe load should be corresponding to the stated total displacement permissible. 50 percent of the final load at which the total displacement equal to 10 percent of the pile diameter in case of uniform diameter piles and 7.5 percent of bulb diameter in case of under-reamed piles.
b.
However, routine test shall be carried for a test load of at least one and times the working load, the maximum settlement of test loading in position being not exceeding 12mm.
Section 2.2
Page : 29 of 31
21.0.0
ROCK ANCHORS GENERAL Rock anchors are provided to prevent uplift of the structure due to underground water. These anchors are provided in the foundations of various buildings- if required from design considerations. These are passive type of rock anchors using tor-steel bars. SCOPE The scope of work covered under this specification is as follows: Drilling of holes in rock at the founding level. Supply and fabrication of anchor rods including sand blasting and application of epoxy paint, which shall include supply of paint. Installation of rock anchors using a non-shrinking cementaceous grout. Testing of a specified number of anchors to specified working load.
MATERIALS The materials to be used under this specification are as follows: High yield strength deformed (HYSD) bars of specified dia. confirming to IS: 1786 (latest edition). Mild steel plates of various thickness confirming to IS:2062 (latest edition). Approved Epoxy paint and Thinner. Approved non-shrinking cementaceous grouting compound of FOSROC make or equivalent.
The grouting compound shall pass the pullout test as specified in this specification. DRILLING OF HOLE The rock strata at the founding level shall be cleaned and the edges of the footings shall be marked. After laying the mud mat PCC, the location of the rock anchors in the foundation shall be accurately marked on the PCC. Holes of required diameter and depth as per the drawings shall be drilled by PERCUSSION method of drilling using a wagon drlling equipment. The depth of the hole shall be measured from the top of the rock and not from the top of the PCC. Usually the depth of the hole shall be 100mm more than the required depth of embedment of the anchor. Verticality of the holes shall be maintained while drilling. However, a maximum inclination of 5 to the vertical can be permitted at the discretion of the Engineer. Immediately after completion of the drilling, the holes shall be plugged with wooden cones until the installation of the rock anchors, to prevent entry of foreign materials or rock pieces, which may obstruct the clearance of the hole. The cement mortar bund shall be made all around the hole to prevent entry of slush. FABRICATION OF ANCHOR ROD TOR steel rods of specified diameter shall be cut to the required size in a shearing machine. Flame cutting of the rods shall not be permitted. The straightness of the rod shall be checked and if required shall be rectified. The top anchor plate shall be fabricated by welding. The hole in the anchor plate for insertion of the rod shall be drilled using drilling machine. Cutting the hole using gas cutting set shall not be permitted. The size of weld shall be as specified in the drawings. All welds shall be visually inspected and 100% DP tested. The entire length of the rock anchor rod including the anchor plate shall be cleaned of all rust, mill scale etc., by sand blasting.
Section 2.2
Page : 30 of 31
Two coats of approved brand of epoxy paint shall be applied on the entire surface, over a coat of approved primer. Care shall be taken to paint the ends of the anchor rods also. Final inspection of the anchor rods shall be offered to the Engineer or his representative. The rods shall be shifted to the site only after obtaining clearance from the Engineer. INSTALLATION OF THE ROCK ANCHOR The hole drilled in the rock shall be cleaned using air-water jet at a pressure of 7 Kg/Sq.cm to remove loose particles if any. The grout shall be mixed with water as per the recommendations of the manufacturer. The mixing shall be done using a mechanical stirrer. Under no circumstances hand mixing shall be permitted. The grout shall be poured into the hole to3/4 th the depth of the hole. The depth of insertion of the anchor rod shall be marked on the rod. The anchor rod shall be lowered into the hole slowly and vertically to the required depth. To ascertain that no voids are left in the hole, the anchor rod shall displace the grout and the excess grout should overflow out of the hole during insertion of the rod. The rock anchor shall be supported suitably on the PCC until the final setting of the grout, to prevent it from lowering itself beyond the specified depth. If settlement of grout occurs, the Contractor shall fill the settlement with same grouting compound at no extra cost. If while lowering, the rod gets stuck, the rod shall be removed and hole shall be washed to remove the grout. In such circumstances, no extra payment shall be made for the grout washed from the hole. The hole shall be inspected for obstructions if any, and the rod shall be inspected for its straightness. Rectification measures shall be taken before attempting to lower the anchor rod again. PULL OUT TEST As a pre-qualification test, to demonstrate the adequacy of the grouting compound for its bond strength with the rod/rock, the Contractor shall conduct pullout test up to failure on test anchors installed at locations outside the structure. At least three anchors shall be tested to failure for each type of rock anchor. The grouting compound is deemed to have been accepted if the bond strength of the grout is not less than that for M-20 grade concrete. Only after satisfactory demonstration of the strength of the grout shall the grouting compound be approved for use. The prequalification test shall be done by the Contractor at no extra cost. 5% of the total number of anchors in any particular structure shall be tested for pullout at the specified working load to check the quality of workmanship. This test shall be conducted in all structures wherein rock anchoring is specified. The test anchor shall be identified by the Engineer-in-charge after completion of installation of the rock anchors in the structure. The cost of testing the working anchors is deemed to have been considered in the quoted rate. A procedure shall be submitted by the Contractor for the approval of the Engineer-incharge prior to testing. The design calculations and drawing showing the test set-up shall also be submitted along with the procedure. The testing shall be done as per relevant IS code. Load settlement graphs shall be plotted.
Section 2.2
Page : 31 of 31
JHABUA POWER LIMITED 1x 600MW + 1x660MW JPL SEONI Project Specification for River Water Intake System
VOLUME II SECTION 2.3 TECHNICAL SPECIFICATION FOR MISCELLANEOUS STEEL WORK
Section 2.3
Page : 1 of 9
Miscellaneous Steel Work
SECTION 2.3 TECHNICAL SPECIFICATION FOR MISCELLANEOUS STEEL WORK CONTENTS
CLAUSE NO.
DESCRIPTION
PAGE NO.
1.0.0 2.0.0 3.0.0 4.0.0 5.0.0
SCOPE ............................................................................................................... 3 CODES AND STANDARDS ................................................................................ 3 MATERIALS........................................................................................................ 3 DRAWINGS AND LISTS ..................................................................................... 3 FABRICATION, INSTALLATION, PAINTING, RATES & PAYMENT ................... 4
Section 2.3
Page : 2 of 9
SECTION 2.3 TECHNICAL SPECIFICATION FOR MISCELLANEOUS STEEL WORK 1.0.0 SCOPE This specification covers the requirements in respect of materials, workmanship and quality for preparation of fabrication drawings, supply, fabrication, inspection, testing, painting and erection of miscellaneous steel work comprising ladders, floor gratings, stairs, handrails, chequered plate covers, inserts plates, anchor and like items. 2.0.0 CODES AND STANDARDS Materials, workmanship and construction shall be as per relevant Indian Standards or equivalent foreign standards where such Indian Standards are not available or applicable. 3.0.0 3.1.0 MATERIALS Structural steel All structural steel shall be of tested quality and shall conform to IS: 2062. High tensile steel, when supplied, shall conform to IS: 8500. 3.2.0 Bolts and nuts All bolts and nuts shall conform to IS: 1363 and IS: 1364 and unless shown or specified otherwise shall be hexagonal. All nuts shall fit tight. Mechanical properties shall conform to IS: 1367 3.3.0 Washers Plain washers shall be made of mild steel, unless otherwise specified. Spring washers shall be provided for those parts which carry dynamic loads and where black bolts for connection are permitted. 3.4.0 Electrodes Mild steel electrodes shall conform to IS: 814. The Contractor shall furnish to the Engineer a certificate issued by the manufacturer to the effect that the electrodes supplied are in accordance with the above specifications. For welding in any particular position, the electrodes used shall be those recommended by the manufacturer for use in that position. 3.5.0 Paints Paints to be used for shop coat of fabricated steel shall conform to IS: 2074 3.6.0 Chequered Plate Chequered plate conforming to IS: 3502 shall be used. Chequered plates shall be fixed by staggered welding of suitable size. 3.7.0 Other Materials Other materials used in association with steel work shall comply with the appropriate Indian Standard specifications. The Contractor shall furnish test certificates for all materials prior to their use in the works. 4.0.0 DRAWINGS AND LISTS
Section 2.3 Page : 3 of 9 Miscellaneous Steel Work
Unless otherwise stated, the Contractor shall be responsible for the preparation of the detailed fabrication/ working drawings, erection and marking plans and all necessary lists such as indents, rivet and bolt lists, material lists, Dispatch Office Dispatch lists and lists for all bought out items. The fabrication drawings shall indicate the size of each component and length and sequence of all welds & bolted connections. All the fabrication drawings shall be prepared in metric units. The drawings shall be preferably of one standard size and the details shown therein shall be clear and legible. The fabrication drawings shall be prepared and submitted for approval in line with the 'Released for Construction' drawings supplied by the Owner. Only approved drawings shall be used for fabrication purpose No detailed shop drawings will be accepted for examination by the Owner unless they are complete and checked and approved by Contractor's qualified structural engineers and accompanied by an erection plan showing the location of all pieces detailed. Contractor should check tor erection clearance and ensure that detailing of connections is carefully planned to obtain ease in erection of structures including field welded connection and bolting. Field connections/splices may be welded or bolted type, as specified in drawings. Acceptance by Owner of any of the drawings/ specifications shall not relieve Contractor from the responsibility for correctness of workmanship, fit of parts, details, material, errors or omissions of any and all work shown thereon. Any work done prior to approval of shop drawings will be at the Contractor's risk. The Contractor shall make such changes when so directed, which are considered necessary to make the structures conform to the provisions and intent of the specifications, without any additional cost to the Owner. Each tot of fabrication drawings submitted by Contractor for Owner's review / acceptance shall be in approximate phased sequence and shall be in an order and manner which follows erection sequence or as required by Owner based on priorities allocated. Owner will return one copy of Contractor's drawing marked with Owner's comments/ approval. Contractor shall also furnish the Owner with two direct reading reproducible of each drawing of quality not lesser than an 'Auto-positive on extra thin paper capable of reproducing legible prints. These reproducible shall incorporate all modifications, field changes substitutions etc, affected and reflect the status "as built". It should be noted that so called sepia' or similar process reproducible are not acceptable. All these reproducible shall be submitted rolled (not folded) on the outside of regular mailing tubes. All these drawings will remain the property of the Owner. Owner reserves the right to use them in any manner whatsoever. SHOP DRAWINGS FOR EMBEDDED PARTS Contractor shall prepare the shop drawings in accordance with 'Released for Construction' drawings and IS: 800, Code of Practice for general construction in steel and wherever IS:800 is not applicable then AISC Manual should be used. 5.0.0 5.1.0 FABRICATION, INSTALLATION, PAINTING, RATES & PAYMENT Anchor Bolts Materials for anchor bolts, nuts, locknuts, washers, pipe sleeves and anchor plates shall conform to their respective Indian Standard specifications Fabrication of anchor bolts and their complete assemblies shall be strictly in compliance with the specifications and drawings/ standards. Anchor bolts shall have coarse type threads conforming to IS: 4218.
Section 2.3
Page : 4 of 9
Anchor bolt assemblies shall be placed in position strictly as per drawings and securely held during pouring and vibrating of concrete with necessary templates and other dummy structures to prevent their dislocation. Tolerances allowed for anchor bolts positioning shall be: For sleeved bolts, one tenth of the bolt nominal diameter. For bolts without sleeves, one twentieth of the bolt nominal diameter.
The exposed surfaces of bolts shall be properly covered (after greasing of bolts and packing of sleeves) with jute cloth so as to protect them from damage till final erection of structure/ equipment is over. Payment shall be made on the basis of actual weight in metric tons of the anchor bolt/ anchor bolt assembly. The rate shall include supply of all materials, handling, transporting, fabrication, turning from available size MS round to required diameter, threading, welding, fixing in position, at all levels and locations, providing necessary templates, greasing, packing of sleeves, covering with jute cloth and other protective measures etc. all complete. The rate shall cover bolt of any diameter and nomenclature. Payment for fixing in position anchor bolt assembly (already fabricated and supplied by the Owner as free issue) shall be made on the basis of actual weight of anchor bolts / bolt assemblies in metric tons. The rate shall include handling, transporting, fixing in position, welding if required, providing necessary templates, greasing, packing of sleeves, covering with jute cloth and other protective measures etc. all complete. No separate payment shall be made for templates, dummy structures, supports etc. and the rate quoted shall be inclusive of all cost related to such provision required for correct and accurate installation of anchor bolts / assembly. 5.2.0 Metal Inserts Materials required for fabricating metal inserts shall conform to their respective Indian Standard specifications. Fabrication of inserts shall be done strictly as per drawings / standards and in compliance with the requirements given in Specification No. Section 2.0 Clause 4.0.0 Steel structures. Metal inserts shall be correctly embedded (in plain concrete / reinforced concrete) as per their location shown on the drawings. Care shall be taken that these are securely held in position and do not get disturbed during concreting. Where necessary, these may be welded to the reinforcement bars. Suitable templates, spacers, dummy structures and temporary, staging shall be provided. Necessary cutting in the formwork and adjustment of reinforcement bars shall be done for the placement of metal inserts where required. The exposed surfaces of inserts shall be given one coat of red oxide zinc chromate primer. Payment shall be made on the basis of actual weight in metric tons of the metal inserts. The rate shall include supply of all materials, handling, transporting, fabrication, welding, fixing in position, at all levels and locations, providing necessary templates, spacers, dummy structures, adjusting the formwork and reinforcement, staging, applying one coat of red oxide zinc chromate primer etc. all complete. 5.3.0 Chequered Plates Chequered plates shall be of mild steel and conforming to IS: 3502. Chequering shall be closed or open-ended or of any other pattern as shown on drawings.
Section 2.3
Page : 5 of 9
Chequered plates shall be fabricated as per the Approved for Construction fabrication drawings (prepared by the Contractor based on design drawings). These shall be perfectly flat and without any dents/deformations and shall be cut to the required size and shape. Holes/ notches/ openings of the required size if any, shown on drawings shall be made. Openings on floors shall have toe guard plate 100 mm high. Nosing for staircase treads shall be made by cold bending of chequered plates. All edges shall be made smooth and even. Stiffeners shall be provided where necessary satisfying stress and deflection limits. Chequered plates shall be fixed to the bearing members by welding/ bolting/ screwing as shown on drawings. All bolts/ screws shall be of counter-sunk type so that the heads remain flush with the top of plate. Where welding is used for fixing, stitch welds of minimum 50mm length with a pitch of 150mm shall be used. Continuous sealing run of weld shall be provided along the junction of two consecutive chequered plates parallel to the span. Removable panels shall be sized for manual removal as far as practicable and shall be provided with lifting devices. Chequered plates shall be cleaned (both the surfaces) with wire brush and given one coat of red oxide zinc chromate primer on both surfaces after fabrication. Payment shall be made on the basis of admissible weight in metric of the chequered plates accepted by the Engineer. Inclusive of stiffeners where used. The rate shall include supplying, fabricating, erecting M.S. chequered plates including transporting, handling, straightening if required, cutting to required size and shape, making holes/ notches/ opening of required size and nosing/ toe guard, smoothening the edges, fixing by welding / bolting / screwing, at all levels and locations, preparing detailed fabrication drawings, surface cleaning, removal of rust, scale, grease and applying one coat of red oxide zinc chromate primer etc. all complete. The weight for payment shall be determined from the fabrication & drawings and respective bill of materials prepared by the Contractor. The bill of materials shall be checked and approved by the Engineer-in-Charge before making the payment. The weight shall be calculated on the basis of IS Hand Book. No allowance in weight shall be made for rolling tolerances. Welds, bolts, nuts, screws, washers, clips shall not be measured. The quoted rate shall be deemed to include the same. 5.4.0 Floor Gratings Materials for fabrication and fixing of Gratings shall conform to specification given in drawings. The gratings may be: 1. Fabricated by the Contractor as per drawings.
These shall be fabricated strictly as per the Approved for Construction fabrication drawings prepared by the Contractor based on approved drawings. Slots in the flats shall be punched and not flame-cut. Continuous alround welding shall be done along the contact-lines between two flats on both the surfaces. All fabrication shall be done in a shop under strict supervision. Fixing clamps shall be fabricated as shown on drawing. 2. Ready made and bought of approved make Gratings shall be from approved manufacturer and designed to carry the applied loads without exceeding allowable stresses or allowable deflections. The deflection shall not exceed span/200 or 6mm whichever is lower.
The maximum clear size of voids in the grating is limited to 30mm x 55mm. The Contractor shall make necessary notches / opening in the gratings as shown in the drawings. All edges affected by such notches / openings shall be suitably stiffened by welding additional flats of the requisite size. Before procurement the Contractor shall submit the design calculations, drawings and manufacturers literature / catalogues and get the same reviewed by the Engineer-in-Charge. The Contractor shall submit sample gratings for inspection and approval by the Engineer whenever required. Gratings shall be fixed to the bearing members by welding / clamping and bolting as indicated in the drawings. Minimum length and maximum pitch of welds shall be 50mm and 150mm respectively where stitch welding is used for fixing along the lines of supports. The edges of two consecutive gratings shall be bolted with minimum two bolts on each side of the grating panel. Gratings which are to be painted shall be cleaned with wire brush and given one coat of red oxide zinc chromate primer after fabrication. Where galvanizing is stipulated in the approved drawings, gratings, fixing clamps, bolts, nuts shall be cleaned with wire brush and galvanization shall be done in accordance with IS:2629 and tested as per IS:2633 & 6745. Quantity of zinc coating shall be minimum 900 gms/ sq.m of surface area (0.12mm uniform thickness). Payment shall be made on the basis of admissible weight in metric of the gratings and accepted by the Engineer. The rate shall include supplying, fabricating, erecting MS gratings (of the specified category) including transporting, handling, cutting to required size and shape, making holes / notches / openings, smoothening the edges, fabricating clamps, fixing by welding / clamping / bolting, at all levels and locations, preparing detailed fabrication drawings, surface cleaning, removal of rust, scale, grease and applying one coat of rex oxide zinc chromate primer etc. or galvanizing as required, all complete. The weight for payment shall be determined from the fabrication drawings and respective bill of materials prepared by the Contractor. The bill of materials shall be checked and approved by the Engineer-in-Charge before making the payment. The weight, shall be calculated on the basis of IS Hand Book as mentioned above. No allowance in weight shall be made for rolling tolerances. Welds, bolts, clamps, nuts and washers shall not be measured. The quoted rate shall be deemed to include the same. 5.5.0 Tubular Handrail Tubes for handrails shall conform to IS1239 Medium grade tubes, unless shown otherwise and approved by the Engineer. Handrailing shall be fabricated strictly as per the Approved for Construction fabrication drawings prepared by the Contractor based on approved drawings and standards. All tubes shall be straight and without any dents/deformations. Tubes shall be cut and ends shall be prepared to a neat and workman-like finish. All elements shall be directly welded. All welded joints shall be cleaned and filed or ground smooth, if required, to have a smooth surface and aesthetically pleasant appearance. Splicing of top rail shall not be allowed. Tubes shall be coldbent to shape and curvature in case of discontinuous ends of handrails. Ripples, kinks and / or dents at bends shall not be accepted. Lower ends of vertical posts, where shown, shall be cut and splayed (for grouting in pockets in the concrete members). For removable type of handrailing, suitable base plates (with provision for bolting) shall be welded to the lower end of vertical posts..
Section 2.3
Page : 7 of 9
Handrailing, shall be fixed to the bearing members by welding/ bolting/ grouting as indicated on the drawings. Local notching shall be made in the floor plate/ grating to accommodate vertical posts/their base plats which shall always be welded to the main supporting member. When the posts are to be fixed in concrete members, suitable pockets shall be made in concrete for grouting as shown on drawings / standards. Tubes shall be cleaned with wire brush and given one coat of red oxide zinc chromate primer after fabrication. Payment shall be made on the basis of measured length in meters (M) of top rail only (Horizontal and /or inclined lengths). The rate shall include preparation of fabrication drawings, supply of materials, handling, transporting, straightening if required, cutting to required size, bending, welding, bolting, fixing in position at all levels and locations, grouting with 1:2 (cement:sand) mortar, surface cleaning, removal of rust, scale, grease and applying one coat of red oxide zinc chromate primer after fabrication etc. all complete. The rate shall include making suitable notches in floor plates / gratings and pockets in concrete structures for fixing the vertical posts. 5.6.0 Structure made from Light Gauge Sections All materials required for fabrication and fixing in position of Light Gauge Steel Structural Sections shall conform to their respective Indian Standard specifications. Fabrication of members shall be done strictly as per the Approved for Construction fabrication drawings prepared by the Contractor based on the approved drawings and in accordance with IS:800, IS:801 and other relevant IS Codes. All members shall be straight and free from any dents / deformations / twists. Members shall be cut to the required sizes and ends prepared to a neat and workman like finish. Holes (for sag rods and cleat bolts) of appropriate size shall be drilled and all members / components shall be given distinct erection marks in accordance with the marking drawings. Holes shall not be formed by gas cutting process. Structural members shall be erected in proper sequence and aligned properly without causing any twist. Permanent bolting / welding shall be done only after proper alignment has been achieved. Proper access, working platforms and safety arrangements shall be provided by the Contractor for working and inspections. All structural components shall be cleaned thoroughly and given one coat of red oxide zinc chromate primer after fabrication. Payment shall be made on the basis of admissible weight in metric tons of the structure accepted by the Engineer. The rate shall include supplying, fabricating, erecting, at all levels and locations, testing of bolted and/or welded light gauge structural steel works including cleats, crook bolts, splices/sleeves, all other fixtures and accessories, straightening if required, cutting, edge preparation, welding and bolting of joints, fixing in line and level with temporary staging and removal of the same after final alignment, handling, transporting, storage, preparation of detailed fabrication drawings and getting them reviewed by the Engineer, surface cleaning, wire brushing, removal of scale, rust, oil or grease and applying one coat of red oxide zinc chromate primer etc., all complete. The weight for payment shall include all structural members, cleats, splices, gussets and sag rods and shall be determined from the fabrication drawings along with respective bill of materials prepared by the Contractor. The bill of materials shall be checked and approved by the Engineerin-Charge before making the payment.
Section 2.3
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The weight shall be calculated on the basis of IS Hand Book. Manufacturers catalogues / charts shall be adopted in case relevant weights of sections used are not covered in IS Hand Book. No allowance in weight shall be made for rolling tolerances. All welds, bolts, nuts washers, fixtures and accessories shall not be measured. The quoted rate shall be deemed to include the same. The rate shall be applicable to all cleats, splices, sleeves and gussets. Sag rods, however, shall be separately measured and paid under structural steel item. 5.7.0 Expansion Fasteners Expansion fasteners (medium and heavy duty) shall be of mild steel/high tensile steel with rust proof coating and be of approved make. The expansion fasteners shall be designed as medium and heavy duty depending on their usage. The broad classification is given below for general guidance. Expansion fasteners shall be used where approved by the Engineer and shall not be used for members supporting equipment and pipes subjected to vibrations.
The Contractor shall submit to the Engineer manufacturers catalogues along with the specimens of expansion fasteners (proposed to be used for the job) for his selection and approval. Selected fasteners shall be capable to carry the specified loads. If so desired by the Engineer, the Contractor shall carry out all the requisite tests (pullout test, torque test etc.) of specimen expansion fasteners (representative of those to be used) from approved laboratory / test house and submit the report to him for approval. The decision of the Engineer regarding the adequacy of strength and load carrying capacity of the expansion fastener shall be final and binding to all. The cost of all such tests shall be borne by the Contractor. The Contractor shall install the expansion fasteners at their correct locations as per the procedure laid down by the manufacturer. Location of all holes shall be premarked on the concrete surfaces and then holes drilled carefully with an electric drill to the correct recommended size and depth. Holes shall be exactly round and true perpendicular to the concrete surface. Edge distance and pitch of fasteners shall be as recommended by the manufacturer. The contractor shall suitably shift the hole with the approval of the Engineer-inCharge in case any reinforcement bar is met with while drilling the hole in RCC structure. Necessary staging shall be provided for working and the Contractor shall take requisite safety precautions so as not to cause any damage to the existing structure / equipment. Any damage done while executing the job shall be made good by the Contractor at his cost. The exposed surfaces of expansion fasteners shall be properly greased & covered with jute cloth so as to protect them from damage. Payment for installing rust proof expansion fasteners shall be made on number basis (each). The rate shall include supply of complete assembly, handling, transporting, providing necessary temporary staging, installing (as per manufacturers) in PCC/RCC structures, at all levels and locations, testing, drilling, cleaning, covering with jute cloth, relocating and redrilling in case of any obstruction, making good any damage done to the structure, grouting the abandoned holes and any gap left between the contact surfaces of PCC/RCC and fixtures to be added, etc. all complete.
Section 2.3
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JHABUA POWER LIMITED 1x600MW + 1x660 MW JPL SEONI Project Specification for River Water Intake System
VOLUME II SECTION 2.4 TECHNICAL SPECIFICATION FOR MASONRY WORKS
Section 2.4 Masonry Works
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SECTION 2.4 TECHNICAL SPECIFICATION FOR MASONRY WORKS
CONTENTS
CLAUSE NO. 1.0.0 2.0.0 3.0.0 4.0.0 5.0.0
DESCRIPTION
PAGE NO.
SCOPE ............................................................................................... 3 CODES AND STANDARDS ............................................................... 3 MATERIALS ....................................................................................... 4 STORAGE AND HANDLING .............................................................. 5 WORKMANSHIP ................................................................................ 5
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TECHNICAL SPECIFICATION FOR MASONRY WORKS 1.0.0 SCOPE This specification covers the requirements in respect of materials, workmanship and quality for brickwork, plastering and water-proofing. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Indian Standards Institution and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and method of testing. Some of the relevant available codes are listed hereunder: Brick work IS: 1077 IS: 1542 IS: 1597 IS: 1661 IS: 1905 IS: 2116 IS: 2185 IS: 2212 IS: 2250 IS: 2572 IS: 2691 IS: 3414 IS: 3495 IS: 3696 IS: 5134 IS: 5454 SP: 20 Common burnt clay building bricks Sand for plaster Code of practice for construction of stone masonry Code of practice for application of cement and cement-lime plaster finishes Code of practice for structural use of un-reinforced masonry. Sand for masonry mortars Specification for Hollow Cement Concrete Blocks Code of practice for brickwork Code of practice for preparation and use of masonry mortars Code of practice for construction of hollow concrete block masonry Burnt clay facing bricks Design and installation of joints in buildings Methods of tests of burnt clay building bricks Safety code for scaffolds and ladders Bitumen impregnated paper Methods of sampling of clay building bricks Explanatory handbook on masonry works
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3.0.0 3.1.0
MATERIALS Cement Cement used shall conform to IS: 269.
3.2.0
Sand The sand shall be approved river or pit sand and it shall conform to IS: 2116 for masonry mortar and to IS: 1542 for plaster mortar. The sand shall be hard, durable, clean and free from adherent coatings, mica, shale organic matter and appreciable amount of clay. The sand shall not have deleterious impurities such as iron pyrites, alkalis, salts, coal, mica, shell etc Sand for masonry mortars shall have particle size grading conforming to IS:2106 - latest edition The grading of sand for use in mortar for unreinforced and reinforced brickwork shall be within, the specified limits for respective works The fineness modulus of sand for mortar in un reinforced or reinforced brickwork shall be between 2.9 and 2.1. A sand whose grading falls outside the specified limits due to excess or deficiency of coarse or fine particles may be processed to comply with the standard, by screening and or blending. Any deviation may be allowed at the discretion of the Engineer.
3.3.0
Bricks The bricks used shall be atleast chamber burnt second class (class B) bricks conforming to IS:1077 having a minimum compressive strength of 50 Kg/cm2. Bricks are to be whole, uniform texture, sound, well burnt, free from cracks, square and well shaped, uniform in size, uniform red cherry or copper colour and shall emit a clear ringing sound when struck. Slight distortion or rounded edges are permitted provided no difficulty arises during laying of uniform course. Water absorption after 24 hours immersion shall not exceed 20% by weight. Dimensional tolerance shall not exceed 8%. They shall not break when thrown on ground on their flat surface in saturated condition from, height of 1600 mm. Good bricks locally available and conforming to above can also be used. Only bricks of one standard size shall be used on one work unless specifically permitted by the Engineer. Each brick shall have the manufacturer's identification mark of initial marked clearly in the frog. Representative samples of full size bricks shall be submitted for approval before commencing the work. Bricks proposed to be used shall conform to the approved samples in all respects. Bricks found not up to the specification shall be removed from the Site at the Contractor's own cost. Representative samples shall be submitted and approved samples shall be retained by the Engineer for future comparison.
3.4.0
Block Work All hollow concrete blocks shall have a density not less than 1500 Kg/Cu.m and shall conform to Grade - A of IS : 2185 (Part - I) in all respects and shall be used for the purpose of load bearing walls, curtain walls and partition walls. Crushing strength shall not be less than 50 Kg/sq.m. Following are the nominal sizes of blocks generally adopted: Size A Size B Size C 400 x 300 x 200 (ht) mm 400 x 200 x 200 (ht) mm 400 x 100 x 200 (ht) mm
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Half size block thick masonry shall refer to size - C and shall be used for partition walls only. 3.5.0 Stone Masonry Building stones shall be obtained from the quarries approved by the Engineer. These shall be free from decay, sand holes, reins, flaws, cracks and other defects. Store not suited for the particular class of work defined shall be rejected and shall be removed from the site at once, by the contractor. 4.0.0 STORAGE AND HANDLING Bricks shall not be dumped at site. These shall be stacked in regular tiers on firm ground, even as these are unloaded, to minimise breakage and defacement of bricks. Bricks selected from different situation of use in the work shall be stacked separately. 5.0.0 5.1.0 WORKMANSHIP Brick work IS: 2212 shall be followed as general guidance for construction of brick work masonry. The whole of the brickwork shall be carried out by the Contractor in a uniform manner. All the bricks shall be kept under water till they are completely soaked and used on the works on their becoming skin dry. The Contractor shall set out and build all brickwork to the dimension, thickness and heights shown on the drawings. The Contractor shall build all brickwork in English bond and half brick walls and casing to pipe, chases etc. in stretcher bond. Brickbats shall not be used except where required for bond. The Contractor shall lay bricks in full mortar beds with shoved joints. The joints are not to exceed 10 mm in thickness and are to be full of mortar, close, well finished and neatly struck. The vertical joints in any course shall not be nearer than quarter of a brick length from those in the course below. All joints shall be of same width except for small variations to maintain bond. The brickwork shall be laid plumb and trim to line and level. No portion of brickwork shall be raised more than 1 metre above another at one time. If the mortar in any course has begun to set, the joints shall be raked out before another course is laid. The top course of brickwork in reinforced concrete framed structure shall be wedged against reinforced concrete surface and joint well filled with mortar. All courses shall be laid truly horizontal and all vertical joints made truly vertical. Vertical joints is in one course and the next below shall not come over another and shall not normally be nearer than 1/4 of brick length. Fixture, plugs, frames etc. if any, shall be built in at places shown in the drawing while laying courses only and not later by removal of the bricks already laid. Bricks with 20 mm deep frog shall be used frog-down. Bricks with 10 mm deep frog shall be used either frog up or frog down. Care shall be taken during construction to see that edges of bricks at quoins, sills, heads etc. are not damaged. All brick work shall be tightly built against columns, floor slabs, or other structural members around door and window frames with proper distance to permit caulked joints In case of very dry weather, the surface of the brick shall be kept wet to prevent drying of mortar. At the end of days work, provision shall be made to keep the surface of brick work wet with water. Brick work shall be added uniformly throughout so that no portion of the work shall be left more than 900 mm lower than other. Verticality of walls and horizontally of the courses shall be checked very often with plumb-bob and spirit level respectively. The Contractor shall flush up thoroughly with mortar all joints as the work proceeds. Where brickwork is to receive plaster, the joints shall be raked to a depth of 12 mm to provide proper bond.
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The brickwork as it progresses shall be thoroughly watered on its faces and top. New work shall be properly bonded with the old work. The surface of unfinished work shall be cleaned and thoroughly wetted before joining new work to it. Any work in which the mortar perishes shall be dismantled and rebuilt by the Contractor at his own expense. The Contractor shall carry out work in as clean a manner as possible and shall remove excess material and mortar droppings daily. Where brick walls, are to receive plaster, excess materials and mortar droppings shall be removed and the surface shall be brushed clean. During cleaning operations, adjacent work shall be protected and any damage resulting from improper protection shall be made good by the Contractor at his own cost. Reinforcement if shown in the drawing shall be provided fully embedding in mortar after thoroughly cleaned. These shall be lapped with dowels if left in RC columns or welded to steel columns. Encasing of structural steel shall be done by building masonry work round flanges, webs etc., and filling the gap between steel and masonry by minimum 12 mm thick mortar. Encased members shall be wrapped with chicken wire mesh when shown on drawings or instructed by the engineer. The minimum lap in chicken wire mesh shall be 50 mm. Other steel embedments shall be generally embedded in mortar and masonry unit shall be cut as required. 5.2.0 Block work IS : 2572 shall be followed as general guidance for construction of hollow concrete block masonry. Blocks shall be used only after shrinkage has taken place. The moisture content must not exceed the limit specified in IS : 2185. Composite cement - lime - sand mortar of proportion 1 : 1 : 8 shall be used. Mortar shall meet the requirements of IS : 2250. The blocks shall be laid with full mortar bedding. All voids shall be filled with full mortar bedding. All voids shall be filled with PCC at plinth level and window sill level, etc. Masonry work shall be cured by keeping it constantly moist on all faces for a minimum period of seven days. 5.3.0 Stone Masonry The Contractor shall furnish all labour, materials and equipment required for the construction of all stone masonry work required as mentioned. IS: 1597 shall be followed as general guidance for stone masonry construction. The stone shall be approved one, free from decay and weathering. The stone shall be obtained from approved quarry. Coloured or distorted stones with boulder skin or earthy or porous matter, or stones with round surface shall not be used. The stones should be clean, flat bedded. The crushing strength of the rubble for use in the stone masonry should not be less than 150 kg/cm2. They should be properly cleaned of dirt and dust and all weathered portions should be skinned off before use. Rubbles having a weight of 20-30 kg per piece should not be less than 70% of the total and other pieces should not have a weight less than 10-15 Kg per piece. The stones shall be hammer dressed on the face, the sides and the bed to enable them to come into close proximity with each other. The stones may be laid at random without being brought up to any level course and with lamination perpendicular to the thrust with a suitable proportion of small stones and chips to fill up interstices. 5.3.1 Laying The stones shall be laid on their broadest face.
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Stratified stones shall be laid on their natural bed, i.e. with the strata perpendicular to the pressure. The courses shall be built perpendicular to the pressure. Where there is to be variation in the depth of courses, larger stones are to be placed in the lower courses, the thickness of courses, decreasing gradually towards the top of the wall. To give sufficient lateral bond, a stone in any course should overlap the stone in the course below, i.e. joints parallel to the pressure in two adjoining courses should not lie too closely in the same vertical line. To give sufficient transverse bond, the prescribed number of headers must extend from front to back of thin walls or from outside wall to the interior of thick walls. At all angle junctions of walls, the stones at each alternative course shall be so carried into each of the respective walls as to unite the work thoroughly. Where breaks are unavoidable in carrying up the work continuously in horizontal courses, sufficient long steps shall be left to join the old and new work. The practice of building two thin faces tied with occasional through stones and filling up the middle with small stuff or even dry packing is strictly prohibited. If it is necessary to move a stone after it has been placed on the mortar bed, it should be lifted clear and rest and not made to slide it over stones already laid. 5.3.2 Watering To prevent absorption of water from the mortar, the stones shall be sufficiently wetted before laying. All masonry shall be kept watered for three weeks from the date of building in place, unless otherwise instructed by the Engineer. At the close of the days work or for other periods of cessation of work, the top of all unfinished masonry is to kept well flooded. Should the mortar perish, i.e. become dry, white or powdery through neglect of watering, the work shall be pulled down and rebuilt. All masonry shall be washed down of all stains on completion of work. 5.3.3 Jambs for Door and Window Openings Jambs for door and window openings shall be formed with quoins of the full height of the course in the case of coursed masonry. The quoins shall be in breadth atleast one and half times the depth of the course and in length atleast twice the depth. For each side of door openings two of these quoins shall be stones of the full thickness of the walls. Unless rebating of the whole frames into the masonry is specially specified. Chisel dressing to the width of door and window frames shall be done to secure a close fit between the frames and the masonry. A rebate shall be made in the frame where plastering is to join with the frame as shown in the standard designs for doors and windows and the plaster shall be keyed well into the rebate to form a neat joint. The contract rates for all classes of masonry are inclusive of quoins, jambs, and chisel dressing as demanded by the above and by the following masonry sub-specifications. 5.3.4 Mortar and Materials to Conform to Standard Specification The mortar to be used for each class of masonry shall conform to the particular standard specification for that class of mortar and the standard specifications for the materials used therein.
Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Detailed Technical Specification Section 2.4 Masonry Works Page : 7 of 10
5.3.5
Holes for Passages of Water etc. Care shall be taken to see that holes for passage of water wherever necessary as from terraces, bath rooms, recesses for downfall pipes, etc. are provided during construction and neatly finished off by pointing or plastering as ordered. Well seasoned wooden plugs of sizes and quality approved by the Engineer are to be built in as work proceeds for fixing door and window shutter appliances, hangers, picture rails, and for any other purpose decided necessary by the Engineer. Holes are also to be cut in the sill-stones to receive the uprights of door - frames, in cases where there is no threshold plate to the frame.
5.3.6
Iron, Stone, Concrete or other Fixtures and Buttresses etc. All iron, stone, concrete or other fixtures, returns, buttresses, counterforts etc., shall be built and bonded into the work as it proceeds and not inserted or joggled on after the masonry is advanced.
5.3.7
Chisel Drafting Corners and Rounding Interior Corners of Rooms The vertical exterior corners of buildings and pillars buildings in coursed rubble in mortar, first and second sort and random rubble in mortar shall be chisel drafted 38 mm width on either side, or such other width as may be specified. At the entrances of doors, windows, archway and other openings, the corners against which doors or windows will open shall be chamfered 25 mm width and chisel - drafted beyond the chamfer 38 mm as above extent when parliamentary hinges are used, in which case chisel - drafting only is necessary. All interior corners of rooms and projecting angles shall be rounded to 25 mm radius. The projecting angles will in such cases be chamfered as necessary and the rounding for both interior corners and projecting angles will then be done in the plaster. Similarly, rounded, chamfered and chisel - drafted corners shall be done wherever they may be shown on the drawings.
5.4.0
Plastering Unless otherwise specified, all plaster work shall be carried out according to IS:1661. thickness and proportion of cement plaster shall be as specified in the drawing. The
The surface to be plastered shall be cleaned of all extraneous matter and rubbish. In brickwork the joints shall be raked and concrete surface roughened by chipping or hacking. Any shuttering material adhering to the concrete shall be removed. The Contractor shall make plaster pads of the required thickness of plaster for correctness of plumb, line and level. The surface shall be thoroughly watered and soaked and aerated and all holes shall be closed before starting plastering operation. Plaster, when more than 15 mm thick shall be applied in two coats - a base coat followed by the finishing coat. The under coat shall be of sufficient thickness to fill up all unevenness in the surface, no single coat, however, shall exceed 15 mm in thickness. For one coat plaster work, the plaster shall be laid slightly thicker than the specified thickness and the surface then leveled with flat wooden rule to the required thickness. The plaster shall be well pressed into the joints and the surface finished as specified. For two coats of plaster work, the first coat shall be applied as described above except that the surface shall be left rough and keys formed for the application of second coat. The second coat shall be applied a day or two after the first coat has set, but the first coat shall not be allowed to dry. The second coat shall consist of mortar ground very fine and shall be laid on with a wooden rule to a specified thickness, rubbed smooth and leveled and the surface plastered completely the same day. The leveling shall be continued till the plaster is quite dry and all moisture which exudes from the plaster shall be wiped off with a fine cloth. The surface shall be kept dry until exudation of moisture ceases, during the process of rubbing.
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5.5.0 5.5.1
Finish Sand faced plaster The plaster shall be applied in two coats. The first coat or the scratch coat should be approximately 14 mm and shall be continuously carried out without breaks to the full length of wall or naturing breaking points such as doors, windows etc. The scratch coat shall be dashed on the prepared to true and even surface and then lightly roughened by cross scratch lines to provide bond for finish coat. The scratch coat shall be cured for atleast 7 days and then allowed to dry. The second coat shall be 6 mm thick and it shall not be applied until atleast 10 days have elapsed after the application at first coat. Before application of the second coat, the scratch coat shall be evenly damped. This coat shall be applied from top to bottom in one operation and without joints, finish shall be straight, true and even. Only approved river sand shall be used for the second coat and for finishing work. Sand for finish shall be of even coarse size and shall be dashed on the surface and sponged.
5.5.2
Plaster-of-Paris Punning Plastered surfaces, where specified, shall be finished with plaster-of-paris punning. The material shall be approved by the Engineer-in-charge. The thickness of punning shall be 2 mm and shall be applied by skilled workman. The finish shall be smooth, even and free from undulation. Before bulk work is taken in hand, a sample of punning shall be done on roughly 1 sq.m area and approval of the Engineer-in-charge taken. The work shall be taken then in hand as per approved sample.
5.6.0
Curing The brick shall be cured for a period of fourteen (14) days after laying and the plaster shall be cured for a period of seven (7) days.
5.7.0
Expansion & Separation Joints Location and details of expansion joints shall be strictly as shown in the drawings and specified in schedule of items. Expansion joint filler boards and sealing strips shall have minimum transverse joints. Transverse joints shall be approved by the Engineer. Separation joints shall be with standard water proof paper or with alkathene sheets about 1 mm in thickness. Length and sealing of taps shall be to the satisfaction of the Engineer.
5.8.0
Damp Proof Course The proportion of cement to aggregates shall be 1:2:4 using 6 mm down stone chips with a water proofing admixture. The percentage of waterproof admixture shall be as per manufacturer's specification but not less than 2% by weight of cement. The brick masonry surface shall be leveled, flushed up and prepared as directed to receive the damp-proof course. The thickness of damp proof course shall be 40 mm. In masonry walls of buildings it shall normally be placed above the external ground level. It shall be laid for the full width of the wall. The top surface shall be kept rough or ribbed for mortar for brickwork coming over it, for proper adhesion. All exposed surfaces of the damp-proof course shall be finished fair and smooth. It shall be cured for atleast 7 days. After the surface has partially set, hot bitumen shall be applied in two coats at the rate of 1.7 kg per sq.m per coat and dry sand spread over it.
5.9.0
Brick - on - edge coping and plinth protection The top course of all plinths, parapets, steps and tops of walls below R.C.C slabs, beams etc. shall be laid with brick - on - edge, unless shown otherwise. Care shall be taken that bricks
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forming the top corners and ends of walls shall be properly radiated and keyed into position as specified in IS: 2212. Plinths of all buildings shall be protected by 12 mm thick cement plaster (CM 1 : 3) over PCC paving of minimum 750 mm width. Proportion of PCC shall be 1 : 2 : 4 with min. thickness of 100 mm. Paving shall be laid in upward slope of 1 in 50 over a 75 mm thick dry graded aggregate grouted with sand. Storm water drain shall be provided by the side of plinth protection.
Section 2.4
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Masonry Works
VOLUME II SECTION 2.5 WATERPROOFING, ROOF INSULATION & ALLIED WORKS
Section 2.5
Page : 1 of 10
Water Proofing, Roof Insulation & Allied Works
TECHNICAL SPECIFICATION FOR WATERPROOFING, ROOF INSULATION & ALLIED WORKS
CONTENTS
CLAUSE NO.
DESCRIPTION
PAGE NO.
1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0
SCOPE ..................................................................................................... 3 CODES AND STANDARDS ...................................................................... 3 MATERIALS.............................................................................................. 3 GRADING UNDERBED ............................................................................ 5 THERMAL INSULATION .......................................................................... 5 WATERPROOFING WITH PREFABRICATED POLYETHYLENE AND POLYMERIC ASPHALT ............................................................................ 6
7.0.0 8.0.0
WATER PROOFING WITH HESSIAN BASED BITUMEN FELTS ............ 8 WATERPROOFING WITH FIBRE GLASS TISSUE REINFORCED BITUMEN FELT ........................................................................................ 9
9.0.0
WATER PROOFING OF ROOFS WITH BRICK LIME CONCRETE AND PRESSED FLAT TILES ............................................................................ 9
10.0.0
ACCEPTANCE CRITERIA ...................................................................... 10
Section 2.5
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SECTION 2.5 TECHNICAL SPECIFICATION FOR WATERPROOFING, ROOF INSULATION AND ALLIED WORKS 1.0.0 SCOPE This specification covers the requirements in respect of materials, workmanship and quality for membrane water proofing of roofs and underground, over-deck insulation and allied works. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the contract, shall govern in respect of design, workmanship, quality and properties of materials and method of testing. Some of the relevant available codes are listed hereunder: IS: 73 IS: 702 IS: 3384 Paving Bitumen Industrial bitumen Specification for Bitumen primer for use in water proofing and damp proofing Bitumen felts for water proofing and damp proofing Code of practice for waterproofing of roofs with bitumen felts Bituminous compound for water proofing and caulking purposes. Code of practice for laying damp-proof course using bitumen felts Specification for Low Density Polyethylene Films. Integrated cement water proofing compounds (1987) Code of practice for general design details and preparatory work for dampproofing and water-proofing of building. Expanded polystyrene for thermal insulation purposes Cellular Concrete for Thermal Insulation Specification for glass fiber base coal tar pitch and bitumen felts.
IS: 1322 IS: 1346 IS: 1580 IS: 1609 IS: 2508 IS: 2645 IS: 3067
IS: 4671 IS: 6598 IS: 7193 3.0.0 3.1.1 MATERIALS
Bituminous Polymeric membrane for roof water proofing Bituminous Polymeric membrane used for waterproofing roofs shall be 90 micron thick HMHDPE Centre core (Tear index greater than 150) protected on both sides with polymeric bitumen of softening point exceeding 115oC and penetration of 55 8 and further covered on both sides with protective thermo fusible polyethylene film. Elongation at break shall be 300% or higher, tensile strength of 220 N/5 cm or higher, pliability of 5oC or lower and heat resistance 100C or higher.
Section 2.5
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For precast roofs, the top HMHDPE layer shall be substituted with embossed aluminium foil 75 microns thick. Product to be used for cast-in-situ roof slab shall be MULTIPLAS STANDARD and that for roof with precast slab panels shall be MULTIPLAS ALUMINIUM or approved equivalent. 3.1.2 Bituminous polymeric membrane for underground damp proofing The membrane used for water proofing underground structures shall be 7 layered membranes similar to 5 layered roofing membrane, but reinforced with a non woven polyester mat of minimum 140 g/m for additional mechanical strength and covered with additional layer of polymeric asphalt. Product to be used shall be MULTIPLAS HYPER or approved equivalent. 3.1.3 Bitumen Felt It shall conform to IS: 1322 and the number of layers shall be as specified in the schedule of items. Bitumen primer shall conform to IS 3384. The bonding materials shall consist of blown type bitumen conforming to IS: 702 or residual bitumen to IS: 73 or a mixture of the two to withstand local conditions of prevailing temperature or gradient of roof surface. 3.1.4 Fiber Glass Tissue Reinforced Bitumen Felt It shall conform to IS: 7193, consisting of reinforced glass fibber base coated on both sides with bitumen modified with thermo plastic polymers. 3.1.5 High Solids Content, Cold Liquid-Applied Elastomeric Waterproofing Membrane The required properties and test methods for a cold liquid-applied elastomeric-type membrane, one or two component, for waterproofing roofs and walls subject to hydrostatic pressure in building areas to be occupied by personnel, vehicles, or equipment shall conform to ASTM C386 and application shall be as per ASTM C398 & C1471. 3.2.0 Bonding Materials Bonding materials used for applying the polymeric bituminous membrane on surfaces shall be 3 fiber and solvent based, rubber modified bituminous primer of density 0.92 g/cm with viscosity 500 to 10,000 cps. Ordinary bitumen wherever used shall be of blown type conforming to IS: 702 or residual bitumen conforming to IS: 73 or a mixture thereof. 3.3.0 Water proofing admixture The water proofing admixture shall conform to IS: 2645 and shall be approved by the Engineer. 3.4.0 Cement Cement shall conform to IS: 269. 3.5.0 Aggregates The aggregates shall conform to IS: 383. Fine aggregate shall be river sand or pit sand from approved pits. Coarse aggregate shall be stone chips of size not exceeding 6 mm. 3.6.0 Metal Flashings Wherever specified on drawings the metal flashings shall be of 18 g or 20 g galvanised iron. 3.7.0 Foam Concrete Foam concrete shall be generally as per IS 6598. Cellular concrete for thermal insulation
3.8.0
Expanded Polystyrene Blocks Expanded polystyrene blocks shall conform to IS 4671.
3.9.0
Polyethylene Sheets Polyethylene sheets shall conform to IS 2508 Specification for Low Density Polyethylene Films.
4.0.0
GRADING UNDERBED The surface to receive the underbed shall be roughened and thoroughly cleaned with wire brush and water. Oil patches if any shall be removed with detergent. The surface shall be soaked with water and all excess water removed just before laying of the underbed. The underbed shall be laid to provide an ultimate run off gradient not less than 1 in 100 or as directed by the Engineer. Upto a thickness of 25 mm the underbed shall usually be composed of cement and sand plaster. For higher thickness the underbed shall be made with cement concrete. The underbed shall be finished to receive the waterproofing treatment direct or insulation as the case may be. The underbed shall not be laid under direct hot sun and shall be kept in shade immediately after laying so as to avoid quick loss of water from the mix and separation, from the roof surface. The underbed shall be cured under water for at least 7 days. The following are the brief details of the types of grading underbed:
4.1.0
Plaster The grading plaster shall be maximum 25 mm thick. It shall consist of cement and sand in ratio 1 : 4 (nominal) by volume. The sand and cement shall be thoroughly mixed dry and then water added. Each batch of mix shall be consumed before the initial set starts. The plaster shall be fully compacted to the desired grade in continuous operation. The surface shall be even and reasonably smooth.
4.1.2
Concrete Concrete shall be used where the underbed is more than 25 mm thick. It shall consist of cement concrete 1 : 2 : 4 nominal mix by volume with 12.5 mm down stone chips and sand. The aggregate shall be mixed dry and minimum quantity of waters shall be added to make the mix workable. The mix shall be laid to proper grade, fully consolidated and surface shall be smooth and even.
5.0.0 5.1.0
THERMAL INSULATION Foam Concrete Foam concrete shall be of light weight - 300 to 500 kg/cum - of minimum 50mm thickness or as specified in the drawings. This may be laid in-situ or as precast blocks / slabs. The thermal conductivity shall not exceed 0.125 kcal.m/sqm/hour/deg C. Before starting of work, samples shall be prepared and got tested for the approval of the Engineer. The foam concrete laid shall have sufficient strength to withstand the usual construction loads and the design loads expected on the roof. Damaged portions, if any, shall be removed and replaced forthwith. The Engineers approval shall be obtained prior to starting of laying of water-proofing course. The water proof course shall be laid over 12mm cement sand plaster unless screed concrete is provided over the foam concrete.
Section 2.5
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5.2.0
Expanded Polystyrene Blocks The expanded polystyrene insulation blocks shall be of fire retading quality having a thermal conductivity not more than 0.026 kcal.m/sqm/hour/deg C. It shall be strong enough to support the anticipated loading on it. The contractor shall furnish the manufacturers specification for the work and get it approved by the Engineer before commencing work. Workers shall be specifically experienced for this wok and shall be done under manufacturers supervision.
5.2.0
Fillets Filets of 150mm x 150mm shall be provided at junctions of roof with walls of the same insulation material as used for the roof. Uninsulated roofs may have fillets of 1:2:4 nominal mix concrete.
6.0.0
WATERPROOFING WITH PREFABRICATED POLYETHYLENE AND POLYMERIC ASPHALT Workmanship Waterproofing for roof with polymeric bituminous membrane. The roof slabs shall be cleaned of all dust, dirt, grit etc. and if rough it shall be made reasonably smooth either by clipping of projections or by applying a thin coat of cement slurry of cement sand and water. The roof surface shall be regraded prior to waterproofing with cement mortar. At the places of drain outlets, projecting pipes, parapet walls and expansion joints etc. the surface shall be prepared in indicated in IS : 1346. Over the hardened and finished surface of the roof slab, fiber and solvent based, rubber modified bituminous primer of density 0.92 g/cm3 and viscosity 500 to 10,000 cps is applied at the rate of 250 g/cm2. First membrane of multiples standard (or approved equivalent) shall be unrolled and extended starting at the fillet end parallel to the largest part of the roof endeavoring to center the membrane over the drain at the lowest point of the roof. One of the ends is bonded by fusing the lower asphalt layer and ensuring that a transverse area, with a minimum width of 20 cm is completely adhered to the substrata. Then one of the men on the application team stands on the area that is bonded to the substrata while another stretches and flattens the membrane at the other end. Once the membrane is stretched, opposite end is bonded to the substrata by fusing the asphalt also on a transverse area with a minimum width of 20 cm ensuring that transverse joints are staggered. While this is being done, the first applicator unrolls the following roll of membrane placing it parallel to the first and extending 10 cm over the same (overlap) fusing and stretching it as with the first membrane. The overlap is kept open with help of a trowel and flame is directed uniformly inside and towards both membrane, working the flame in opposite direction in advance of the applicator. When asphalt starts to flow, applicator should press both membrane with his foot on the opposite side holding the torch until a thin string of fluid asphalt appears, indicating correct fusing and bonding. External fusing of the overlap is finished off by leveling and homogenizing exterior asphalt with the trowel, having previously heated the area with torch. In case of roofs with parapets, a chase 75 mm deep shall be cut in the parapet masonry at about 150 mm above the roof level and the membrane shall be laid as flashing in widths with a minimum overlap of 100 mm. The lower edge of the flashing shall overlap the membrane laid on the flat portion, and the upper edge of the flashing shall be tucked into the groove made in the parapet. After the flashing has been properly bonded, the chase shall be cleaned and shall be filled up with cement mortar 1 : 4 flush with the face of the wall, and allowed to set by adequate curing. For gutters, the membrane shall be laid over a primer coat, and finally painted with a coat of hot bitumen at not less that 1.5 Kg/sg.m. The membrane treatment shall be carried down into the outlet pipes to a minimum depth of 100 mm. After the treatment is over, the surface shall
6.1.0 6.1.1
Section 2.5
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be covered with 20 mm plaster of cement mortar 1:4 reinforced with chicken wire wesh marked off into squares 600 mm wide with expansion joints provided at a distance of 3 metres. 6.1.2 Damp proofing for underground structures Waterproofing for underground structures wherever indicated in the drawings shall be done with polymeric bituminous membrane strengthened with high quality polyester for resisting static water pressure. Half brick thick brick work in cm 1 : 4 shall be provided as protection to waterproofing on external side faces. Membranes shall be fastened with the vertical surfaces for height exceeding 4,5 mtrs. Prior to application of the membrane, the surface shall be coated with fibre and solvent based rubber modified bituminous primer of density 0.92 g/cm and viscosity 500 to 10,000 cps applied at the rate of 250 g/m. 6.1.3 WATER-PROOFING OF UNDERGROUND STRUCTURES CBT AND INJECTION GROUTING STRUCTURES Underground structures shall be treated with waterproofing treatment as described herein under. This treatment shall also apply to other areas of work if required as per detailed design. The Contractor shall ensure that the waterproofing treatment renders the structures completely watertight and does not allow any leakage / seepage of water in any direction over a specified period. The structures shall be in bonedry condition. The waterproofing treatment shall be proven system by reputed organizations. The Contractor shall enlist the works carried out by him for his waterproofing treatment. METHOD CBT TREATMENT Raft - Cement based treatment shall be applied over PCC (Mud-mat). The top surface of PCC shall be finished smooth with wooden trowel. Before laying the waterproofing treatment, the top surface of PCC shall be cleared of timber, spoils, laitance, scum or loose concrete. Thereafter cement based treatment (CBT) shall be laid over PCC as per manufacturer's recommendations. Over CBT, RC raft will be concreted as early as possible. CBT shall be cured by spraying water over it till construction of RC raft during concreting of RC raft, 25 mm dia G.I. grout pipes shall be placed at suitable locations (2 meters to 3 meters spacing) and inclination as per expert's accepted practice. Along construction joints extra care shall be taken while deciding on spacing of G.l grout pipes to ensure that grouting around water stops is done satisfactorily. Construction joints shall be hacked to expose aggregates and shall be treated with rich cement slurry. The Contractor shall specifically note that deformed bars anchors which pierce the CBT shall be completely treated by injection grouting or as recommended by water proofing agency. The Contractor shall clearly indicate his process of waterproofing including material and application he proposes to use. Walls - CBT shall be applied or external faces of wall as per manufacturers specifications. Construction joints in walls shall be treated as mentioned in preceding paragraphs. To ensure water-tightness of walls, Contractor shall place grout pipes at construction joints. Contractor shall place these pipes before concreting of walls with approval of Engineer. WATERPROOFING TREATMENT (BY GROUTING) After curing of raft and waits is completed, inject cement grout of correct consistency shall be injected through G.I. pipes in raft and walls under low pressure by means of hand-pump or other approved system. The low pressure grouting shall be such that grout penetrates through all pores and crevices and fills all the voids in the concrete, thus blocking the passage of water through concrete. Contractor shall add correct amount of admixture to ensure satisfactory performance of the treatment.
Section 2.5
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WATERPROOFING TREATMENT BY LIQUID WATERPROOFING MEMBRANE The Liquid waterproofing membrane treatment for the underground structures as well as for roofs where insulation requirements are not specified. The scope includes supply and application of the treatment in line with the specifications and drawings. The work shall be carried out with the best workmanship. The materials and the application shall be subjected to the qualification requirements and acceptance requirements in line with the specifications to the satisfaction of the Engineer. The work shall proceed only after the approval from the Engineer. The procedure for the treatment for underground structures shall be as follows: The entire surface on which the treatment is to be given shall be cleaned with wire brush to make it free from loose dust, dirt, etc. Apply first coat of liquid waterproofing membrane at the rate of 1.5 kg/sq. m. Apply second coat of liquid water proofing membrane at the rate of 1.5 kg/sq. m To protect the liquid water proofing membrane from damage, provide 12 mm thick plaster in cement mortar 1:4.
The procedure for the treatment to the flat roof shall be as follows: Clean the entire surface with the help of wire brush so as to make it free from loose dust, dirt, etc, Apply a coat of bituminous primer of approved make at the rate of 0.2 kg/sq.m Lay 4mm thick polyester reinforced polymer modified bituminous membrane of approved make The joints shall be sealed properly. Apply a coat of bituminous aluminium paint on entire surface of the membrane (where roof is inaccessible) To protect polyester reinforced polymer modified bituminous membrane, provide 25mm thick plaster in cement mortar 1:4 with chicken wire mesh as reinforcement (where roof is accessible)
7.0.0 7.1.0 7.1.1
WATER PROOFING WITH HESSIAN BASED BITUMEN FELTS Workmanship Waterproofing for roof The roof slab shall be cleaned of all dust, dirt, grit etc. and if rough it shall be made reasonably smooth either by chipping of projections or by applying a thin coat of cement slurry of cement, sand and water. The roof surface shall be regarded prior to waterproofing either with cement mortar or limesurkhi mortar. At the places of drain outlets, projecting pipes, parapet walls and expansion joints etc. the surface shall be prepared as indicated in IS: 1346. The workmanship in general shall conform to IS: 1346 unless otherwise specified. Over the hardened and finished surface of the roof slab, a thin layer of approved bitumen primer shall be first brushed over the roof surface and allowed to dry.
Section 2.5
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The felt shall be first cut to the required lengths and laid out flat on the roof in position at right angles to the direction of run-off gradient and shall be brushed clean of dusting materials. Each length of felt thus laid in position shall be rolled up for a distance of half of its length. Then the bonding material heated to correct temperature shall be poured on to the roof across the full width of the rolled felt as the latter is steadily rolled out and pressed down. Excess bonding material shall be squeezed out at the ends and removed as the laying proceeds. When the first half of the strip of felt has been bonded to the roof, the other half shall be rolled up and then unrolled on to the hot bonding material in the same way. Minimum overlaps of 100 mm shall be allowed at the end and the sides of strips of felt. All overlaps shall be firmly bonded with hot bitumen. The laying of the second layer of felt shall be so arranged that the joints are staggered with those of the layer beneath it. In case of roofs with parapets, a chase 75 mm deep shall be cut in the parapet masonry at about 150 mm above the roof level and the felt shall be laid as flashings in widths with a minimum overlap of 100 mm. The lower edge of flashing shall overlap the felt laid on flat portion of the roof and the upper edge of the flashing shall be tucked into the groove made in the parapet. After the flashings have been properly bonded, the chase shall be cleaned and shall be filled up with cement mortar (1:4) flush with the face of the wall and allowed to set by adequate curing. In case of drain mouths, waterproofing shall be done as specified for the roof excepting that the treatment shall be carried inside the drain pipes overlapping at least 100 mm. For gutters, a priming coat shall first be applied. Over this, a specified number of layers of felt shall be laid and bonded together with hot bitumen and finally painted with a coat of hot bitumen at not less than 1.5 kg per sq. metre. The felt layers laid separately in the gutters shall be overlapped with the corresponding layers on the roof proper. The felt treatment shall be carried down into the outlet pipes to a minimum depth of 100 mm. After the treatment is over, the surface shall be covered by pea-sized gravel or grit at the rate of 0.6 cu.m per 100 sq.m. On flashings and at drain mouths a finish of two coats of approved bituminous primer shall be provided. 7.1.2 Damp Proofing For Under Ground Structures Damp proofing for under ground structures wherever indicated shall be done as per recommendations of IS: 1609 - 1976 clause 5.2(b), for heavy treatment with three layers of felt. The method of laying damp proofing treatment shall be as per clause 6 of IS:1609. 8.0.0 8.1.0 8.1.1 WATERPROOFING WITH FIBRE GLASS TISSUE REINFORCED BITUMEN FELT Workmanship Water proofing for roofs shall be according to the guide lines in IS: 1346. Other aspects shall be the same as in clause 6.1.1. Damp Proofing of Under Ground Structures It shall be done as per guidelines laid in IS: 1609 - 1976 clauses 5.2(b) & 6. The felt layers shall be fastened to the wall surface wherever the height exceeds 4.5 meters. Half brick wall in C M 1.4 shall be erected as protection to the external face of the water proofing. 9.0.0 WATER PROOFING OF ROOFS WITH BRICK LIME CONCRETE AND PRESSED FLAT TILES Workmanship The exposed surfaces of the roof slab shall be thoroughly cleaned. A layer of brick lime concrete shall be laid over the cleaned surface. Brick lime concrete shall be 1:2:4 by volume
8.1.2
9.1.0
using 20 mm down graded brick bats. The slope of the lime concrete layer shall be 1:100 and the minimum thickness shall be 50 mm. The slope of the draining surfaces shall be formed on all the sides as necessary. Care shall be taken to check the quantity of water. The quantity of water shall be so as to make the concrete just workable. Cement sand mortar 1:3 with 2% mixture of "Accoproof"(or approved equivalent water proofing agent) shall be laid over the underbed to a thickness of 20 mm. Pressed flat tiles are set over the mortar and painted with cement mortar 1:3 with 2% "Accoproof" (or approved equivalent water proofing agent). 10.0.0 ACCEPTANCE CRITERIA The surface level shall be such as to allow quick draining of water without leaving any pool anywhere. The finishing course shall be fully secured and shall have an even density. There shall not be any bubble formation or crushed or squeezed insulation or underbed. The Contractor shall give a guarantee in writing for all works executed under this specification supplemented by a separate and unilateral guarantee from the specialised agency for the roof waterproofing treatment work. The guarantee shall be for materials and workmanship for five (5) years in case of normal treatment, ten (10) years for heavy treatment and fifteen (15) years for extra heavy treatment. The mode of execution of the guarantee shall be acceptable to the Owner.
Section 2.5
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JHABUA POWER LIMITED 1x600 MW + 1x660MW JPL Seoni Project
Tender Documents for River Water Intake System
VOLUME II SECTION 2.6 TECHNICAL SPECIFICATION FOR DOORS, WINDOWS, LOUVRES, ROLLING SHUTTERS & GLAZING
Section 2.6
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Doors, Windows, Louvers, Rolling Shutters & Glazing
TECHNICAL SPECIFICATION FOR DOORS, WINDOWS, LOUVERS, ROLLING SHUTTERS & GLAZING
CONTENTS
CLAUSE NO.
DESCRIPTION
PAGE NO.
1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0
SCOPE ..................................................................................................... 3 CODES AND STANDARDS ..................................................................... 3 MATERIALS & WORKMANSHIP .............................................................. 4 STORAGE AND HANDLING .................................................................... 9 ASSEMBLY AND ERECTION .................................................................. 9 HARDWARE AND FIXTURES................................................................ 10
Section 2.6
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SECTION 2.6 TECHNICAL SPECIFICATION FOR DOORS, WINDOWS, LOUVERS, ROLLING SHUTTERS & GLAZING 1.0.0 SCOPE This specification covers the requirements in respect of materials, workmanship and quality for doors, windows louvers, Rolling Shutters and glazing work. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and method of testing. Some of the relevant available codes are listed hereunder: Metal Doors & Windows IS: 733 IS: 1038 IS: 1361 IS: 1948 IS: 1949 IS: 4351 Timber Doors IS: 4021 IS: 1003 IS: 2191 IS: 2202 Timber door, window and ventilator frames Timber paneled and glazed shutters. Wooden flush door shutter (cellular and hollow core type) Wooden flush door shutters (solid core type) Wrought aluminium and aluminium alloy bars, rods and sections (for general engineering purposes) Steel doors, windows and ventilators Steel windows for industrial buildings Aluminium doors, windows and ventilators Aluminium windows for industrial buildings. Steel door frames
Rolling Shutters IS: 6248 Glazing IS: 1081 Code of practice for fixing and glazing of metal (steel and aluminium) doors, windows and ventilators Flat transparent sheet glass for glazing and framing purposes Code of practice for glazing in buildings Code of practice for Putty (latest edition) Metal rolling shutters and rolling grills
IS: 2835 IS: 3548 IS: 419
Builder's Hardware
Section 2.6
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IS: 204 IS: 205 IS: 208 IS: 281 IS: 363 IS: 723 IS: 1823 IS: 2209 IS: 2681 IS: 3564 IS: 3847 IS: 4992 IS: 6607 3.0.0 3.1.0
Tower bolts Non-ferrous metal butt hinges Door handles Mild steel sliding door bolts for use with padlocks Hasps and staples Steel counter sunk head wire nails Floor door stoppers Mortice locks (vertical type) Non-ferrous metal sliding door bolts for use with padlocks Door closers (hydraulically regulated) Mortice night latches Door handles for mortice locks (vertical types) Rebated mortice locks (vertical type)
MATERIALS & WORKMANSHIP STEEL DOORS, WINDOWS, VENTILATORS ETC. SUPPLY AND INSTALLATION The work in general shall of supplying and/or erecting and installation of all metal doors, windows, ventilators, louvers, glazed partitions, etc complete with frame, fittings, fixtures, lock sets with duplicate set of keys and all hardware as a complete package as indicated in Door Schedule including supply of glass and glazing. The scope of work shall also include filling up the hollow metal door frame with concrete 1:2:4 and then erect at site as per approved drawings and/or specifications. Door closures are also covered under this specification. The air tight doors shall include necessary heading/gasket, hook strip at threshold etc for air tightness. In general, wherever applicable and unless otherwise noted, the work shall conform IS:1038, IS:1361, IS:1949, IS:1948, IS:4351 latest editions and/or other relevant Indian standard code. All components for steel doors and windows shall be brought to the site completely fabricated with a cost of shop paint. All aluminium doors, windows, frames and bars for glazing, mullions, transoms, glazing beads, necessary frame reinforcements and all other accessories are included in the work. All aluminium door and window fixtures are also included in this specification and shall be factory fabricated wherever possible. Erection shall be done at site including assembling composite units where required. All materials shall be from approved manufacturers. After installation of steel doors, windows etc. all abrasions to shop coat of paint shall be retouched and made good with the same quality of paint used in shop coat. Rates quoted shall also include minor rectification at site if found required such as welding of fixtures, making screw holes and providing screw and rectification of dents formed in the doors and shutters. All steel doors, windows, louvers, frames etc. shall be painted with one coat of zinc chromate rich primer after installation and touch up as above, and finished with two coats of synthetic enamel paint.
Section 2.6
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3.1.1
Door Frames Frames shall be rolled or pressed sections from 18 G sheet conforming to IS: 4351. They shall be mortised, reinforced, drilled and tapped for hinges and lock and bolt strikes. Where necessary, frames shall be reinforced for door closures. Welded construction with mitred corners shall be used. Rubber door silencers shall be furnished for the striking jamb. Loose 'T' masonry anchors shall be provided. Frames shall finish flush with floor and adjustable floor anchors shall be supplied. Frames shall be brought to site with floor ties/ weather bars installed in place.
3.1.2
Double Plate Flush Door Shutters Door shutters shall be 45 mm thick, completely flush design and shall comprise of two outer sheets of 18 G steel sheets rigidly connected and reinforced inside with continuous vertical 20 G stiffeners, spot welded in position at no more than 150 mm on centers. Both edges of doors shall be joined and reinforced full height by steel channels placed immediately inside and welded to the door faces. Top and bottom of doors shall be reinforced horizontally by steel channels running full width of door. Doors shall not have more than 2.5 mm clearance at jambs and head, shall have proper bevel on lock stiles and rails to operate without binding, and shall be reinforced at corners to prevent sagging or twisting. Pairs or double doors shall have meeting-stile edges beveled or rebated. All doors shall be insulated with spun mineral wool insulation for sound deadening. Door frames 45mm x 45mm x 6mm MS angle sections, shutters made of 43mm rolled steel channel section framework with stiffeners of 40mm x 40mm x 3mm M.S. angle section spaced approximately 45cms c/c, skin plate of one face of the shutter welded to the frame and stiffeners and the other face fixed with machine screws after inserting mineral wool, all other details remaining as per the approved drawings and specifications. The mounting of the door shutters shall ensure leak tightness. Doors shall not have more than 2.5 mm clearance at jambs and head, shall have proper level on lock stiles and rails to operate without binding Doors shall be mortised, reinforced, drilled and tapped in shop for hinges, locks and bolts. The finished work shall be strong and rigid, neat in appearance and free from defects. They shall also be reinforced for closures, push-plates and other surface hardwares where necessary. Any drilling and tapping required for surface hardware shall be done at site. Where necessary, provision shall be made for fixing glazing, vision panels, louvers etc. glazing mouldings shall be of 18 G steel and suitable for fixing 6 mm glass. Louver blades shall be V or Z shaped and made out of 16 G sheets. Wherever required, provisions shall be made for fixing louvers (made of 16 G steel sheets) and/or 6.3 mm thick sheet glass, Glazing beads where required shall be from 20 G steel and shall be removable.
3.1.3
Sliding Doors Sliding doors shall be double plate construction made out of 18 G steel sheets with adequate stiffness. The Contractor shall specify the weight of the door in his shop drawing and submit the manufacturer's catalogue of the sliding gear he proposes to use. Where shown on drawings or call for in the Schedule of Items, the Contractor shall make provisions for openings in the door for monorail beams. Doors shall close positively to exclude rain water from seeping in. Sliding doors shall withstand specified wind loads without buckling or jamming. The door shall slide freely under all ambient conditions.
3.1.4
FIRE PROOF DOORS SCOPE The work under this section shall include supply and/ or erecting and installing fireproof doors as shown in approved manufacturers drawing with all material complete.
Section 2.6
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The scope of work shall also include assembly and erection of composite types of fireproof doors. Supplying and/or fixing of all door accessories and hardware and also include in the scope. The fire proof door shall be 30 mm thick composite type side hung airtight fire check steel flush door in prestressed steel frame with two hour fire rating including 200 mm x 200 mm vision panel of 6 mm thick wired glass and panic device complete with related hardware and a coat of approved primer and shall conform to IS: 3614 (Part I and II). Standard practice of testing of fireproof doors shall be carried as per the relevant IS codes at the manufacturer works before dispatch. INSTALLATION Purpose of fire proof door is to confine outbreak of fire to the smallest possible area and minimise damage to adjoining property. An effective fire proof door must be able to resist the intense heat from out break of fire on one side without distorting. Thermal conductivity of fireproof door shall be sufficiently low to prevent ignition of combustible materials on the other side of door. COMPOSITE FIRE PROOF DOORS Composite fire proof doors shall be side hung doors. Doors shall be built within a stout inner frame of flat steel bars bound together at the corners by angle iron brackets. Core of the doors shall be made of angular steel strips at right angles, slotted and interlocked to form a pattern of square cells. Asbestos millboard shall be fastened over both faces of core and the whole is covered by steel sheets. The sheets shall be riveted through with countersunk rivets spaced not more than 900mm apart, one rivet to each 600mm x 600mm of door area. The assembly shall be then bound together by a channel section of border riveted through the door with rivets spaced 150 mm apart. The face on both sides of door shall be made plain. Composite fire proof doors shall be fitted with automatic closing gear. In the event of fire a fusible link shall operate and allow the door to close. Hinged door shall be fitted with rising hinges or an overhead oil check action spring as recommended by the manufacturer. Fire resistant grade for composite fire proof doors shall be as given in Schedule of Items. All composite fire proof doors shall be fitted with locks. Fire proof doors shall be approved manufactured by Engineer. Before starting fabrication of all fire proof doors the contractor shall submit detailed fabrication drawings to the Engineer for approval. The fabrication shall be started only after approval of drawings. 3.1.4 Steel Windows, Sashes, Ventilators, etc. These shall conform in all respects to IS: 1038 and IS: 1361. The details as called for in the above codes shall be applicable for coupling mullions, transoms, weather bars, pivot arrangements for ventilators, etc. All welds shall be dressed flush on all exposed and contact surfaces. Where composite unit openings are provided the individual window units shall be joined together with requisite transoms and mullions. All windows shall be outside glazed, fixed with putty or metal glazing beads. All welds at the corner of casement shall be done by flash butt welding process and dressed flush on all exposed and contact surfaces.
Section 2.6
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3.2.0
ALUMINIUM DOORS, WINDOWS AND FRAMES Aluminium sections for fabricating doors, windows, partitions etc., shall be extruded sections conforming to IS: 1948 & IS:1949 or as manufactured by Indian Aluminium Company Ltd. or approved equivalent. The alloy used shall conform to IS designation HE 9-WP of IS: 733. Extruded sections shall have a minimum 2 mm wall thickness. All sections shall be approved by the Engineer before fabrication is taken up. Doors, frames, mullions, transoms etc. shall be anodized in a bath of sulphuric acid to provide a clear coating of minimum 0.06 mm thickness. The anodized materials shall then be sealed by immersing in boiling water for 15 minutes. A protective transparent coating shall be applied to the sections before shipment from the factory. All work shall be fitted and shop assembled to a first class job, and ready for erection. Shop joints shall be made to hair lines and then welded or braced by such method as will produce a uniform colour throughout the work. Work on the above, other than described, shall be neatly finished with concealed fasteners. Glazing beads shall be snap fit type, without visible screws and shall be of sizes to accommodate 6 mm thick glazing.
3.3.0 3.3.1
TIMBER DOORS Materials All timber shall be best quality well seasoned specified species free from large or loose knots cracks or other defects. Where specified, timber shall be treated with approved wood preservative before starting the joinery work, the Contractor shall have the rough timber approved by the Engineer. Plywood shall be of commercial quality or with decorative surface veneer as specified. The core for solid core doors shall be of block board or wood particle board. Manufacturer's literature and test certificates shall be submitted for the approval of the Engineer. The Contractor shall give a guarantee that the adhesive used is phenol-formaldehyde confirming to IS: 848. The thickness shall be as specified in the "Schedule of Items". Fixtures for doors, windows, furniture etc. shall be as shown on drawing or specified in the "Schedule of Fixtures". These shall be of heavy type, best quality and from approved manufacturer. The Contractor shall have to mention the name of the manufacturer for different types of joinery hardwares, fittings and fixtures. Samples of each type of fittings shall have to be submitted to the Engineer for obtaining approval before bulk supply.
3.3.2
Workmanship The work shall be done by skilled carpenters as per details shown on drawing or instructed by the Engineer. Framing timber and other work shall be close-fitting with proper wood joinery, accurately set to required lines or levels and rigidly secured in place. The surface of frames etc. which will come in contact with masonry after fixing, shall be given two coats of approved paint before fixing. Mastic caulking shall be done after fixing external door and window frames. Special care shall be taken to match the grain of timber or plywood which will be subsequently polished. Screwing or nailing will not be permitted to the edge of plywood or chip-board sheets. All exposed plywood edges shall be finished with teakwood timber lipping unless otherwise shown on drawings. All carpentry work after finishing shall be sand papered smooth. Prime coat paint shall be given after inspection of the Engineer to all surfaces other than those which shall be subsequently polished or covered with laminated plastic sheet.
Section 2.6
Page : 7 of 10
When shown on drawings or called for in Schedule, decorative ply or laminated plastic sheets shall be bonded under pressure to the surface to be finished. The adhesive used shall be of approved brand and bought to site in sealed containers. The rate of application and the length of time for which the pressure is to be applied shall be as per the manufacturer's instruction. The edge of sheets shall be protected by teakwood timber lipping. However, where available factory made ready for use material of reputed manufacturer shall be used. All frames shall be square and flat at the time of delivery and shall be checked for dimensions and corner angles. After fixing they shall be on a fine vertical plane. All external door and window frames shall be caulked with mastic. 3.4.0 PVC DOORS & WINDOWS PVC doors and windows shall be obtained from reputed manufacturers and shall be SINTEX or approved equivalent quality. The material used shall be unplasticised PVC having superior impact resistance. Density of the material shall be 1.4 grams/cm3 and tensile stress and bending stress of 480 and 770 kilopascal/cm. The outer section wall thickness shall be min. 2.8 mm. The section shall be reinforced with steel sections concealed inside a cavity of PVC sections. Corners shall be welded, transome / mullions welded or mechanically joined. Weather sealing shall be by double sealing with elastomeric weather strip, the corners being glued. Opening for PVC doors / windows shall be 10 mm more than the window / door size. The doors shall be fixed to the wall by expandable fasteners or by brackets. Manufacturers recommendation shall be followed for installation. 3.5.0 ROLLING SHUTTER (HAND OPERATED, MECHANICAL GEAR OPERATED AND ELECTRICALLY OPERATED) Rolling shutters shall be fabricated from 18 gauge steel and machine rolled with 75 mm rolling centers with effective bridge depth of 12 mm lath sections, interlocked with each other and ends locked with malleable cast iron chips to IS:2108 and shall be designed to withstand a wind load of 200 Kg/m2 without excessive deflection. The guides shall be either rolled or pressed deep channel sections 75 mm and 25 mm wide fitted with necessary fitting and fixtures. The suspension shaft shall be formed from heavy duty tubes conforming to IS:1161 and of sufficient diameter so as to resist deflection due to weight of the rolling shutter. The deflection shall not exceed 5 mm/ metre width. The shaft shall be provided with CI pulleys and helical springs for counter balancing the weight of the shutter adequately. The springs shall be approved high tensile flat springs conforming to Grade 2 of IS:4454. These shall be fitted inside the fabricated housing of either ends which counter-balance the shutter curtain. The ball bearings shall be double row self-aligning ball bearings fitted inside C.I. housing fixed on side brackets holding the suspension shaft at either end. The roller assembly shall be designed so as to be capable of producing sufficient torque to ensure easy operation of the rolling shutter in any position. The spring tension shall be adjustable by means of suitable adjustments holes drilled on the rims of the pulley. The hood cover shall be made of 20 gauge galvanized sheets with necessary stiffeners and framework to prevent sag. The bottom lock plate shall be made of 5 mm thick M.S. plate and 95 mm wide reinforced with angle/T iron of suitable section with 6 mm dia M.S. rivets interlocked with last stride of curtain.
Section 2.6
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The locking arrangement shall consist of sliding bolts at both ends of the bottom plate fitted to engage with suitable receiving pockets at the bottom of guide channels. Unless otherwise specified, for overall area of rolling, shutters up to 9 sq.m pull and push type hand-operated shutters shall be used; for area between 9 and 12 sq.m pull and push type shutters shall be provided with ball bearings; for area larger than 12 sq.m mechanical gear type or electrically operated shutters shall be supplied. 3.6.0 GLAZING Glass for glazing shall be of the following types: 4 mm thick transparent sheet glass conforming to IS: 2835 generally used for openable shutters of windows. 5.5 mm thick wired glass conforming to IS: 5437 generally used for fixed shutters of windows. 6.3 mm thick laminated safety glass conforming to IS: 2553 generally used for fixed glazed partitions. 5.5 mm thick transparent sheet glass used for aluminium glazed doors.
All glass shall be cut according to the sizes required as per drawings. Glazing of metal doors, windows and ventilations shall conform to IS: 1081 either with putty or metal clips. The Contractor shall thoroughly clean all glass and replace all putty or glass damaged during the work. All glass shall be cut according to the sizes required as per drawings. Glazing of metal doors, windows and ventilators shall conform to IS: 1081 either with putty or metal clips. The Contractor shall thoroughly clean all glass and replace all putty or glass damaged during the work. 3.6.1 PUTTY In general, the putty shall conform to IS:419 latest edition. The putty shall be of best quality from approved manufacturer. It shall be brought to site in the manufacturer's original packing. Quick setting putty shall be used for windows and sashes except when glare reducing glass is used. 4.0.0 STORAGE AND HANDLING All metal doors, windows etc. shall be packed and crated properly before dispatch and shall be stored under cover in a way to prevent damage or distortion. Special care shall be taken to prevent staining of aluminium products by rust or mortar etc. Glass shall be brought to site in manufacturer's original packing. 4.1.0 TRANSPORTING All metal doors, windows, etc., shall be packed and crated properly before dispatch, to ensure that there will be no damage to the fabricated materials. Loading into wagons and trucks shall be done with all care to ensure safe arrival of materials at site in undamaged condition. 5.0.0 ASSEMBLY AND ERECTION The Contractor shall assemble and install all doors, windows, louvers, etc. including transoms mullions for composite units in respective places keeping proper lines and levels, and in approved workman like manner, to give trouble free and leak proof installations. The
installations shall be done according to the instructions of the manufacturer and/or as approved by the Engineer-in-charge. If required by the Engineer-in-charge, the installation shall have to be carried out under the supervision of the manufacturer's staff. After installation of steel doors, windows etc. all abrasions to shop-coat of paint shall be retouched and made good with the same quality of paint in shop coat. All coupling mullions, transoms, frames etc. in contact with adjacent steel and other members shall be well bedded in mastic. Door shutters, partitions, hardware fixtures shall be fixed only after major equipments have been installed in rooms. 6.0.0 HARDWARE AND FIXTURES Hardware and fixtures shall be best quality from the approved manufacturers and able to withstand repeated use. The Contractor has to provide the required number / size of fixture for trouble free operation and adequate strength. Door closers shall be suitable for shutter weight and shall be guaranteed against manufacturing defect for one year and any defect found within this period shall be rectified or the door closer replaced without extra cost to the Owner. The Contractor shall submit samples of each type of hardware to the Engineer-in-charge and the approved samples shall be retained by the Engineer-in-charge for comparison of bulk supply. 6.1.0 PAINT AND FINISH Shutters shall be painted with one coat of red lead or zinc chromate primer. Where specified, doors shall be galvanized and subsequently painted one coat of zinc chromate for adhesion of field coat. All the above finished works shall be up to the satisfaction of the Engineer.
Section 2.6
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VOLUME II SECTION 2.7 TECHNICAL SPECIFICATION FOR PAINTING, COLOUR WASHING ETC
Section 2.7 Painting, Colour Washing, etc.
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SECTION 2.7 TECHNICAL SPECIFICATION FOR PAINTING, COLOUR WASHING ETC.
CONTENTS
CLAUSE NO.
DESCRIPTION
PAGE NO.
1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0
SCOPE .............................................................................................. 3 CODES AND STANDARDS ............................................................... 3 MATERIALS ....................................................................................... 4 WHITE WASHING, COLOUR WASHING AND DISTEMPERING ...... 5 PAINTING .......................................................................................... 7 ACCEPTANCE CRITERIA ................................................................. 8
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SECTION 5.7 TECHNICAL SPECIFICATION FOR PAINTING, COLOUR WASHING ETC. 1.0.0 SCOPE This specification covers the requirements in respect of materials, workmanship and quality for finishing works to masonry, concrete and steel such as white washing, colour washing, distempering and painting. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Indian Standards Institution and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and method of testing. Some of the relevant available codes are listed hereunder: White washing, colour washing and distempering IS: 427 IS: 428 IS: 6278 Painting IS: 5 IS: 102 IS: 123 IS: 1477 IS: 2074 IS: 2338 IS: 2339 IS: 2395 IS: 2932 Colours for ready mixed paints and enamels Ready mixed paint, brushing, red lead, non-setting, priming Ready mixed paint, brushing, finishing, semigloss, for general purposes Code of practice for painting of ferrous metals in buildings Ready mixed paint, air drying, red oxide-zinc chrome, priming Code of practice for finishing of wood and wood based materials. Aluminium paint for general purposes in dual container Code of practice for painting concrete, masonry and plaster surface Enamel, synthetic, exterior, a. IS: 2933 Under coating b. Finishing Distemper, dry colour as required Distemper, oil emulsion, colour as required Code of practice for white washing and colour washing
Enamel, exterior, a. Under coating b. Finishing
IS: 5410
Specification for cement paint, colour as required
IS 158/81 & IS 9862/81 Bituminous paint
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3.0.0 3.1.0
MATERIALS Distemper Dry Distemper shall be made from suitable pigments, extenders lime proof tinters, water soluble binders confirming to IS: 427. Oil bound washable distemper shall be of oil emulsion type containing suitable preservatives confirming to IS: 428.
3.2.0
Gum and blue pigment Gum and blue pigment for white wash shall be of best quality and of approved make.
3.3.0
Water Proof Cement Paint Water proof cement paint shall be made from best quality white cement and lime resistant colours with accelerators, water proofing agents and fungicides. The paint shall confirm to IS: 5410.
3.4.0
Paint The painting and finishing materials for use in the work shall conform to relevant Indian Standards specifications and shall be best brands of approved make produced for each kind of work. Aluminium paint shall be in two back containers and shall resist weathering. The acrylic emulsion paint, after it is dried, shall be able to withstand washing with mild soap and water without any deterioration in colour or without showing flaking, blistering or peeling.
3.5.0
Acrylic Emulsion Paint Acrylic emulsion paint shall be water-based acrylic copolymer emulsion with rutile titanium dioxide and other selected pigments and fungicide it shall exhibit excellent adhesion to plaster and cement surface and shall resist deterioration by alkali salts. The paint film shall allow the moisture in wall to escape without peeling or blister. The paint, after it is dried, shall be able to withstand washing with mild soap and water without any deterioration in colour; or without showing flaking, blisters or peeling.
3.6.0
Synthetic Enamel Paint Synthetic enamel paint shall be made from synthetic resins and drying oil with rutile titanium dioxide and other selected pigments to give a smooth, hard, durable and glossy finish to all exterior and interior surfaces. White and pastel shades shall resist yellowing and darkening with aging. The paint shall conform to IS : 2932 & IS : 2933.
3.7.0
Epoxy Protective Coating The paint and thinner shall be supplied by the Contractor. The properties of the paint to be supplied are as given below. TYPE: All catalyzed epoxy floor paints shall be cold cured, high building, epoxy system. Polyamide cured epoxy paint will consist of two packs. The epoxy system shall consist of a base and hardener mixed in parts recommended by the manufacturer. Mixing time - 5 minutes Pot life - 8 hours at 22C Curing time - Tough - 30/40 min. Hard 12 hours
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Film thickness - 1.5 mil /coat a) Polyurethane Coatings The contractor shall follow the specifications as suggested by the manufacturer of the above material and the m hod of coating and the material duly approved by the Engineer. 3.8.0 Bitumastic Paint for Isolation Joints Bitumastic paint conforming to IS: 9862 shall be supplied and applied by the Contractor. Two coats of paint shall be applied over surfaces to form isolation joints. Painting shall be performed in accordance with the manufacturer's instructions or/and as directed by the Purchaser. A sample of material shall be approved by the Engineer before it is used on site. 3.9.0 Primer coat Unless otherwise specified, the primer coat for concrete steel and iron work shall be as specified by the manufacturer. 4.0.0 4.1.0 WHITE WASHING, COLOUR WASHING AND DISTEMPERING Mixing The slaked lime shall be screened to pass through a sieve of 49 meshes per sq.cm. and dissolved in a tub with sufficient quantity of water and shall be well mixed to give a thin creamy consistency. It shall then be strained through a clean coarse cloth and clean gum dissolved in hot water added to it at the rate of 2 kg for each cubic meter of lime and ultramarine blue added to the mixture in small proportion just sufficient to give a very light bluish tint. Colour wash shall be prepared in the same way as for white washing except that necessary amount of colouring matter shall be added to lime wash to obtain the colour specified. No blue shall be added in this case. The entire quantity shall be mixed strictly in accordance with the manufacturer's instructions unless these are varied by the Engineer. Distemper shall not be mixed in a larger quantity than is actually required for a day's work and hot water shall be used in preparing the mixture. 4.2.0 Preparation of Surface Before white wash is laid on new wall, the surface of wall shall be well cleaned and brushed and all patching must be scraped properly. After cleaning the surface, all holes, cracks and patches shall be made good with approved materials. Masonry cracks shall be cleaned out and patch filled with mortar similar to the original surface and finished with cement wash. For all internal painting the surface shall be made smooth by application of approved paste fillers before applying primer. The distemper shall not be applied on damp walls and shall be applied in dry weather. The surface to be distempered shall be thoroughly cleaned of dust, dirt, grease, oil marks, cement marks, loose scales etc. and rubbed with sand paper to give a uniform smooth surface. Metal All metal surfaces shall be absolutely clean, dry and free from wax, grease or dried soap films. All steel and iron surfaces, in addition, shall be free from rust. All steel or galvanized iron surfaces shall be pre-treated with a compatible primer according to the manufactures
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direction. Prime coat for steel work shall, however, be applied by the fabricator. Any abrasion in shop coat shall be touched up with the same quality of paint as, the original coat. Surface Preparation for Epoxy Protective Coating I) Concrete and Cement Plastered Surfaces
Concrete floor and plastered surfaces should be structurally sound, dry and cleaned of all dirt, dust, oils, grease, paint, curing compounds and other foreign materials. The ultimate adhesion of the protective coating is dependent upon a clean surface. Badly soiled concrete floors or surfaces that are very dense and slick should be slightly roughened to provide a proper 'teeth' for the coating. All surfaces requiring painting shall be cleaned of all oil, grease and other foreign matter as directed by the Purchaser. All concrete surfaces shall be sack rubbed prior to this cleaning operation. a) Cleaning shall be a high pressure water wash. Water shall be applied to the concrete/plaster surface by means of an air water nozzle using a tip with an orifice size of 15 mm. Water shall be potable. Water pressure connection to the pressure cleaning unit shall be at a minimum of 7Kg/sq. cm. and the pressure will be increased if the cleaning is not satisfactory. Work shall commence at the top of the walls working down, applying the spraying in a manner that will prevent surface water from the area being cleaned passing over previously cleaned areas. The nozzle shall be held approximately 300 mm from the surface at a slight angle perpendicular to the surface Sufficient time shall be spent on each area to remove all loose particles from the surface. Should any surface be oily, a detergent wash shall be applied before the water wash. The floor shall be thoroughly rinsed with clear water after acid has stopped bubbling. All surface water shall be removed. The surface shall be allowed to dry out completely if necessary by force drying, before application of the protective coating. b) Sealing Coats
After cleaning small pockets, pits, cracks and gorge, the surface shall be filled with an epoxy filler compatible with the epoxy painting system or the knifing compound, to be supplied by the contractor, for the vinyl painting. The sealing filler is generally "to be applied by troweling into holes to form a smooth even surface. Care should be taken to mix a quantity enough to last for the life specified by the manufacturer The sealing filler is to be generally left overnight for curing hard and dry. ii) Metal Metal shall be cleaned to a bright finish by wire brushing. One coat of metal primer shall be applied and allowed to dry. 4.3.0 Workmanship White wash shall be applied with brush, each coat consisting of vertical stroke from top downwards followed by opposite stroke upwards over the first stroke and horizontal stroke from left to right followed by stroke right to left. Each coat must be allowed to dry before the next coat is applied. On completion, the surface when it becomes dry, shall present a uniform white appearance. When dry, no coat of white wash shall show any patches, haircracks or streaks nor shall it come off when rubbed with hands. White washing shall be done in 3 coats unless otherwise specified. Doors, windows, floors etc. must be protected from white wash splashes. Any splashes and droppings shall be removed and cleaned.
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Colour wash shall be applied in the same manner as specified for white wash. During application, the solution shall be stirred continuously and wash shall be applied with care to avoid any cut shade or brush marks on the walls when the work is complete. For all new work, the surface to be colour washed shall first be treated with a priming coat of lime wash. Unless otherwise specified, two coats of white wash shall first be applied before colour wash is applied. Number of coats of colour wash shall be as specified in the drawings or in the Schedule of Rates. The colour washes, whether applied inside or outside of a building shall be of uniform tint and shade. The workmanship for distempering shall conform to IS: 427 and IS: 428 unless specified otherwise. Distempering shall be done with proper distemper brushes of approved quality. The finished surface shall be of absolutely uniform shade throughout and free from brush marks. On drying, the distemper shall not come off on touch and shall not crack. Distemper shall be applied in two coats over one coat of priming. The priming coat shall be as specified and the primer shall be in accordance with the recommendation of the manufacturer. Before applying the primer, the plastered surface shall be washed with a solution of 100 gm of zinc sulphate to one C of water and then allowed to dry. Succeeding coats shall not be applied until the previous coat has been approved by the Engineer. The first coat shall always be of a lighter tint and shall be applied with care. In case the finish is not upto the standards, the entire surface shall be sand-papered and a fresh coat or coats of distemper shall be supplied without any extra cost. All decorative mouldings, cornices, bands etc. shall be finished according to detailed drawings. All splashes of distemper shall be removed by the Contractor at his own cost. The surface to be coated with water proof cement paint shall be washed and brushed down. As soon as the moisture has disappeared, the surface shall be given one coat of paint. Care shall be taken so that the paint does not dry out too rapidly. After four to six hours, water shall be sprinkled over the surface to assist curing and prevent cracking. After the first coat has dried (24 to 48 hours), the second coat shall be applied in a similar manner. The finished surface shall be kept moist by occasional sprinkling with water for seven days after painting. 5.0.0 5.1.0 PAINTING Preparation of surface The surfaces of iron and steel work to be painted millscale and be thoroughly dry before painting. descaling wherever necessary shall be carried out galvanised iron surfaces shall be pre-treated with manufacturer's direction. shall be cleaned free of dirt, oil, rust, Cleaning, degreasing, derusting and as specified in IS: 1477 (Part I). All a compatible primer according to the
The surfaces of wood shall be rubbed down smooth. All nails and screws shall be sunk below the surface and filled with mastic after applying an under coat. Small knots that do not justify cutting and sap streaks shall be covered with minimum two coats of pure shellac coating applied thinly and extended 25 mm beyond the area. All large, loose or resinous knots shall be removed and filled with sound wood. All work shall be done as per IS: 2338. 5.2.0 Application Painting of iron and steel work shall generally be carried out as per IS: 1477. The paint manufacturer's specification/instructions shall be followed as far as possible at all times. Particular attention shall be paid to the following: a. Proper storage to avoid exposure, as well as extremes of temperature.
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b. Surface preparation prior to painting c. Mixing and thinning
d. Application of paints and the recommended time limit on time intervals between coats. Painting operations shall not proceed until the Engineer has the opportunity to inspect the condition of prepared surface to be painted. Paint shall be thoroughly mixed and not more than 1/2 kg of recommended thinner per 4.5 kg liters of paint shall be added if thinning is necessary. Exterior paint shall not be performed during the period of inclement weather. Interior painting may proceed during such periods only with the approval of the Engineer. Prior to application of subsequent coat, the Engineer shall be given the opportunity to inspect the prior coat. Should the work be judged by the Engineer be inferior, a supplementary coat shall be applied at no additional cost. The number of coats including the primer coat shall be applied as specified. Each coat shall be allowed to dry sufficiently before the succeeding coat is applied. The type of intermediate and finish coat and the number of coats to be applied shall be as specified. Intermediate and finish coats may be oil bound, bituminous, aluminium or other types of paints. Aluminium paint shall conform to IS: 2339. The intermediate and finish coats for structural steel work, sheet metal work and cast iron work shall be applied as specified in IS:1477 (Part II). Storage The contractor shall arrange for safe and proper storage of all materials and tools The storage space if allotted within the building shall be adequately protected from damage, disfigurement and stains Paints shall be kept covered at all times and mixing shall be done in suitable containers, All necessary precautions shall be taken by the Contractor to prevent fire. 6.0.0 ACCEPTANCE CRITERIA a) All the painted surface shall be uniform and pleasing in appearance. b) The colour, texture etc. shall match exactly with those of approved samples. c) All stains, splashes and splatters of paints shall be removed from surrounding surface.
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VOLUME - II SECTION 2.8 TECHNICAL SPECIFICATION FOR FLOOR AND FLOOR FINISHING
Section 2.8 Floor and Floor Finishing
Page : 1 of 13
SECTION 2.8 TECHNICAL SPECIFICATION FOR FLOOR AND FLOOR FINISHING
CONTENTS
CLAUSE NO. 1.0.0 2.0.0 3.0.0 4.0.0 5.0.0
DESCRIPTION
PAGE NO.
SCOPE ......................................................................................3 CODES AND STANDARDS ......................................................3 BOULDER SOLING...................................................................3 CEMENT CONCRETE FLOORING ...........................................3 FLOOR FINISHES.....................................................................4
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SECTION 2.8 TECHNICAL SPECIFICATION FOR FLOOR AND FLOOR FINISHING 1.0.0 SCOPE This specification covers requirements in respect of material, workmanship and quality for soling, concrete floor and floor finishes work. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest additions as published by Bureau of Indian Standards and all other such as may be directed published by them during currency of the contract, shall govern in respect of design, workmanship, quality and properties of materials and method of testing. Some of the relevant available codes are listed here under: IS: 777 IS: 1237 IS: 1443 IS: 2114 IS: 2571 IS: 3461 IS: 3462 IS: 4457 IS: 5318 IS: 5491 3.0.0 Specification for glazed earthenware wall tiles. Specification for Cement Concrete Flooring Tiles Code of Practice for Laying and Finishing Cement Concrete Flooring Tiles Code of Practice for Laying in-situ Terrazzo Floor Finish Codes of practice for Laying in-situ Concrete Flooring Specification for PVC asbestos Floor Tiles. Specification for Unbacked Flexible PVC Flooring Ceramic Unglazed Vitreous Acid-Resistant Tiles Code of Practice for Laying PVC Flooring Code of Practice for Laying in-situ Granolithic Concrete Floor Topping.
BOULDER SOLING The boulders for soling shall be granite, basalt or similar hard stone approved by the Engineer and generally shall be 200 mm thick. The sub grade shall be dressed to correct level and shall be rammed or rolled to proper consolidation before laying the soling. Stones shall be placed close to each other. The specified thickness shall be made up in one layer only. The voids between the stones shall be hard packed first with smaller pieces and hammered into place so as to completely fill up the void along with moorum as binding material and the layer is watered and compacted well by roller / mechanical compactor. No stone after packing shall move or tilt in any direction when walked over. In case of building enclosing heavy machinery like gas turbine / steam turbine, the compaction shall be by roller of 8/10 MT capacity.
4.0.0 4.1.0 4.1.1
CEMENT CONCRETE FLOORING Materials Cement Ordinary Portland cement shall conform to IS: 269.
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4.1.2
Aggregate The aggregates shall conform to IS: 383. The size of coarse aggregate shall be 40 mm down graded. Grading of coarse aggregates shall conform to Table 1 of IS: 2571. The fine aggregates shall be either of grading zone 1 or 2 of Table 2, IS: 2571.
4.2.0
WORKMANSHIP The workmanship shall generally conform to the specification for Plain & Reinforced concrete (C: 2) and also to IS: 2571. For ground floor slab or paving in open area, where the slab has to be laid over a consolidated ground, soling, a kraft paper shall be spread over the area and kept moist before concreting. The floor shall be laid in alternate panels, of size not exceeding 4 m to reduce risk of cracking, intermediate panels being filled in after two or three days. For paving in open area, contraction joint and expansion joints shall be provided as per IS specification. The expansion joints shall be filled with bitumen impregnated boards 25 mm thick of approved manufacturer and top 25 mm shall be covered with approved mastic sealing compound.
5.0.0 5.1.0
FLOOR FINISHES Granolithic/ Indian Patent Stone (IPS) Flooring with ironite topping It shall consist of a under bed and a topping laid on an already laid and matured concrete base.
5.1.1
Thickness The total thickness of finish shall be 40 mm (or as stated in the schedule of items) of which the topping shall be 12 mm. While the topping shall be uniform thickness the under bed may vary in thickness to provide necessary slopes.
5.1.2
Mix For underbed, it shall be 1:2:4 mix using 10 mm down graded stone chips. For toppings of heavy duty, the proportion of metallic hardener shall be strictly as specified by the manufacturer. In absence of such direction, one (1) part of metallic hardener shall be mixed dry with 4 parts of cement by volume. To this mixture, 6 mm nominal size stone chips shall be added in portion of 1:4 (mixture of hardener & cement : stone chips) by volume. Minimum quantity of water to be added to make it workable.
5.1.3
Laying Workmanship in general shall conform to IS 5491.The topping including the underbed shall be laid in alternate bays or in chequered board pattern. No panel shall be cast in contact with another already laid till the contraction of latter has already been taken place. The maximum area of each panel shall be 3 Sq.m of which no side shall be more than 2 m long. A cement grout shall be applied and worked into the surface to receive the finish, the under bed then laid, compacted and leveled to proper grade with a screed or float. The topping shall be applied evenly on the underbed while it is not fully set, but firm enough and rolled and pressed to get full bond. The topping shall be troweled to a dense finish to the satisfaction of the Engineer-in-Charge. All trowel marks shall be mopped out with a cloth to give a clean smooth surface.
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5.1.4
Curing After the surface is sufficiently set, the finished floor shall be kept moist for 7 days for curing.
5.2.0
Granolithic/ Indian Patent Stone (IPS) with Non-Metallic Surface Hardener Finish It shall consist of an underbed and a topping on which the hardener shall be laid.
5.2.1
Thickness The total thickness of finish shall be 40 mm of which the topping shall be 12 mm including the hardener finish.
5.2.2
Mix Mix for underbed and topping shall be same as for IPS flooring.
5.2.3
Hardener Hardener shall be non-metallic abrasion resistant surface hardener NITOFLOR HARDTOP or equivalent.
5.2.4
Laying Workmanship in general shall conform to IS 5491.The topping and underbed shall be laid as for IPS flooring. While the topping is still green, the hardener shall be applied by dry shake-on-system. Cleaning of surface, surface preparation, curing and trowel finish shall be as per manufacturers specifications and recommendation. The surface hardener application rate shall be as follows: Heavy duty Medium duty Light duty : : : 7 kg/ m 5 kg/ m 3 kg/ m
5.3.0
Precast Terrazzo Tile Finish It shall consist of manufactured terrazzo tiles and an underbed. Tiles shall conform to IS 1237 and shall be laid and finished as per IS 1443
5.3.1
Thickness The total thickness of finish including underbed shall be minimum 40 mm for floors and 30 mm for skirting. The skirting shall project 6 mm out from the adjacent wall finish. The necessary cutting into the surface receiving tile finish shall also be done.
5.3.2
Tiles The tiles shall be hydraulically pressed under strict quality control in a shop. The size of tiles shall be 250 x 250 x 20 mm or as stated in the schedule of items. The topping of tiles shall not be less than 10 mm. Maximum tolerance allowance in length & breadth shall be 1 mm and the thickness 3 mm. All angles of tiles shall be right angles, all arises sharp and true, colour and texture of wearing face uniform throughout, and face shall be plane, free from pin holes and other blemishes. The topping of tiles shall be composed of cement, (grey or white or mixture of two) colour pigment, marble dust and marble chips (chips size 3 to 20 mm) in such a proportion so as to produce the desired colour, texture & pattern approved by the Engineer-in-charge.
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The backings shall be composed of 1 part of ordinary grey cement, 1 1/2 part of sand and 3 parts of 6 mm down graded stone chips mixed with water. First grinding shall be given to the tiles at the shop before delivery. Tiles shall be packed properly to prevent damage during transit and storage. The tiles must be stored carefully to prevent staining of damp, rust, oil and grease or other chemicals. 5.3.3 Underbed The underbed for floor shall consist of a mix of 1 part cement, 1 1/2 parts coarse sand and 3 parts machine crushed 10 mm down stone chips by volume. For skirting, the mix shall consist of 1 part cement and 3 parts coarse sand. Only sufficient water to be added to give workable consistency. 5.3.4 Laying The underbed mortar shall be evenly spread and brought to proper grade and consolidated. The surface shall be roughened for better bond. Before the underbed has time to set and while it is still fairly moist but firm, cement shall be hand dusted over it or a cement slurry applied and tiles shall immediately be placed upon and firmly pressed by wooden mallet onto the underbed until it achieves the desired level. The tiles shall be kept soaked for about 10 minutes just before laying. The joints between tiles shall be also as possible and not more than 1.5 mm wide. When tiles are required to be cut to match the dimensions, these shall be sawn and edges rubbed smooth. The location of cut tiles shall be planned in advance and approval of the Engineer-in-charge taken. The floor tiles shall atleast enter 12 mm under the skirting tiles. After fixing, the floor shall be kept moist and allowed to mature undisturbed for 14 days. If desired, aluminium or glass dividing strips shall be used for forming the panels. 5.3.5 Grinding and Polishing After sufficient curing, the surface shall be ground with fine grit blocks. It shall again be cleared with water, the slurry (mixture of cement & pigment) applied again to fill up any pinholes that might have appeared and allowed to be cured again for five days. The surface is ground again with very fine grit blocks to get smooth surface without any pinhole. The grinding shall be done by a suitable machine. Where grinding machine cannot be used, hand grinding may be allowed. The choice of grit blocks at different stages of polishing shall be as per manufacturer's recommendations. The surface shall be cleaned with water, dried and covered with oil free clean saw dust if directed by the Engineer-in-charge. The final polishing shall be postponed till before handing over if so desired by the Engineer-in-charge. Just before handing over, the surface shall be dusted with oxalic acid at the rate of 0.33 gm per sq.m, water sprinkled on to it and finished by buffing with felt or hessian bobs. The floor shall be cleaned with soft moist rag and dried. If desired by the Engineer-in-charge, wax polish shall be applied. However, all excess wax polish to be wiped off and surface to be left glossy but not slippery. 5.4.0 Acid Resistant Tile Finish This shall include all varieties of special tiles used for specific chemical/ acid resistance function and an underbed over already laid concrete or masonry.
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5.4.1
Thickness The total thickness of finish shall be 46 mm of which the tile shall be 25 mm, acid proof mortar 6 mm, bitumen 3 mm and cement mortar underbed 12mm.
5.4.2
Tiles The tiles shall be of best approved manufacture, conforming to IS: 4457 and resistant to the chemical likely to come in contact. The tiles shall have straight edges, uniform thickness, plain surface, uniform non-fading colour and textures. The water absorption after 24 hours of soaking shall not be more than 2% by weight. The compressive strength of tiles shall not be less than 700 kg/cm2. The surface shall be abrasion resistant and durable.
5.4.3
Underbed The underbed shall be laid in three layers. The first layer shall be composed for 1 part cement and 3 parts river sand with just enough water to make the mix workable. This layer shall be trovelled level and cured with water for atleast 3 days prior to application of the second layer. The second layer consists of 3 mm thick hot blown bitumen conforming to IS: 702 of grade 85/25 and shall be applied in three coats with brush or spray. The third layer acid proof mortar as specified by manufacturer shall be applied. The acid proof mortar shall have equal chemical resistant properties desired.
5.4.4
Laying The tiles shall be embedded in the acid proof mortar and the gap between the tiles shall be grouted to the full depth of tile. The setting and fixing shall be strictly as per the manufacturer's specification and shall be approved by the Engineer-in-charge.
5.4.5
Curing The joints in the floor shall be cured with the solution of 25% proof hydrochloric acid or as specified by the manufacturer.
5.5.0
In-situ Terrazzo Finish It shall consist of an underbed and a topping laid over an already laid and matured concrete base.
5.5.1
Thickness Unless otherwise specified the total thickness of the finish shall be minimum 40 mm for horizontal and 25 mm for vertical surface of which the topping shall be not less than 10 mm. While the topping shall be of uniform thickness the underbed may vary in thickness to provide necessary slopes. The vertical surface shall project out 6 mm from the adjacent plaster or other finish. Necessary cutting into the surface receiving the finish shall be done to accommodate the specified thickness. All junctions of vertical with horizontal shall be rounded neatly to uniform radius of 25 mm.
5.5.2
Underbed The underbed for floors and similar horizontal surfaces shall consist of a mix of 1 part cement, 1-1/2 parts sand and 3 parts stone chips by volume or cement sand mixture 1:3 as specified in drawing/schedule. For vertical surfaces the mix shall consist of 1 part cement to 3 parts sand by volume. The sand shall be coarse. The stone chips shall be 10 mm down well graded. Only sufficient water to be added to give a workable consistency. Stone chips are machine crushed blue granite metal.
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Topping: The mix of the topping shall be composed of cement, colour pigment, marble dust and marble chips. Proportions of the ingredients shall be such as to produce the terrazzo of colour, texture and pattern approved by the Engineer. The cement shall be white or grey or a mixture of the two to which pigment shall be added to achieve the desired colour. To3 parts of this mixture 1 part marble powder by volume shall be added and thoroughly mixed dry. To 1 part of this mix 1 to 1-1/2 parts of marble chips by volume shall be added and thoroughly mixed dry again. The pigment must be stable and nonfading. It must be very finely ground. The marble powder shall be from white marble and shall be finer than I.S. Sieve No. 30. The size of marble chips may be between 3 mm to 20 mm. Sufficient quantity to cover all visible area shall be prepared in one lot to ensure uniform colour. Water to make it just workable shall be added to a quantity that can be used up immediately before it starts to set. 5.5.3 Laying The underbed shall be laid in panels. The panels shall not be more than 5 sq.m in area of which no side shall be more than 2.5 m long. For exposed locations the maximum area of a panel shall be 2.0Sq.m. The panel shall be laid in alternate bays or chequered board pattern. No panel shall be cast in contact with another already laid until the latter has contracted to the full extent. Dividing strips made of aluminium or glass shall be used for forming the panels. The strips shall exactly match the total depth of underbed plus topping. These strips shall be left in place and the rates shall be inclusive of these. After laying, the underbed shall be leveled compacted and brought to proper grade with a screed or float. The topping shall be laid after about 24 hours while the underbed is still somewhat 'green' but firm enough to receive the topping. Slurry of the mixture of cement and pigment already made shall be spread evenly and brushed in just before laying the topping. The topping shall be rolled for horizontal areas and thrown and pressed for vertical areas to extract all superfluous cement and water and to achieve a compact dense mass fully bonded with the underbed. The surface of the topping shall be troweled over, pressed and brought to a smooth dense surface showing a minimum 75% area covered by marble chips in an even pattern of distribution. 5.5.4 Curing The surface shall be left for curing for about 12 to 18 hours and then cured by allowing water to stand on the surface or by covering with wet sack for four days. 5.5.5 Grinding and Polishing When the surface has sufficiently hardened it shall be watered and ground evenly with rapid cutting coarse grade (no.60) grit blocks, till the marble chips are exposed and the surface is smooth. Then the surface shall be thoroughly washed and cleaned. A grout with already prepared mixture of cement and pigment shall be applied to fill up all pinholes. This surface shall be cured for seven (7) days by keeping it moist and then ground with the fine grit blocks (no. 120). It shall again be cleared with water, the slurry applied again to fill up any pinholes that might have appeared and allowed to be cured again for five (5) days. Finally the surface is ground again third time with very fine grit blocks (no. 320) to get smooth surface without any pin hole. The grinding shall be done by a suitable machine. Where grinding machine cannot be used hand grinding may be allowed when the first
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rubbing shall be with carborundum stone of coarse grade (no.60), second rubbing with medium grade (no.120). The surface shall be cleaned with water, dried and covered with oil free clean sawdust if directed by the Engineer. The final polishing shall be postponed till before handing over if desired by the Engineer. Just before handing over the surface shall be dusted with oxalic acid at the rate of 0.33 gm per sq.m., water sprinkled on to it and finished by buffing with felt or hessian bobs. The floor shall be cleaned with soft moist rag and dried. If desired by the Engineer, wax polish shall be applied. However, all excess wax polish to be wiped off and the surface to be left glossy but not slippery. The choice of grit blocks at different stages of polishing shall be as per manufacturer's recommendations. 5.6.0 Ceramic Floor Tile/ Glazed Wall Tile Finish This finish shall be composed of glazed earthen ware tiles with an underbed laid over a concrete or masonry base. 5.6.1 Thickness The total thickness shall be between 20 mm and 25 mm including the underbed. The tile finish on vertical surface shall project out 6 mm uniformly from the adjacent plaster or other wall finishes. The necessary cutting into the surface receiving the finish, to accommodate the specified thickness shall be done. 5.6.2 Tiles The glazed tiles shall be of earthenware, covered with glaze, white or coloured, plain or with designs, of 150 mm x 150 mm nominal sizes and 6 mm thick unless otherwise specified. The tolerance shall be 1.5 mm for length and breadth and 0.5 mm for thickness. Specials like internal and external angles, beads, coves, cornices, corner pieces etc. shall match. The top surface of the tiles shall be glazed with a gloss or matt unfading stable finish as desired by the Engineer. The tiles shall be flat and true to shape. The colour shall be uniform and fractured section shall be fine grained in textures, dense homogenous. The tiles shall be strong and free from flaws like cracks, chips, craze, specks, crawlings etc. and other imperfections. The edges and the underside of the tiles shall be completely free from glaze and the underside shall have ribs or indentations for better anchorage with the fixing mortar. The coloured tiles, when supplied, shall preferably come from one batch to avoid difference in colour. 5.6.3 Underbed The mix for the underbed shall consist of 1 part cement and 3 parts coarse sand by weight mixed with sufficient water or any other mix if specified. 5.6.4 Laying Same as cl. 5.2.4 5.6.5 Finishing The joints shall be cleaned and flush pointed with white cement and cured for seven (7) days by keeping it wet. The surface shall be cleaned with soap or suitable detergent, washed fully and wiped with soft cloth to prevent scratching before handing over.
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5.7.0
Carborundum Tile Finish It shall consist of manufactured carborundum tile and an underbed.
5.7.1
Thickness The total average thickness including underbed shall be minimum 40 mm for floors and 30 mm for skirting unless otherwise specified.
5.7.2
Tiles The tiles shall be heavy duty carborundum tile STILAN or equivalent, machine made under quality control in a shop. The tiles shall be pressed hydraulically to a minimum of 140 kg/cm. Each tile shall bear on its back, permanent and legible trade mark of the manufacturer. All angles of the tiles shall be right angles, all edges sharp and true, colour and texture of the wearing face uniform throughout. Maximum tolerance / allowance for length and breadth shall be 1 mm and the thickness + 3 mm along the wearing surface of the tile and the wearing surface shall be plane and free from pin-holes and other blemishes. The tiles shall be composed of a backing and topping. The topping shall be of uniform thickness not less than 6 mm. The total thickness including the topping shall be as specified but not less than 20 mm in any case. The backing shall be composed of 1 part ordinary grey cement, 2 parts and sand 4 parts of stone chips by volume and mixed with water. The topping shall be carborundum grit (passing 1.18 mm mesh but retained on 0.67 mm mesh) and shall be sprinkled on the surface at the rate of 1.35 kg/m and worked into the surface, to achieve a smooth and uniform surface. The tile shall be cured at the shop atleast 14 days before delivery to the site. Tiles shall be packed property to prevent damage during transit and storage. The tiles must be stored carefully to prevent staining by damp, rust, oil and grease, or other chemicals. Tiles made in each batch shall be kept and used separately so that the colour of each area of the floor may remain uniform. The manufacturer shall supply along with the tiles the grout mix containing cement and pigment in exact proportions as used in topping of the tiles. The containers of the grout mix shall be suitably marked to relate it to the particular type and batch of tiles.
5.7.3
Underbed The underbed for floors and similar horizontal surfaces shall be 1 part cement, 2 parts coarse sand and 4 parts stone aggregate by volume mixed with sufficient water to form a stiff workable mass. For skirting and dado and all vertical surfaces it shall be about 10 mm thick and composed of 1 part cement and 3 parts coarse sand by volume.
5.7.4
Laying The underbed mortar shall be evenly spread and brought to proper grade and consolidated to a smooth surface. The face shall be roughened for better bond. Before the underbed has time to set and while it is still fairly moist but firm, cement shall be hand-dusted over it or a cement slurry applied and the tiles shall be immediately placed upon the firmly pressed by wooden mallet onto the underbed until it achieves the desired level. The tiles shall be kept soaked for about 10 minutes just before laying. The joints between tiles shall be as close as possible and not more than 1.5 mm wide.
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Special care shall be taken to check the level of the surface and the lines of the joints frequently so that they are perfect. When tiles are required to be cut to match dimension. These shall be sawn and the edges nubbed smooth. The location of cut tiles shall be planned in advance and approval of the Engineer taken. At the junction of horizontal surface with vertical surface, the tiles on the former shall enter atleast 12 mm under the latter. 5.8.0 PVC or Vinyl Asbestos Tile/ Sheet Finish This shall include various types of tiles or sheets manufactured from PVC, set with a sticker on concrete or masonry or practical base. An underbed may be required to secure desirable surface and grade. 5.8.1 Thickness The thickness of the tiles/ sheets shall be 2 mm for light duty and 3.2 mm for heavy duty applications. The total average thickness including the underbed shall be 40 mm. 5.8.2 Tiles Unless otherwise specified, the tiles/ sheets shall conform to the requirements of IS: 3461 and IS: 3462 and shall be of approved dimensions. The tolerance in dimensions shall be 1.5 mm. The face of the tiles shall be free from porosity, blisters, cracks, embedded foreign matters or other physical defects which affect appearance or serviceability. All edges shall be cut true and square. The colour shall be non-fading and uniform in appearance insoluble in water and resistant to alkalies, cleaning agents and usual floor polishes. Each tile shall be marked on the back legibly and indelibly with manufacturers trade mark, the thickness, sizes, batch number and date of manufacture. Tiles / sheets shall be delivered securely packed and stored in a clean, dry, well ventilated place at a temperature near about to that the tiles / sheets shall be called upon to stand ultimately. Adhesive to be used for sticking the tiles or sheets shall be neoprene based rubber adhesive of approved make and approved by the manufacturer of the tile. The adhesive shall have a short drying time and long life in addition to toughness. 5.8.3 Underbed The underbed where required to make-up the specified thickness or to give the required grade or to get the right type of surface shall be composed of 1 part cement : 2 parts of coarse sand : 4 parts stone aggregate 10 mm down size, mixed with just sufficient water to make it workable. 5.8.4 Laying The tiles or sheets shall be kept in the room to b e tiled for at least 24 hours to bring them to the same temperature as the room. For air conditioned space, the air-conditioning shall be completed before tiling is taken-up.
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The surface to receive this finish shall be firm, even textured, but not too smooth, without undulations and other deficiencies. If an underbed is laid, the same shall be cured for atleast 7 days by keeping it moist and then fully dried. The surface shall be thoroughly cleaned. All loose dust particles shall be removed. Oil and grease, if any, shall be completely cleaned by use of detergent. The adhesive shall be applied to fully dry surface in desired thickness uniformly. The adhesive shall also be applied to the backs and edges of the tiles or sheets and allowed to surface dry. The tiles and sheets shall be placed neatly on the surface exactly to the approved pattern and set with a suitable tool. If the edges tend to curl up, weights shall be used to keep the edges down. Special care shall be taken to avoid formation of air pockets under the tiles or sheets. The joints shall be very fine. Any adhesive squeezed out through the joints shall be removed immediately. 5.8.5 Finishing If any adhesive mark is there on the surface, a soft cloth soaked in solvent shall be used to wipe it off. The surface shall be cleaned with soft water and soap, dried and polished with an approved type of polish just before handing over. 5.9.0 Epoxy Floor Coating Epoxy floor coating shall consist of a solvent based, two pack system with epoxy resins and amine curing agents, chosen to withstand high degrees of chemical and abrasive action. 5.9.1 Thickness Thickness of the epoxy coating including screening shall be minimum 3 mm. Total thickness of finish including underbed shall be 40 mm when applied on floors of buildings. In pits and dyke areas, no underbed is required to be provided. 5.9.2 Materials The screed shall be solvent free combination of epoxy resin, modified amine hardeners filled with specially graded and selected chemically inert aggregates of high strength. The system shall include an epoxy resin primer and screed which are both supplied in preweighed units ready for on-site mixing and application. An epoxy resin sealing coat of specified thickness shall form the topping coat. 5.9.3 Underbed Underbed shall be similar to that PVC floor finish. 5.9.4 Laying The surface shall be sound, clean and dry in order to achieve maximum adhesion with the primer coating. The primer shall be applied by brush and shall be allowed to become tacky. The screed shall be prepared as per manufacturers specification and laid in specified thickness evenly over the base floor by trowel. The finished, cured screed shall have a slightly granular texture of uniform brown. The epoxy resin topping shall be applied atleast 24 hours after the laying of the screed. This topping shall be applied by brush or sprayed to a specified thickness in two coats with 3-5 hours interval between them. Care shall be taken to finish the topping perfectly
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smooth and devoid of any bubbles and unevenness. The newly laid floor shall b e protected from dust or moisture and allowed to be used only after a minimum lapse of 48 hours. 5.10.0 5.10.1 PAVER BLOCK MATERIAL Paver block shall be of approved colour and conform to the IS: 15658. The Paver blocks shall be sound and free of cracks or other visual defects which will interfere with the proper paving of the unit or impair the performance of the pavement. The dimensional tolerances shall be within the limits specified in Table-2 of IS: 15658. When tested as per Annexure-C of IS: 15658, the average water absorption of 3 specimens shall not be more than 6% and that of an individual specimen shall not be more than 7%. The specified average compressive strength of different grade of paver blocks shall be as per Table-3 of IS: 15658. However, the minimum specified strength of an individual sample shall not be less than 85% of the specified compressive strength. The material for bedding shall be well graded sand / Stone dust. The edges of paved area shall be formed with Kerb stones or blocks fixed in Cement Mortar. 5.10.2 WORKMANSHIP The top soil forming the base of paver blocks must be free from vegetation, sod, weed and any kind of organic matter. Such soil should be removed and replaced by selected excavated earth for a thickness of 100 mm minimum. The base shall be properly compacted / rammed / trimmed / leveled to the required elevation & slope for proper drainage of rain-water. Wherever possible, use of 8 to 10 T smooth wheeled roller shall be envisaged for proper compaction. The base should be prepared as per the specification under the clause Filling in Pits and around structures. The bedding material shall be spread, leveled & compacted to average thickness of 40 mm. Sufficient water shall be sprinkled over the bedding before and during ramming the same in order to achieve a dense bedding layer. As soon as the bedding is ready, the placement of paver blocks shall commence. The blocks shall be placed on the firm bedding in close contact with each other. After placing the block, it should be struck lightly with a wooden millet in order to establish complete contact between the underside of paver block and top surface of bedding. Care should be taken so that no damage occurs to the blocks or their edges during handling, placing and finishing. The gaps between the paver blocks shall be filled up with fine sand by spreading with suitable tools and watering the top surface so as to let the sand particles fill the gaps completely. The peripheral unlocked edges of paved area should be bound with cast in-situ concrete of proportion not leaner that 1: 1: 3. Kerb stones shall be provided wherever there is level difference between the top of paved surface and ground / floor adjoining it in order to check overturning of paver block. Kerb stones shall be embedded in the ground to the depth of 300 mm minimum. The finished surface shall be cleaned by brooming and / or watering before handing over.
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VOLUME II
SECTION 2.9
TECHNICAL SPECIFICATION FOR WATER SUPPLY, DRAINAGE AND SANITARY WORKS
Section 2.9
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Water Supply, Drainage & Sanitary Works
SECTION 2.9 TECHNICAL SPECIFICATION FOR WATER SUPPLY, DRAINAGE AND SANITARY WORKS
CONTENTS
CLAUSE NO.
DESCRIPTION
PAGE NO.
1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0
SCOPE .......................................................................................... 3 CODES AND STANDARDS .......................................................... 3 QUALITY ASSURANCE ................................................................ 5 SUBMITTALS ................................................................................ 5 MATERIALS .................................................................................. 5 GENERAL ..................................................................................... 6 INSTALLATION ............................................................................. 6
Section 2.9
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SECTION 2.9 TECHNICAL SPECIFICATION FOR WATER SUPPLY, DRAINAGE AND SANITARY WORKS 1.0.0 SCOPE This specification covers the requirements in respect of materials, installation and quality for water supply, drainage and sanitary works. The scope shall include separate drainage system for sewage water to be installed in the non plant buildings or any other buildings wherever sanitary installations are required including all necessary accessories such as gutters, pipe work, gullies, traps, catch pits and manholes. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise the design, workmanship, quality, properties of materials and methods of testing shall be in accordance with the latest editions / amendments of all applicable codes and standards as published by the Bureau of Indian Standards and those published during the progress of the contract. Roof Drainage System IS: 1230 IS: 1626 IS: 1729 Cast iron rain water pipes and fittings Asbestos cement building pipes, gutters and fittings (spigot and socket type) Specification for sand cast iron spigot and socket soil waste and ventilating pipes, fittings and accessories. Code of practice for building drainage. Code of practice for fixing rainwater gutters and down pipes for roof drainage.
IS: 1742 IS: 2527
Pipes and fittings for sanitary plumbing and drainage IS: 239 IS: 404 IS: 405 IS: 458 IS: 651 IS: 771 IS: 774 IS: 775 IS: 778 IS: 781 IS: 782 IS: 783 Galvanized Iron Pipes Lead pipes Lead sheet and strip Precast Concrete pipes (with and without reinforcements) Salt glazed stoneware pipes and fittings Glazed fire clay sanitary appliances (Part 1 to Part 7) Flushing cistern for water-closets and urinals (other than plastic cisterns) Cast iron brackets and supports for wash basins and sinks Copper alloy gate, globe and check valves for water works purposes. Cast copper alloy screw down bib taps and stop valves for water services Caulking lead Code of practice for laying of concrete pipes
Section 2.9
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IS: 804 IS: 1172 IS: 1230 IS: 1239 IS: 1536 IS: 1537 IS: 1538 IS: 1703 IS: 1711 IS: 1726 IS: 1742 IS: 1795 IS: 2065 IS: 2104 IS: 2326 IS: 2470 IS: 2548 IS: 2556 IS: 2963 IS: 3004 IS: 3006 IS: 3076 IS: 3114 IS: 3311 IS: 3486 IS: 3597 IS: 3989
Rectangular pressed steel tanks Code of basic requirement for water supply drainage and sanitation Cast Iron Rain Water Pipes Mild steel tubes, tubular and other wrought steel fittings Centrifugally cast (spun) iron pressure pipes for water, gas and sewage Vertically cast iron pressure pipes for water, gas and sewage. Cast iron fittings for pressure pipes for water, gas and sewage. Copper alloy float valves (horizontal plunger type) for water supply purposes Self closing taps for water supply purposes Cast iron manhole covers and frames Code of practice for building drainage Specification for pillar taps for water supply purposes Code of practice for water supply in buildings Specification for water meter boxes (domestic type) Automatic flushing cisterns for urinals Code of practice for installation of septic tanks Plastic seats and covers for water-closet (Part 1 & 2) Vitreous sanitary appliance (vitreous china) (Part 1 to 15) Specification for copper alloy waste-fittings for wash basins and sinks Specification for plug cocks for water supply purposes Specification for Chemically resistant glazed stoneware pipes and fittings Low density polyethylene pipes for potable water supplies Codes and practice for laying of cast iron pipes Waste plug and its accessories for sinks and wash basins Cast iron spigot and socket drain pipes Methods of test for concrete pipes Centrifugally Cast (Span) Iron Spigot & Socket Soil, Waste and Ventilating Pipes, Fittings and Accessories Code of practice for laying of glazed stoneware pipes Specification for washers for use with fittings for water services
IS: 4127 IS: 4346
Section 2.9
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IS: 4984
Specification for high density poly-thelene pipes for water supplies, sewage and industrial effluents Specification for unplasticised PVC pipes for potable water supplies Cast copper alloy traps (`P' & `S' traps) (Part-I) Code of practice for sanitary pipe work above ground for buildings Cast iron gratings for drainage purposes Code of practice for plastic pipe work for potable water supplies (Part 1 to 4) Injection moulded high density polyethylene (HDPE) fittings for potable water supplies (Part 1 to 7) Fabricated PVC fittings for potable water supplies (Part 1 to 13)
IS: 4985 IS: 5219 IS: 5329 IS: 5961 IS: 7634 IS: 8008
IS: 10124 3.0.0
QUALITY ASSURANCE The quality shall comply with, but not limited to the requirement of applicable codes and standards.
4.0.0
SUBMITTALS The Contractor shall submit to the Engineer samples of all materials, fittings and appliances for approval well in advance of starting the work. All materials, fittings and appliances used in the work shall conform to the approved samples.
5.0.0
MATERIALS Water Supply Drinking water pipelines shall be constructed in conformance with IS: 2065. The following materials may be used for water supply piping. Galvanized Iron, PVC, HDPE pipes conforming to IS: 239, IS: 4985 and IS: 4984 respectively. Also PVC fitting for water supply lines shall conform to IS: 10124. The tubes and fitting of other materials if used shall conform to local regulations and approved by Owners Engineer. Drainage System Piping for drainage system shall be constructed in conformance with IS: 1742. The following materials may be used for drainage system. CI pipes and specials shall conforming to IS: 3486, Stoneware pipes conforming to IS: 651, RCC pipes of class P1 conforming to IS: 458, CI rain water conforming to IS: 1230. Sanitary Fittings All sanitary fittings shall be procured from approved vendors and shall conform to the requirements of the relevant IS Codes listed above. The sizes shall be as specified in the General Technical Specification, where not specific, the same shall be as per Engineers approval. The sanitary fittings shall be corrosion resistant materials and shall be easy to clean. Glazed earthenware fittings shall be of Hindustan Sanitary ware or approved equivalent make, white colour and one piece construction. All metallic fixtures like taps, stop cocks, soap holders etc. shall be of Chromium Plated (CP) brass, GEM or approved equivalent make PVC fixtures shall be CALIPLAST or approved equivalent make. All wall fittings shall be fixed with wooden cleats (or) Nylon sleeves and CP brass screws and washers.
Section 2.9
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6.0.0
GENERAL All water supply, drainage and sanitary works shall be executed by a licensed or authorized plumbing supervisor or a license or authorized plumber and shall be in accordance with the requirements of relevant codes. For items such as earthworks, excavation, concrete, brick work, stonework, painting etc. relevant specifications for these shall apply, unless other wise specified. Unless otherwise specified, all exposed work such as cisterns, brackets etc. shall be painted with one coat of red oxide paint and two coats of oil paint of approved colour wherever applicable. The sewerage system collects the sanitary sewage water (i.e. all run-off from toilets, showers, kitchen etc.). The sewage water shall be drained by pipes into the closed septic tank. The arrangement of sewerage sewers shall be dictated by the levels of buildings to be connected. The gradient of the sewer shall correspond to most favorable hydraulic conditions. The basis of the sewerage quantities is minimum 350 litres/ person on a day. Manholes shall be provided at all inlets, change in direction and at points where sewers are crossing as well as 50 m along the straight sections. Between manholes the sewer must run in a straight line. The job shall include the cost of making necessary chases, holes etc., in walls, floors and in other places and also making good on completion of the works. Any damage caused to floors, walls etc. during execution of the sanitary and plumbing works shall be made good by the Contractor at his own cost to the satisfaction of the Engineer. PROTECTIVE PAINTING All exposed wrought iron clamps, steel suspenders or brackets for fixing the cast iron pipes to the wait fact- in case of vertical pipes and suspending the horizontal run of pipes shall be painted with one coat of red oxide primer and two coats of paint of approved make and shade.
7.0.0
INSTALLATION All execution will be done on the basis of instruction in such a way given by the Engineer. Fittings meant for operation shall be located and oriented to allow easy reach and operation, maintenance, repairs and replacements of pipes, fittings and fixtures.
7.1.0
Laying and Jointing of Pipes Water Supply
7.1.1
Galvanized steel water supply pipes Screwed galvanized steel pipes conforming to IS: 1239 shall be jointed with screwed joints and screwed fittings of the same material as that of the pipes. Any burrs remaining on the pipe ends after the treads are cut shall be removed. An approved jointing compound together with a grummet of a few strands of fine yarn shall be used for jointing pipes and fittings. Any pipe thread exposed after jointing shall be painted. In the case of underground piping pipes shall be thickly coated with approved bituminous compound to prevent corrosion. Piping shall not be concealed in walls or floors as far as possible. However, when unavoidable, piping shall be concealed for the shortest distance necessary marking shall be provided against damage. Galvanized steel piping shall be secured by iron or steel clamps and hooks when fixed on walls. All pipe work shall be completely watertight and the joints shall be such that there are no projections of jointing materials or the like in the interior of pipes. Before the pipe line is commissioned, all piping and fittings shall be flushed clean.
Section 2.9
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7.1.2
High Density Polyethylene water supply pipes HDPE pipe shall conform to IS: 4984. All high density polyethylene pipes shall have screwed ends and shall be jointed with screwed fittings of the same materials of that of the pipes. Any burrs remaining on the pipe ends after cutting threads shall be removed. If necessary, an approved jointing compound with a few strands of fine yarn may be used for jointing pipes and fittings. All exposed high density polyethylene pipes shall be installed with PVC saddles screwed on 25 mm thick wooden blocks securely fixed on walls at suitable intervals not exceeding 1 m. HDPE pipe shall be secured by hooks, when fixed on wall chasings.
7.1.3
PVC water supply pipes PVC pipes for water supply lines shall be of Class 4 conforming to IS: 4985 and all fitting shall conform to IS: 10124. All exposed pipes shall be installed with PVC saddles screwed on 25 mm thick wooden blocks securely fixed on walls at suitable intervals not exceeding 1 m. PVC pipes shall be secured by hooks, when fixed on wall chasings. Drainage System
7.1.4
Cast iron pipe line
7.1.4.1 Laying Cast iron pipes, socket and spigot shall be of standard quality conforming to IS: 3486 (heavy duty) when the pipe has to be laid for sewer and waste line. The inside of socket and the outside of spigot shall be thoroughly cleaned of all foreign matter before laying. The pipes shall be laid with their socket ends facing the direction of the flow. The pipes shall be lowered by a method as approved by the Engineer. The pipes shall then be jointed by rubber ring as specified in Clause 7.1.4.2. After each section of the pipeline has been laid, it shall be tested for water - tightness. When the pipe line has to be laid above ground vertically by the side of wall, it shall be securely fixed to the wall with wooden plugs and nails. All pipes shall be painted with two coats of paint of approved make and shade over a coat of primer. 7.1.4.2 Jointing In the case of rubber ring joints or push on joints, the groove and the socket shall be thoroughly cleaned before inserting the rubber gasket. While inserting the gasket it shall be made sure that it faces the proper direction and that it is correctly seated in the groove. After cleaning dirt or foreign materials from the plain end, lubricant shall be applied in accordance with the pipe manufacturers recommendations. The Contractor shall make sure that the plain end is beveled as square as sharp edges may damage or dislodge the gasket and cause a leak. When the pipe is cut at site, the plain end shall be beveled with a heavy file or grinder to remove all sharp edges. The plain end of the pipe shall be pushed into the socket of the pipe and while pushing, the pipe shall be kept straight. If any deflections are to be made in the alignment, it may be made after the joint is assembled. 7.1.5 Cast iron rainwater pipes Cast iron rainwater pipes fixed exposed to the external walls shall conform to IS:1230 and shall be blocked out atleast 20 mm from the plastered surfaces by means of cast iron bobbins. The rainwater pipes at the roof level shall be fitted with a cast iron bend with a masonry bell mouth of
Section 2.9
Page : 7 of 11
suitable size fitted with a cast iron grating. The bottom of the down pipe shall be fitted with a shoe fixed 150 mm above ground/spron level of the building. The socket and spigots of pipes and fittings shall be jointed as specified in Clause 7.1.4.2 above. 7.1.6 M.S. Drain Pipes Where specifically desired rain water down comer shall be of M.S. pipes. M.S. pipes shall be painted outside with two coats of anti-corrosive paints under a coat of primer. 7.2.0 Testing and Acceptance Criteria Water Supply 7.2.1 Galvanized steel water supply pipes After the laying and fixing of all galvanized steel water supply pipes and fittings are completed, the line shall be slowly and carefully charged with water to a test pressure of 5 kg per Sq.cm or the specified working pressure plus 50% as may be prescribed by the Engineer. Care shall be taken that air in pipelines is completely exhausted while filling the pipelines with water. This pressure shall be maintained for at least one hour, unless otherwise specified. The pipes and fittings shall then be inspected for any leakage of water. Defects in pipes and fittings, if detected, shall be remedied by the Contractor at his own cost. 7.3.0 Installation of sanitary appliances All sanitary appliances shall be fixed in position rigidly on floor and walls as directed by the Engineer. All appliances shall be from the approved manufacturer and approved colour. 7.3.1 Indian Water Closet (IWC) - Squatting type Squatting type water closet shall be fitted on trap and jointed with gasket yarn and cement mortar. Rim of the pan shall be leveled properly and set flush with the finished floor. The pan shall be connected to cast iron high level pull and let go type flushing cistern of capacity. The flushing cistern shall be supported on a pair of CI or MS cantilever brackets firmly embedded in the wall in cement mortar (1:4) or screwed to wall with suitable plugs. Height of the bracket from the top of pan shall be at 2150 mm. The flush pipe from the cistern shall be 32 mm dia tested quality galvanized steel pipe (light quality) and connected to the pan inlet by means of hemp and putty joint. 7.3.2 European Water Closet (EWC) - Pedestal type Pedestal type water closet shall be rigidly fixed on the finished floor by means of 75 mm long brass screws with suitable plugs. The flushing cistern shall be of porcelain or cast iron or cast iron low level push down cistern of capacity. The cistern shall be supported on a pair of cast iron or rolled steel cantilever brackets firmly fixed on wall with brass screws and suitable plugs. The flush pipe from the cistern shall be 40 mm dia chromium plated brass end and fitted to the closet by means of rubber adopter. The closet shall be provided with double plastic seat cover conforming to IS: 2548 and chromium plated hinges. 7.3.3 Urinals Urinals shall consist of glazed vitreous material with flushing rim complete with flushing facilities and trap. Where urinals are installed in multiple units each unit shall be separated by marble partitions. Standing type urinals shall be firmly fitted on finished wall by means of 50 mm long brass screws and suitable plugs. Height of the lip from the standing point shall be as indicated by the Engineer in charge. Urinals shall be fitted with cast iron automatic flushing cistern of capacity as described in the Schedule of Items. Flushing pipes shall be of galvanized steel pipes of required size and
Section 2.9
Page : 8 of 11
connected to the urinal with 15 mm dia PVC connector fitted with brass cap and lining at one end. The joint to the inlet of urinal shall be neatly finished with putty joints. The arrangement of waste pipes and discharge to the floor trap shall be as directed by Engineer. For single urinal the discharge may be direct to the floor trap through a 40 mm dia waste pipe. For a range of urinals, the discharge may be collected in a common waste pipe of 50 mm dia leading to the floor trap. Each urinal shall be connected to the common discharge pipe by 40 mm dia waste pipes. Alternatively, the discharge from each urinal through 40 mm dia pipe shall be lead to the 100 mm W.G half round channel laid on the floor leading to the floor trap. 7.3.4 Wash hand basin Material of wash hand basin shall be glazed vitreous. This shall be flat back washbasin with one tap hole conforming to IS: 2556, Part-IV. Wash basins shall be of one piece construction including a combined overflow. Slot type of overflow having an area of not less than 5 Sq.cm., shall be provided in the front or back of the bowl and it shall be so designed as to facilitate cleaning of the overflow. This shall be fitted on CI or MS brackets. Brackets shall conform to IS: 775. The brackets shall be given two coats of white enamel paint or aluminium paint, over a coat of primer. The wall side shall be fixed well flushed with the plaster of wall and the joint if any, shall be properly stopped with mortar and painted white. One pillar cock, PVC connecting pipe with brass union, a CP brass bottle trap with union, CP brass chain and rubber PVC stopper, 32 mm dia, GI waste pipe shall also be supplied and fitted with the wash basin. The top of rim of the wash basin shall be fixed at 800 mm above finished floor level, unless otherwise specified. Each hand wash basin shall be provided with a mirror. 7.3.5 Sink Porcelain sink of size shall be leveled properly and fitted in position on a pair of cast iron cantilever brackets firmly embedded in the wall in cement mortar (1:4). The sink shall be fitted with chromium plated brass waste fittings of standard size. The type of waste pipes and their connections shall be as directed by the Engineer. Taps shall be fitted at such a height so as to facilitate easy filling of buckets. 7.3.6 Other miscellaneous fittings (e.g. mirror, towel rails, soap cases, lockers, emergency showers and eye baths etc.) All such fittings shall be of type and sizes prescribed in the Schedule of Items and shall be fitted in position true to line, level and plane as directed by the Engineer. The lockers shall be in the form of single or double row steel cupboards and designed in such a way to store clothes etc. The locker shall be provided with suitable keys. The keys shall bear the same number as the number embossed on the corresponding lockers. Emergency shower and eye baths shall be provided in laboratories, battery room and other areas where dangerous products are stored and likely that people can come in contact with these products. 7.3.7 Marble Partitions The marble partition shall be of 25 mm thick and it shall be approved by the Owner. The edges of marble shall be cut by machine to have proper smooth edges.
Section 2.9
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Other Drainage Items 7.4.0 7.4.1 Septic tank Septic Tank Septic tank shall be constructed in a tight closed manner. Septic tank shall consist of sewage receiving chamber, inspection doors, inlet and outlet connections, manhole cover etc. The septic tank will be constructed near the Toilet and with the provision to empty the contents with portable pumping unit. The details of septic tank shall be approved by the Owners Engineer. This item shall also include ventilating pipe of at least 100 mm dia whose top shall be provided with a suitable mosquito proof wire meshes and cowl. Ventilating pipe shall extend to a height of about 2 m above the top of building. Ventilating pipes can be connected to the normal soil ventilating system of the building wherever it is allowed. After the Septic tank has been proved water tight and the sewage system is checked, the tank shall be filled with water upto its outlet before the sewage is let into the tank. It shall be filled up with well digested sludge obtained from septic tank or sludge digestion tank. In the absence of digested sludge, small quantity of delaying organic matter such as digested cow dung may be introduced. 7.5.0 Water tanks All tanks for storage of water shall be provided at the top of the control building / toilet building and shall be completely watertight and properly covered with dust, light and mosquito proof cover approved type. They shall be fitted with a ball valve of the inlet pipe. A mosquito proof overflow pipe shall be fixed to the tank with the pipe invert about 25 mm above the top of water line. Approved type of stop valve shall be provided for every outlet pipe. Inside surface of galvanized steel tanks shall be painted with anti-corrosive drinking water paints. All storage tanks, water supply fittings and pipes before being put into commission shall be disinfected with liquid chlorine by the Contractor at his own cost. 7.6.0 Sintex Tank Sintex tank shall be made of one piece construction and these tanks shall be made from materials having Environment Stress Crack Resistance (ESCR) ratings of over 1000 hours according to ASTM test, method D-1693 and also all the tanks shall be made under atmospheric pressure by a special molding process. They shall not have any seams joints (or) any welds. All tanks shall be leak proof. 7.7.0 RAINWATER PIPES Rainwater down comers shall be standard cast iron and shall run along the exterior walI/ column surface. The scope of work comprised in this specification is as follows. Supply, erecting, fixing cast iron Roof drain and floor drain pipes at various elevations Caulking of all joints using lead and spun yam. Painting with 3 coats of approved bituminous paint. Supply, fixing necessary fittings inclusive of shoes, gratings, bends, sockets, etc. Materials Cast Iron Rain Water Pipes and Fittings confirming to IS 1230 & IS 1536
Section 2.9
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Bituminous Paint confirming to IS 158/81 & IS 9862/81 Testing as per IS 1742. Lead and Spun Yarn of approved quality. Cast Iron Fittings confirming to IS 1538. Description Rainwater down comers shall run along the exterior surface of wall/column and longitudinally over the roof and to be secured well to walls/columns with strong clamp brackets. When desired by the Engineer these may have to be installed in chases cut in the structure. The brackets may be wrought iron clevis type, split ring or perforated strap iron type as approved by the Engineer. For vertical runs each pipe shall hang freely on its brackets fixed joust below the socket. Suitable spacer shall be provided against the vertical surface. All bends and junctions shall be supplied with watertight clean outs. All CI pipes and fittings shall be pre-painted with 3 coats of approved bituminous paint. Testing shall be carried out as per IS 1742. Roof drains at top shall be provided with suitable MS gratings as specified. Caulking of all spigot and socket joints shall be done as follows. One complete tap of clean spun yarn shall be driven into the bottom of socket without being forced through the joint into the pipe. The lead shall be then be run with molten lead in sufficient quantity so that after being caulked solid, the lead may project above 3mm beyond the face of the socket against outside of spigot. The joint shall be then caulked well when cool by suitable caulking tools and finished smooth. Recommended use of lead per joint: 100mm dia - 2.2 Kg of lead per joint 150mm dia - 3.4 Kg of lead per joint
Section 2.9
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VOLUME II SECTION 2.10
TECHNICAL SPECIFICATION FOR GATE & FENCING
Section 2.10 Gate and Fencing
Page : 1 of 4
SECTION 2.10 TECHNICAL SPECIFICATION FOR GATE & FENCING
CONTENTS
CLAUSE NO. 1.0.0 2.0.0 3.0.0
DESCRIPTION
PAGE NO.
SCOPE ................................................................................... 3 CODES AND STANDARDS .................................................... 3 MATERIAL & INSTALLATION ................................................ 3
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SECTION 2.10 TECHNICAL SPECIFICATION FOR GATE & FENCING 1.0.0 SCOPE This specification covers the requirement in respect of materials, workmanship and quality for M.S. gates, barbed wire fencing and chain link fencing for the Approach bridge at near the shore line and around the onshore Transformer yard. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and method of testing. Some of the relevant available codes are listed hereunder: IS: 1161 IS: 2721 3.0.0 Steel tubes for structural purposes. Galvanised steel chain link fabric.
MATERIAL & INSTALLATION Angle Iron Post Angle Iron Post shall be rolled angle section conforming to IS: 2062 and shall be double dip galvanised.
Chain link fence Chain link shall conform to IS: 2761. It shall be procured in rolls of appropriate length and width and shall consist of 10 G hot dip galvanised steel wires woven in the form of zigzag mesh giving an opening size of 50 mm square. Chainlink shall be secured to the posts with 6 mm dia GI hooks/ rings. Tension wire shall be provided through the mesh at top, centre and bottom of the erected chainlink mesh and shall be of 3 mm dia hot dip galvanised wire and shall be stretched to keep the chainlink in taut position. 25 mm 6 mm GI flat stretcher bar shall be provided at the end posts to tie the tension wires. Barbed Wire Fence Barbed wire shall conform to IS: 278 Barbed wire shall be made from hot dipped galvanised wire of 12 G, 2 ply with barbs of 18 G spaced at 100 mm. Barbed wire shall be procured in bundles of standard weights and shall be fully stretched across the posts and secured with G.I. hook bolts and washers. Spacing of horizontal wires shall not be greater than 225 mm or as specified in the drawing. Diagonal wires shall be provided in each bay between two adjacent posts. No wire shall be left loose or sagging.
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Gate Gate shall be fabricated out of tubular sections conforming to IS: 1161 and shall be hot dipped galvanised. Outer frame shall be 65 NB (medium) tube and diagonal 50 NB (medium) tube 50 mm sq. welded mesh with 4 mm dia GI wire fabric shall be welded to 25 mm 6 mm thick GI flat which in turn shall be welded to the outer tubular frame. The gate shall be provided with 20 mm wide 80 mm dia flat M.S. roller at the bottom. The gate frame shall be fixed to GI tubular post or RCC post. All the assembly of fencing and gates shall have galvanization as per specification.
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VOLUME II SECTION 2.11 TECHNICAL SPECIFICATION FOR APPROACH BRIDGE
Section 2.11 Approach Bridge
Page : 1 of 68
Table of Contents
2.11.1
Technical Specification for Structural Concrete for Approach Bridge 3 21
2.11.2 2.11.3
Technical Specification for Offshore Caisson and Piles Technical Specification for Substructure Pier and Pier Cap, Abutment and Abutment Cap
34 38 41 46 58
2.11.4 2.11.5 2.11.6 2.11.7
Technical Specification for Superstructure Technical Specification for Formwork Technical Specification for Bearings Technical Specification for Expansion Joints
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2.11.1 1.0.0
Technical Specification for Structural Concrete for Approach Bridge

SCOPE This specification covers the requirements in respect of material, workmanship and quality of structure concrete for structures in water.
2.0.0
CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and methods of testing. Some of the relevant available codes are listed hereunder: Cement IS:269 IS:1489 IS:4032 IS:8041 IS:8112 IS:12330 IS:455 Aggregate IS:383 IS:2386 IS:2430 Coarse and fine aggregates from natural sources for concrete Methods of test for aggregates for concrete Methods of sampling of aggregates for concrete Ordinary and low heat Portland cement Portland pozzolana cement part 1 calcined clay based. Method of chemical analysis of hydraulic cement. Rapid hardening Portland cement High strength ordinary Portland cement Sulphate resisting Portland cement Blast furnace slag cement
Concrete Plain and Reinforced IS:456 IS:516 IS:1199 IS:1607 IS:1834 IS:2645 IS:2750 IS:2974 IS:9013 Code of practice for plain and reinforced concrete Methods of test for strength of concrete Methods of sampling and analysis of concrete Methods for test sieving Hot applied sealing compounds for joints in concrete Integral cement water proofing compounds Steel scaffolding Code of practice for design and construction of machine foundations Method of making, curing and determining compressive strength of accelerated cured concrete test specimens.
Section 2.11 Approach Bridge Page : 3 of 68
IS:9103 IS:9893 IS:10262 IS:10297
Admixtures for concrete Precast concrete lintels and sills Recommended guidelines for concrete mix design. Code of practice for design and construction of floors/roofs using pre-cast reinforced/pre-stressed concrete ribbed or cored slab units. Methods of tests for pre-formed fillers for expansion joints in concrete paving and structural construction Methods of sampling of steel for pre-stressed and reinforced concrete.
IS:10566
IS:10790 Steel IS:432
Mild steel and medium tensile steel bars and hard-drawn steel wire for concrete reinforcement Hard-drawn steel wire fabric for concrete reinforcement Wire cloth for general purposes High strength deformed steel bars and wires for concrete reinforcement Code of practice for bending and fixing of bars for concrete reinforcement Code of practice for welding of mild steel plain and deformed bars used for reinforced concrete construction. Fusion bonded epoxy coated reinforcing bars.
IS:1566 IS:1568 IS:1786 IS:2502 IS:2751
IS:13620 Water IS:3025 Vibrator IS:2506 IS:2514 IS:4656
Methods for sampling and test for water.
General requirements for screed board concrete vibrators. Concrete vibrating tables. Form vibrators for concrete.
3.0.0 3.1.0
MATERIALS Cement Cement to be used in the works shall be Blast Furnace Slag Cement as per IS:455 with slag content not exceeding 60% and a minimum grade of 43. The minimum cement content and the maximum water cement ratio shall be as follows: Structural Member Min. cement content kg/ cum 400 Max. water cement ratio Exposure Condition
RCC
0.40
Severe
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PCC
310
0.45
Severe
For underwater concreting, the cement content shall be increased by 10 percent. The minimum cement content in the grades of concrete shall be as per MoRTH Standards Specification for road and bridge works as mentioned in the Table above. 3.2.0 Aggregates The size (maximum nominal) of coarse aggregates for concrete to be used in various components shall be given in Table 1.4. Table 1.4 COMPONENTS i. ii. iii. iv. RCC well curb RCC well steining Well cap or Pile Cap Solid type piers RCC work in girders, slabs, wearing coat, kerb, approach slab, hollow piers and abutments, pier / abutment caps, piles Any other item MAXIMUM NOMINAL SIZE OF COARSE AGGREGATE (mm) 20 40 40 20
v.
As specified by Engineer
Maximum nominal size of aggregates shall also be restricted to the smaller of the following values : a. 10 mm less than the minimum lateral clear distance between main reinforcements b. 10 mm less than the minimum clear cover to the reinforcements The proportions of the various individual sizes of aggregates shall be so adjusted that the grading produces densest mix and the grading curve corresponds to the maximum nominal size adopted for the concrete mix. Coarse aggregate of concrete shall be chemically inert, hard, strong, durable against weathering, of limited porosity and free from deleterious materials. It shall meet the requirements of IS:383 and tests for conformity shall be carried out as per IS:2386 Parts I to VIII. Sand shall be hard, durable, clean and free from adherent coatings of organic matter and clay balls or pellets. Sand, when used as fine aggregate in concrete shall conform to IS:383 and tests for conformity shall be carried out as per IS:2386 Parts I to VIII. 3.3.0 Water Water used for cement concrete shall be clean and free from oil, acids, alkalis, organic matters or other harmful substances. Portable water shall generally be considered satisfactory. The Contractor shall carry out necessary tests in advance to prove the suitability of the water proposed to be used. The water shall be tested as per IS:3025 for permissible limits of solids. When water from the proposed source is used for making the concrete, the maximum permissible impurities, development of strength and initial setting time of concrete shall meet the requirements of IS:456.
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3.4.0
Reinforcement The reinforcement bars of minimum grade Fe415 shall conform to grade 1 of IS:432 / IS:1786. All reinforcement shall be corrosion resistant such as TISCON CRS / SAIL TMTHRC where the corrosion resistant alloy shall not be less than 0.75%.
3.5.0
Structural steel Structural steel, including embedded steel, shall be straight, sound, free from twists, cracks, flaws, laminations and all other defects. Structural steel shall be of tested quality and shall be of structural steel coated with epoxy paint conforming to IS:2062, stainless steel / corrosion resistant steel conforming to IS:1570 & IS:6603 and cast steel conforming to IS:1030. Radiographic examination or magnetic particle testing or other comparable tests shall be required for determining the soundness of steel castings and shall be conducted if asked by the Owner.
4.0.0
GRADES OF CONCRETE Concrete used in any component or structure shall be only design mix. The minimum grade of RCC shall be M30 and for PCC shall be M20.
5.0.0
PROPORTIONING OF CONCRETE Prior to the start of construction, the Contractor shall design the mix and submit to the Owner for approval, the proportions of materials, including admixtures to be used. Waterreducing admixtures (including plasticisers or super-plasticisers) shall be used at Contractors option, subject to the approval of the Owner. Other types of admixtures shall be prohibited, unless specifically permitted by the Owner. Admixtures used by the Contractor shall be at no extra cost to the Owner.
5.1.0
Requirements of Consistency The mix shall have the consistency, which shall allow proper placement and consolidation in the required position. Every attempt shall be made to obtain uniform consistency. The optimum consistency for various types of structures shall be as indicated in Table 1.1 below, or as directed by the Owner. The slump of concrete shall be checked as per IS:516. Table 1.1 SL. NO. 1 TYPE RCC structures with widely spaced reinforcements, e.g. solid columns, piers, abutments, footings, well steining RCC structures with fair degree of congestion of reinforcement, e.g. pier and abutment caps, well curb, well cap, walls with thickness greater than 300 mm Underwater concreting through tremie e.g. bottom plug, cast-in-situ piling RCC with highly congested reinforcements e.g. deck slab girders, walls with thickness less than 300 mm SLUMP (mm) 40 50
50 - 75
100 - 200
75 -125
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5.2.0
Requirements for Design Mixes a. Target mean strength The target mean strength of specimen shall exceed the specified characteristic compressive strength by at least the current margin. i. The current margin for a concrete mix shall be determined by the Contractor and shall be taken as 1.64 times the standard deviation of sample test results taken from at least 40 separate batches of concrete of nominally similar proportions produced at site by the same plant under similar supervision, over a period exceeding 5 days, but not exceeding 6 months. Where there is insufficient data to satisfy the above, the current margin for the initial design mix shall be taken as given in Table 1.2. Table 1.2 Concrete Grade M 20 M 25 M 30 M 35 Current Margin (MPa) 10 11 12 12 Target Mean Strength (MPa) 30 36 42 47
ii.
The initial current margin given in the Table 1.2 shall be used till sufficient data is available to determine the current margin as per sub-clause (i) above. b. Trial Mixes The Contractor shall give notice to enable the Owner to be present at the making of trial mixes and preliminary testing of the cubes. The Contractor shall prepare trial mixes, using samples of approved materials typical of those he proposes to use in the works, for all grades to the Owners satisfaction prior to commencement of concreting. The initial trial mixes shall generally be carried out in an established laboratory approved by the Owner. In exceptional cases, the Owner may permit the initial trial mixes to be prepared at the site laboratory of the Contractor, if a fullfledged concrete laboratory has been established well before the start of construction, to his entire satisfaction. In all cases complete testing of materials forming the constituents of proposed Design Mix shall have been carried out prior to making trial mixes. Sampling and testing procedures shall be in accordance with these specifications. When the site laboratory is utilised for preparing initial mix design, the concreting plant and means of transport employed to make the trial mixes shall be similar to that proposed to be used in the works. Test cubes shall be taken from trial mixes as follows. For each mix, set of six cubes shall be made from each of three consecutive batches. Three cubes from each set of six shall be tested at an age of 28 days and three at an earlier age approved by the Owner. The cubes shall be made, cured, stored, transported and tested in accordance with these specifications. The average strength of the nine cubes at 28 days shall exceed the specified characteristic strength by the current margin minus 3.5 MPa.
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c.
Control of Strength of Design Mixes Adjustment to Mix Proportions Adjustments to mix proportions arrived at in the trial mixes shall be made subject to the Owners approval, in order to minimise the variability of strength and to maintain the target mean strength. Such adjustments shall not be taken to imply any change in the current margin. Change of Current Margin When required by the Owner, the Contractor shall recalculate the current margin in accordance with 5.2.0 (a). The recalculated value shall be adopted as directed by the Engineer, and it shall become the current margin for concrete produced subsequently. Additional Trial Mixes During production, the Contractor shall carry out trial mixes and tests, if required by the Owner, before substantial changes are made in the material or in the proportions of the materials to be used, except when adjustments to the mix proportions are carried out in accordance with sub-clause mentioned above.
5.3.0
Grade of Concrete The characteristic strength of the grades of concrete shall be as per IS : 456-2000 as tabulated below Grade Designation Specified characteristic compressive strength of 150 mm cubes at 28 days, in Mpa 20 25 30 35
M20 M25 M30 M35
5.4.0
Additional Requirements Concrete shall meet with any other requirements as specified on the drawing or as directed by the Owner. Additional requirements shall also consist of the following overall limits of deleterious substances in concrete: a. The total chloride content of all constituents of concrete as a percentage of mass of cement in mix shall be limited to values given below: Reinforced concrete exposed to chlorides in service (e.g. structures located near seacoast) Other reinforced concrete construction : 0.2 percent
0.3 percent
b. The total sulphuric anhydride (SO3) content of all the constituents of concrete as a percentage of mass of cement in the mix shall be limited to 4 percent. 5.5.0 Suitability of Proposed Mix Proportions The Contractor shall submit the following information for Owners approval :
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a. Nature and source of each material b. Quantities of each material per cubic meter of fully compacted concrete c. Either of the following: i. Appropriate existing data as evidence of satisfactory previous performance for the target mean strength, current margin, consistency and water / cement ratio and any other additional requirement(s) as specified. Full details of tests on trial mixes.
ii.
d. Statement giving the proposed mix proportions for design mix concrete. Any change in the source of material or in the mix proportions shall be subject to the Owners prior approval. 6.0.0 ADMIXTURES Use of admixtures such as super plasticisers for concrete shall be made with the approval of the Owner at no extra cost to the Owner. As the selection of an appropriate concrete admixture is an integral part of the mix design, the manufacturers shall recommend the use of any one of his products only after obtaining complete knowledge of all the actual constituents of concrete as well as methodologies of manufacture, transportation and compaction of concrete proposed to be used in the project. 7.0.0 7.1.0 EQUIPMENT Batching Plant / Ready Mix Concrete (RMC) For production of concrete, batching plant shall be preferably used. The type of batching plant shall be i. Batch type concrete mixing plant diesel or electric operated, with a minimum size of 200 litres, automatic water measuring system and integral weigher (hydraulic / pneumatic type). or ii. Concrete batching and mixing plant fully automatic with minimum capacity of 15 cum per hour.
All measuring devices of the equipment shall be maintained in a clean and serviceable condition. Its accuracy shall be checked over the range in use, when set up at each site and thereafter periodically as directed by the Owner. The accuracy of the measuring devices shall fall within the following limits: Measurement of Cement Measurement of Water Measurement of Aggregate Measurement of Admixture 3 percent of the quantity of cement in each batch 3 percent of quantity of water in each batch 3 percent of quantity of aggregate in each batch 5 percent of the quantity of admixture in each batch
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The area for setting up a batching plant shall be identified by the Contractor at no extra cost. 7.2.0 Equipment for Transportation and Compaction a. For Concrete transportation i. ii. iii. iv. v. vi. vii. viii. ix. x. Concrete dumpers Powered hoists Chutes Buckets handed by cranes Transit truck mixer Concrete pump Concrete distributor booms Belt conveyor Cranes with skips Tremies : depending upon actual requirement minimum 2 tonnes capacity minimum 0.5 tonnes capacity
b. For Compaction of Concrete i. ii. iii. 8.0.0 MIXING Concrete shall be mixed either in a concrete mixer or preferably in a batching and mixing plant, as per these specifications. Hand mixing shall not be permitted. The mixer or the plant shall be at an approved location considering the properties of the mixes and the transportation arrangements available with the Contractor. The mixer or the plant shall be approved by the Owner. Mixing shall be continued till materials are uniformly distributed and a uniform colour of the entire mass is obtained, and each individual particle of the coarse aggregate shows complete coating of mortar containing its proportionate amount of cement. In no case shall mixing be done for less than 2 minutes. Mixers, which have been out of use for more than 30 minutes shall be thoroughly cleaned before putting in a new batch. Unless otherwise agreed to by the Owner, the first batch of concrete from the mixer shall contain only two thirds of the normal quantity of coarse aggregate. Mixing plant shall be thoroughly cleaned before changing from one type of cement to another. 9.0.0 TRANSPORTATION, PLACING AND COMPACTION OF CONCRETE The method of transporting and placing concrete shall be approved by the Owner. Concrete shall be transported and placed as near as practicable to its final position, so that no contamination, segregation or loss of its constituent materials takes place. Concrete shall not be freely dropped into place from a height exceeding 1.5 meters.
Internal vibrators Form Vibrators Screed vibrators
Size 25 mm to 70 mm minimum 500 watts full width of carriageway (up to two lanes)
When concrete is conveyed by chute, the plant shall be of such size and design as to ensure practically continuous flow. Slope of the chute shall be so adjusted that the concrete flows without the use of excessive quantity of water and without any segregation of its ingredients. The delivery end of the chute shall be as close as possible to the point of deposit. The chute shall be thoroughly flushed with water before and after each working period and the water used for this purpose shall be discharged outside the formwork. All formwork and reinforcement contained in it shall be cleaned and made free from standing water, dust, snow or ice immediately before placing of concrete. No concrete shall be placed in any part of the structure until the approval of the Owner has been obtained. If concreting is not started within 24 hours of the approval being given, it shall have to be obtained again from the Owner. Concreting then shall proceed continuously over the area between the construction joints. Fresh concrete shall not be placed against concrete, which has been in position for more than 30 minutes unless a proper construction joint is formed. Except where otherwise agreed to by the Owner, concrete shall be deposited in horizontal layers to a compacted depth of not more than 450 mm when internal vibrators are used and not exceeding 300 mm in all other cases. Concrete when deposited in thickness exceeding 1.2 m shall have a temperature less than 30 degrees Celsius. It shall be compacted in its final position within 30 minutes of its discharge from the mixer, unless carried in properly designed agitators, operating continuously, when this time shall be within 1 hour of the addition of cement to the mix and within 30 minutes of its discharge from the agitator. It may be necessary to add retarding admixtures to concrete if trials show that the periods indicated above are unacceptable. In all such matters, the Owners decision shall be final. Concrete shall be thoroughly compacted by vibration or other means during placing and worked around the reinforcement, tendons or duct formers, embedded fixtures and into corners of the formwork to produce a dense homogenous void-free mass having the required surface finish. When vibrators are used, vibration shall be done continuously during the placing of each batch of concrete until the expulsion of air has practically ceased and in a manner that does not promote segregation. Over vibration shall be avoided to minimise the risk of forming a weak surface layer. When external vibrators are used, the design of formwork and disposition of vibrator shall be such as to ensure efficient compaction and to avoid surface blemishes. Vibrations shall not be applied through reinforcement and where vibrators of immersion type are used, contact with reinforcement and all inserts like ducts etc., shall be avoided. The internal vibrators shall be inserted in an orderly manner and the distance between insertions should be about one and a half times the radius of the area visibly affected by vibration. Additional vibrators in serviceable condition shall be kept at site so that they can be used in the event of breakdowns. Mechanical vibrators used shall comply with IS:2502, IS:2506, IS:2514 and IS:4656. 10.0.0 CONSTRUCTION JOINTS Refer also Cl. 8.0.0 of Section 2.2 Construction joints shall be avoided as far as possible and in no case the location of such joints shall be changed or increased from those shown on the drawings, except with the approval of the Owner. The joints shall be provided in a direction perpendicular to the member axis.
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10.1.0
Location The location of construction joints shall be as shown on the drawing or as approved by the Owner. If additional / new joints are approved by the Owner, the following considerations for their location shall be taken into account: i. Joints shall be provided in non-aggressive zones or in non-splash zones. If not feasible, the joints shall be sealed. Joints should be positioned where they are readily accessible for preparation and concreting, such as location where the cross section is relatively small, and where reinforcement is not congested.
ii.
iii. Location of joints shall minimise the effects of the discontinuity on the durability, structural integrity and the appearance of the structure. iv. In beams and slabs, joints should not be near the supports. Construction joints between slabs and ribs in composite beams should be avoided. 10.2.0 Preparation of Surface of the Joint Laitance shall be removed before fresh concrete is cast. The surface shall be roughened. Care shall be taken that they should not dislodge the coarse aggregates. Concrete may be brushed with a stiff brush soon after casting while the concrete is still fresh. If the concrete has partially hardened, it shall be treated by wire brushing or with a stiff a water jet followed by drying with air jet immediately. Fully hardened concrete shall be treated with mechanical hand tools or grit blasting, taking care not to split or crack aggregate particles. Before further concrete is cast, the surface should be thoroughly cleaned to remove debris and accumulated rubbish, one effective method being by air jet. Where there is likely to be a delay before placing the next concrete lift, protruding reinforcement shall be protected. Before the next lift is placed, rust, loose mortar or other contamination shall be removed from the reinforcements. In aggressive environment, the concrete shall be cut back to expose the reinforcements for a length of about 50 mm to ensure that contaminated concrete is removed. The joint surface shall not be contaminated with release agents, dust or curing membrane. 10.3.0 Concreting of Joints The old surface shall be thoroughly cleaned and soaked with water. Standing water shall be removed shortly before the new concrete is placed and the new concrete shall be thoroughly compacted. Concreting shall be carried out continuously up to the construction joints. Surface retarders may be used to improve the quality of construction joints. For a vertical construction joint, a stopping board shall be fixed previously at the predetermined position and shall be properly stayed to prevent its displacement or bulging when concrete is compacted against it. Concreting shall be continued right up to the board. 11.0.0 CONCRETING UNDER WATER When it is necessary to deposit concrete under water, the methods, equipment, materials and proportions of mix to be used shall be got approved from the Owner before any work
is started. Concrete shall contain 10 percent more cement than that required for the same mix placed in the dry. Concrete shall not be placed in water having a temperature below 5 degrees Celsius. The temperature of the concrete, when deposited, shall not be less than 16 degrees Celsius, nor more than 30 degrees Celsius. Coffer dams or forms shall be sufficiently tight to ensure still water conditions, if practicable, and in any case to reduce the flow of water to less than 3 meters per minute through the space into which concrete is to be deposited. Cofferdams or forms in still water shall be sufficiently tight to prevent loss of mortar through the joints in the walls. Pumping shall not be done while concrete is being placed, or until 24 hours thereafter. To minimise the formation of laitance, great care shall be exercised not to disturb the concrete as far as possible while it is being deposited. All under water concreting shall be carried out by tremie method only, using tremie of appropriate diameter. The number and spacing of the tremies should be worked out to ensure proper concreting. The tremie concreting when started should continue without interruption for the full height of the member being concreted. The concrete production and placement equipment should be sufficient to enable the underwater concrete to be completed uninterrupted within the stipulated time. Necessary stand-by equipment should be available for emergency situation. The top section of the tremie shall have a hopper large enough to hold one full batch of the mix or the entire contents of the transporting bucket as the case may be. The tremie pipe shall not be less than 200 mm in diameter and shall be large enough to allow a free flow of concrete and strong enough to withstand the external pressure of the water in which it is suspended, even if a partial vacuum develops inside the pipe. Preferably, flanged steel pipe of adequate strength for the job shall be used. A separate lifting device shall be provided for each tremie pipe with its hopper at the upper end. Unless the lower end of the pipe is equipped with an approved automatic check valve, the upper end of the pipe shall be plugged with a wadding of gunny sacking or other approved material before delivering the concrete to the tremie pipe through the hopper; so that when the concrete is forced down from the hopper to the pipe, it shall force the plug (and along with it any water in the pipe) down the pipe and out of the bottom end, thus establishing a continuous steam of concrete. It shall be necessary to raise slowly the tremie in order to allow a uniform flow of concrete, but it shall not be emptied so that water is not allowed to enter above the concrete in the pipe. At all times after placing of concrete is started and until all the required quantity has been placed, the lower end of the tremie pipe shall be kept below the surface of the plastic concrete. This will cause the concrete to build up from below instead of flowing out over the surface and thus avoid formation of layers of latiance. If the charge in the tremie is lost while depositing, the tremie shall be raised above the concrete surface and unless sealed by a check valve, it shall be replugged at the top end, as at the beginning, before refilling for depositing further concrete. 12.0.0 HOT WEATHER CONDITIONS When depositing concrete in very hot weather, precautions shall be taken so that the temperature of wet concrete does not exceed 30 degrees Celsius while placing. This shall be achieved by stacking aggregate under the shade and keeping them moist, using cold water, reducing the time between mixing and placing to a minimum, cooling formwork by sprinkling water, starting curing before the concrete dries out and restricting concreting as far as possible to early mornings and late evenings. When ice is used to cool mixing water, it shall be considered a part of the water in design mix. Under no circumstances shall the mixing operation be considered complete until all the ice in the drum has melted. The Contractor shall be required to state his methodology for the Engineers approval when temperatures of concrete are likely to exceed 30 degrees Celsius during the work.
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13.0.0
PROTECTION AND CURING Concreting operations shall not commence until adequate arrangements for concrete curing have been made by the Contractor. Curing and protection of concrete shall start immediately after compaction of the concrete to protect it from: a. b. c. d. e. f. Premature drying out particularly by solar radiation and wind High internal thermal gradients Leaching out by rain and flowing water Rapid cooling during the first few days after placing Low temperature or frost Vibration and impact, which may disrupt the concrete and interfere with its bond to the reinforcement.
Where members are of considerable size and length, with high cement content, accelerated curing methods may be applied, as approved by the Owner. 13.1.0 Water Curing Water for curing shall be clean and possible as specified in IS:456. Exposed surfaces of concrete shall be kept continuously in a damp or wet condition by ponding or by covering with a layer of sacks, canvas, Hessian or similar materials and shall be kept constantly wet for a period of not less than 14 days from the date of placing of concrete. 14.0.0 FINISHING Immediately after the removal of forms, exposed bars or bolts, if any, shall be cut inside the concrete member to a depth of at least 50 mm below the surface of the concrete and the resulting holes filled with cement mortar. All fins caused by form joints, all cavities produced by the removal of form ties and all other holes and depressions, honeycomb spots, broken edges or corners, and other defects, shall be thoroughly cleaned, saturated with water, and carefully pointed and rendered true with mortar of cement and fine aggregate mixed in the proportions used in the grade of concrete that is being finished and of as dry a consistency as is possible to use. Considerable pressure shall be applied in filling and pointing to ensure thorough filling in all voids. Surfaces, which have been pointed, shall be kept moist for a period of twenty-four hours. Special pre-packaged proprietary mortars shall be used where appropriate or where specified in the drawing. All construction and expansion joints in the completed work shall be left carefully tooled and free from any mortar and concrete. Expansion joint filler shall be left exposed for its full length with clean and true edges. Immediately on removal of forms, the concrete work shall be examined by the Owner before any defects are made good. a. The work that has sagged or contains honeycombing to an extent detrimental to structural safety or architectural appearance shall be rejected. b. Surface defect of a minor nature may be accepted. On acceptance of such work by the Owner, the same shall be rectified as directed by the Owner. 15.0.0 STEEL EMBEDMENTS All embedment shall be in accordance with Cl. 13.0.0 of Section 2.2. However, the embedments supporting the steel structures exposed to water corrosion shall be suitably painted with epoxy to protect them against corrosion.
16.0.0
TOLERANCES Tolerances for dimensions / shape of various components shall be as shown on the drawings or as directed by the Owner.
17.0.0
TESTS AND STANDARDS OF ACCEPTANCE Concrete shall conform to the surface finish and tolerance as prescribed in these specifications for respective components. Random sampling and lot-by-lot of acceptance inspection shall be made for the 28 days cube strength of concrete. a. Concrete under acceptance shall be notionally divided into lots for the purpose of sampling, before commencement of work. The delimitation of lots shall be determined by the following: i. ii. No individual lot shall be more than 30 cum in volume At least one cube forming an item of the sample representing the lot shall be taken from concrete of the same grade and mix proportions cast on any day. Different grades of mixes of concrete shall be divided into separate lots Concrete of a lot shall be used in the same identifiable component of the bridge.
iii. iv.
b. Sampling and Testing 1. Concrete for making 3 test cubes shall be taken from a batch of concrete at point of delivery into construction, according to procedure laid down in IS:1199. A random sampling procedure to ensure that each of the concrete batches forming the lot under acceptance inspection has equal chance of being chosen for taking cubes shall be adopted. 150 mm cubes shall be made, cured and tested at the age of 28 days for compressive strength in accordance with IS:516. The 28-day test strength result for each cube shall from an item of the sample.
2.
3.
c.
Test specimen and sample strength Three test specimens shall be made from each sample for testing in 28 days. Additional cubes may be required for various purposes such as to determine the strength of concrete at 7 days or for any other purpose. The test strength of the sample shall be the average of the strength of 3 cubes. The individual variation should not be more than 15 percent of the average.
d. Frequency The minimum frequency of sampling of for each grade shall be in accordance with Table 1.5.
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TABLE 1.5 Quantity of Concrete in Work, m3 15 6 15 16 30 31 50 51 and above No. of samples 1 2 3 4 4 plus one additional sample for each additional 50 m3 or part thereof
At least one sample shall be taken from each shift of work. e. Acceptance criteria Compressive strength When both the following conditions are met, the concrete complies with the specified compressive strength: i. The mean strength determined from any group of four consecutive samples should exceed the specified characteristic compressive strength. Strength of any sample is not less than the specified characteristic compressive strength minus 3 MPa.
ii.
The quantity of concrete represented by the test results includes the batches from which the first and last samples were taken, together with all intervening batches. 17.1.0 Chloride and Sulphate Content The total chloride and sulphuric anhydride (SO3) content of the all the constituents of concrete as a percentage of mass of cement in the mix shall not exceed the values given in this section of the specifications. 17.2.0 Density of Fresh Concrete Where minimum density of fresh concrete is specified, the mean of any four consecutive samples shall not be less than the specified value and any individual sample result shall not be less than 97.5 percent of the specified value. 17.3.0 Density of Hardened Concrete Where minimum density of hardened concrete is specified, the mean of any four consecutive samples shall not be less than the specified value and any individual sample result shall not be less than 97.5 percent of the specified value. 17.4.0 Permeability Test The concrete should pass the following test if it is properly compacted and is not considered permeable. i. ii. Prepare a cylindrical test specimen 150 mm diameter and 160 mm high. After 28 days of curing, the test specimen is fitted in a machine such that the specimen can be placed in water under pressure up to 7 bars.
iii. At first a pressure of one bar is applied for 48 hours, followed by 3 bars for 24 hours and 7 bars for next 24 hours.
iv. After the passage of the above period, the specimen is taken out and split in the middle by compression applied on two round bars on opposite sides above and below. v. The water penetration in the broken core is to be measured with a scale and the depth of penetration assessed in mm (max. permissible limit 25 mm).
If the concrete is not able to meet any of the standards of acceptance as prescribed, the effect of such deficiency on the structure shall be investigated by the Contractor as directed by the Owner. The Owner may accept the concrete as sub-standard work. Any additional work required by the Owner for such acceptance shall be carried out by the Contractor at his cost. In case the concrete is not found to be acceptable after investigation, the Contractor shall remove the rejected concrete forthwith. 18.0.0 REINFORCEMENT Reinforcement shall be as described this section. Reinforcements shall be either mild steel / medium tensile steel or high strength deformed bars. TISCON CRS / SAIL TMT HCR shall be used. 18.1.0 Protection of Reinforcement Uncoated reinforcing steel shall be protected from rusting or chloride contamination. Reinforcements shall be free from rust, mortar, loose mill scale, grease, oil or paints. This shall be ensured either by using reinforcement fresh from the factory or thoroughly cleaning all reinforcement to remove rust using any suitable method such as grit blasting, mechanical wire brushing, etc., as directed by the Engineer. Reinforcements shall be stored on blocks, racks or platforms and above the ground in a clean and dry condition and shall be suitably marked to facilitate inspection and identification. Portions of uncoated reinforcing steel and dowels projecting from concrete shall be protected within one week after initial placing of concrete with a brush coat of neat cement mixed with water to a consistency of thick paint. This coating shall be removed by lightly tapping with a hammer or other tool not more than one week before placing of the adjacent pour of concrete. Coated reinforcing steel shall be protected against damage to the coating. If the coating on the bars is damaged during transportation or handling and cannot be repaired, the same shall be rejected. 18.2.0 Bending of Reinforcement Bar bending schedule shall be furnished by the Contractor and got approved by the Engineer before start of work. Reinforcing steel shall conform to the dimensions and shapes given in the approved Bar Bending Schedules. Bars shall be bent cold to the specified shape and dimensions or as directed by the Engineer using a proper bar bender, operated by hand or power to obtain the correct radii of bends and shape. Bars shall not be bent or straightened in a manner that will damage the parent material or the coating. Bars bent during transport or handling shall be straightened before being used on work and shall not be heated to facilitate straightening.
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18.3.0
Placing of Reinforcement a. The reinforcement cage should generally be fabricated in the yard at ground level and then shifted and placed in position. The reinforcement shall be placed strictly in accordance with the drawings and shall be assembled in position only when the structure is otherwise ready for placing of concrete. Prolonged time gap between assembling of reinforcements and casting of concrete, which may result in rust formation on the surface, shall not be permitted. b. Reinforcement bars shall be placed accurately in position as shown on the drawings. The bars, crossing one another shall be tied together at every intersection with binding wire (annealed), conforming to IS:280 to make the skeleton of the reinforcement rigid such that the reinforcement does not get displaced during placing of concrete, or any other operation. The diameter of binding wire shall not be less than 1 mm. c. Bars shall be kept in position usually by the following methods : i. In case of beam and slab construction, industrially produced polymer cover blocks of thickness equal to the specified cover shall be placed between the bars and formwork subject to satisfactory evidence that the polymer composition is not harmful to concrete and reinforcement. Cover blocks made of concrete may be permitted by the Engineer, provided they have the same strength and specification as those of the member. In case of dowels for columns and walls, the vertical reinforcement shall be kept in position by means of timber templates with slots cut in them accurately, or with cover blocks tied to the reinforcement. Timber templates shall be removed after the concreting has progressed up to a level just below their location. Layers of reinforcements shall be separated by spacer bars at approximately 1m intervals. The minimum diameter of spacer bars shall be 12 mm or equal to maximum size of main reinforcement or maximum size of coarse aggregate, whichever is greater. Horizontal reinforcement shall not be allowed to sag between supports. Necessary stays, blocks, metal chairs, spacers, metal hangers, supporting wires etc. or other subsidiary reinforcement shall be provided to fix the reinforcements firmly in its correct position. Use of pebbles, broken stone, metal pipe, brick, mortar or wooden blocks etc., as devices for positioning reinforcement shall not be permitted.
ii.
iii.
iv.
v.
d. Bars coated with epoxy or any other approved protective coating shall be placed on supports that do not damage the coating. Supports shall be installed in a manner such that planes of weakness are not created in hardened concrete. The coated reinforcing steel shall be held in place by use of plastic or plastic coated binding wires especially manufactured for the purpose. e. Placing and fixing of reinforcement shall be inspected and approved by the Engineer before concrete is deposited. 18.4.0 18.4.1 Bar Splices Lapping All reinforcement shall be furnished in full lengths as indicated on the drawing. No splicing of bars, except where shown on the drawing, shall be permitted without approval of the Engineer. The lengths of the splice shall be as indicated on drawing or as approved by the Engineer. Where practicable, overlapping bars shall not touch each other, and shall
be kept apart by 25 mm or 1 times the maximum size of coarse aggregate, whichever is greater. If this is not feasible, overlapping bars shall be bound with annealed steel binding wire, not less than 1 mm diameter and twisted tight in such a manner as to maintain minimum clear cover to the reinforcement from the concrete surface. Lapped splices shall be staggered or located at points, along the span where stresses are low. 18.4.2 Welding Splicing by welding of reinforcement shall be permitted only if detailed on the drawing or approved by the Engineer. Weld shall develop an ultimate strength equal to or greater than that of the bars connected. While welding may be permitted for mild steel reinforcing bars conforming to IS:432, welding of deformed bars conforming IS:1786 shall in general be prohibited. Welding may be permitted in case of bars of other than S 240 grade including special welding grade of S 415 grade bars conforming to IS:1786, for which necessary chemical analysis has been secured and the carbon equivalent (CE) calculated from the chemical composition using the formula :
CE
is 0.4 or less.
Mn Cr Mg V Ni Cu 6 5 15
The method of welding shall conform to IS:2751 and IS:9417 and to any supplemental specifications to the satisfaction of the Engineer. Welding shall be carried out by metal arc welding process. Oxyacetylene welding shall not be permissible. Any other process may be used subject to the approval of the Engineer and necessary additional requirements to ensure satisfactory joint performance. Precautions on over heating, choice of electrode, selection of correct current in arc welding etc., should be strictly observed. All bars shall be butt welded except for smaller diameter bars (diameter of less than 20 mm) which may be lap welded. Single-V or Double-V butt joints may generally be used. For vertical bars single bevel or double bevel joints may be used. Welded joints shall be located well away from bends and not less than twice the bar diameter away from a bend. Generally, shop welding in controlled conditions is to be preferred, where feasible. Site welding where necessary shall, however, be permitted when the facilities, equipments, process, consumables, operators, welding procedure are adequate to produce and maintain uniform quality at par with that attainable in shop welding to the satisfaction of the Engineer. Joint welding procedures, which are to be employed, shall invariably be established by a procedure specification. All welders and welding operators to be employed shall have to be qualified by tests prescribed in IS:2751. Inspection of welds shall conform to IS:822 and destructive or non-destructive testing may be undertaken when deemed necessary. Joints with weld defects detected by the visual inspection or dimensional check inspection shall not be accepted. Suitable means shall be provided for holding the bars securely in position during welding. It must be ensured that no voids are left in welding. When welding is done in 2 or 3 stages, previous surface shall be cleaned properly. Bars shall be cleaned of all loose scale, rust, grease, paint and other foreign matter before carrying out welding. Only competent and experienced welders shall be employed on the work with the approval of the Engineer. no welding shall be done on coated bars. M.S. electrodes used for welding shall conform to IS:814.
Welded joints shall preferably be located at points where steel shall not be subject to more than 75 per cent of the maximum permissible stresses and welds so staggered that at any one section, not more than 20 per cent of the bars are welded. Welded pieces of reinforcement shall be tested. Specimens shall be taken from the site and the number and frequency of tests shall be as directed by the Engineer. 18.4.3 Mechanical Coupling of Bars Bars shall be joined with approved patented mechanical devices as indicated on the drawing or as approved by the Engineer e.g. by special grade steel sleeves swagged on to bars in end to end contact or by screwed couplers. In case such devices are permitted by the Engineer, they shall develop at least 125 per cent of the characteristic strength of the reinforcement bar. 18.5.0 Testing and Acceptance The material shall be tested in accordance with relevant IS specifications and necessary test certificates shall be furnished. Additional tests, if required, shall be carried out by the Contractor at his own cost. The fabrication, furnishing and placing of reinforcement shall be in accordance with these specifications and shall be checked and accepted by the Engineer.
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2.11.2 1.0.0
Technical Specification for Offshore Caisson and Piles SCOPE This specification covers the construction of a caisson intake well / Piles as per approved drawings and specifications given herein. The work broadly consists of sinking the well to the required depth in riverbed, controlled excavation of soil and other materials from in and around the well confining to the cutting edge, excavation by pneumatic appliances, plugging the bottom with concrete of specified grade, casting of PCC and RCC, providing water inlet openings, openings for installing stop log gates, trash racks and travelling water screens in concrete as per approved drawings and directions of the Engineer. This specification also covers the construction of all types of piles for structures in water in accordance with the details shown on the drawings and conforming to the requirements of these specification.
2.0.0
CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and methods of testing. Some of the relevant available codes are listed hereunder: IS : 456 IS : 2911 IS : 4138 IRC: 78 Code of practice for plain and reinforced concrete. Code of practice for design and construction of pile foundation. Safety code for working in compressed air. Standard Specifications and Code of Practice for Road Bridges, Section VII-Foundation of Substructure. Recommendations for estimating the resistance of soil below the maximum scour level in the design of well foundations of bridges. Standard specifications and code of practice for road bridges, Section IILoads and stresses
IRC: 45
IRC:6 3.0.0 GENERAL
The Contractor shall provide all plant and equipment for construction of the well / pile in the dry dock and / or in floating condition or at the shore. In case of dry dock construction is proposed by the Contractor, he has to arrange area / space from the authorities at his own cost. Necessary approvals from the authorities for construction of the well at shore or in floating condition shall also be obtained by the Contractor at his own cost. 4.0.0 4.1.0 SPECIFICATION FOR WELL FOUNDATIONS UNDER WATER Foundation General The foundation for the well shall be taken to hard soil / rock. The lump sum offer shall be based on this assumption. However, the Contractor shall give or be given a rebate over the lump sum price based on the item rate. Lump sum quotation shall hold good for all methods of sinking wells unto levels as indicated or unto levels as required from design considerations, whichever are lower including the employment of divers and equipment, floating caisson or islands to enable well sinking operations to be carried out (as the site conditions may warrant). The lump sum quotation shall also include sinking wells in all kinds of soils, soft and hard murrum, soft rock and admixtures thereof and mixed with boulders of all varieties and of all sizes
and including blasting, if found necessary, or chiselling of hard rock to the extent that may be necessary for square seating of well, removal of any trees, logs of trees, fossils, isolated boulders of all sizes and all varieties, if met with in the case of sinking. At least one borehole must be available / carried out in accordance with these specifications at the well foundation location, prior to commencement of the work. The depth of boreholes should extend up to a depth equal to two times the outer diameter / least dimension of the well below the anticipated founding level. The results of soil exploration should be presented as per Cl.7.4 of IRC:78. In case the well foundation is to rest on a rocky strata additional borings / probing shall be necessary to ascertain the actual profile. 4.2.0 Well Foundation (Cutting edge, well curb and well steining ) A temporary benchmark shall be established near the well foundation away from the zones of blow-ups or possible settlement, which shall be checked regularly with the permanent benchmark established at the bridge site. The well foundation shall be sunk unto hard soil / rock strata and a sump of not less than 500 mm depth below the top of the hard stratum (i.e bottom of cutting edge) and equal to the dredge hole shall be provided. Test boring shall be carried out to ensure the properties of the soil encountered at the founding strata to confirm the characteristics of the soil to that adopted in the design. Well of the foundation shall be anchored to rock, if encountered, with 8 numbers of 32 mm diameter HYSD bars with anchors embedded 2.5 m in the steining and curb. Sump shall be as an alternative to anchors. Seating of foundation in hard stratum shall be properly checked in wet conditions, through divers, before plugging of the well to the satisfaction of the Engineer. 4.2.1 Cutting Edge The cutting edge shall be provided with a 10 mm thick armour plate all round the inner face of the kerb and 8 mm thick plate on the outer surface, both the plates being cross connected by angle or channel bracing together. The cutting edge shall consist of MS angles not less than 100 x 100 x 12 angles and stiffening plates of 350 x 12 mm all to be connected by welded construction (the weight shall not be less than 40 kg per meter length). Design calculations to substantiate the steel requirement shall be submitted and approved by the Engineer. This steel armour of the curb is specified to protect the RCC curb during blasting or sinking should this become necessary (The cost of the steel armour shall be included in the lump sum) The parts of the cutting edge shall be erected on level firm ground with temporary supports to facilitate erection and maintaining the assembly in true shape. The steel sections should not be heated and forced into shape. Joints in the lengths of the structural sections, unless otherwise specified shall be fillet welded using single cover plate to ensure the requisite strength of the original section. The cutting edge shall be laid about 300 mm above prevalent water level. 4.2.2 Well Curb The well curb shall be of RCC with reinforcement of not less than 75 kg/m3 (excluding wastage) of the concrete excluding bond rods from the steining taken into the curb to provide for grip etc. The inner inclined face of the well curb shall have a slope of about 30C to the normal. The concrete mix shall not be leaner than grade M35 with minimum cement content of 400 kg/m3. The external surface of the curb shall be vertical. All concreting in the well curb shall be done in one continuous operation. The formwork on the outer face of the curb may be removed within 24 hours after concreting. The formwork on inner face shall be removed after 72 hours.
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4.2.3
Well Steining The well steining shall not be less than 600 mm and the concrete mix for the well shall be not lesser than M35 concrete with cement content not less than 400 Kg/m3. The vertical reinforcement (bond rods) in steining shall not be less than 9 Kg/m3 (excluding wastage, laps etc.) of concrete in steining. In addition, hoop (ring) reinforcement of not less than 3.5 Kg/m3 of the steining section shall be provided. The bond rods shall be located in two rows along the periphery namely one near outer face and the other near the inner face of the well steining. Half the hoop reinforcement shall be disposed near the inner face and the outer half on the outer face of the well steining around the bond rods. The minimum clear cover to reinforcement shall not be less than 75 mm. Bond rods connecting the cutting edge to the curb shall extend to at least 1.5 m into the steining concrete. The steining built in the first lift above the well curb shall not be more than 2 m and in the subsequent lifts it shall not exceed the diameter of the well or the depth of the well sunk below the adjoining bed level at any time. Concreting of steining may be carried out in subsequent lifts of about 2 to 2.5 m. The concreting layers shall be limited to about 450 mm restricting the free fall of concrete to not more than 1.5 m. The well shall be considered as cast with horizontal construction joints at any level (preferably NOT at the location of laps in the vertical steining bars) and the permissible tensile stresses in the concrete of the steining shall be limited to 1/6th of the cube strength of the concrete adopted in the steining. However, attempts shall be made to minimize the number of construction joints. The steining of the well shall be built in one straight line from bottom to top such that if the well is tilted, the next lift of steining shall be aligned in the direction of the tilt. The work shall be carefully checked with the aid of straight edges of lengths approved by the Engineer. Plumb bob or spirit level shall not be used for alignment. After sinking of a stage is complete, damaged portions if any, of steining at the top of the previous stage shall be properly repaired before constructing the next stage. The steining rods shall be properly anchored into well cap No plums shall be allowed in the concrete of the well steining as well as in the bottom plug. Concrete method of placing concrete is not acceptable in any part of the structure RCC as well as plain concrete. After reaching the founding level, the well steining shall be inspected to check for damages and cracks. The Engineer shall direct and the Contractor shall execute the remedial measures before acceptance of the well. In case the well cannot be accepted even with any remedial measures, then the well shall stand rejected.
4.3.0
Towing and sinking of well For floating the caisson, a detailed method statement for fabrication, floating and sinking of caisson shall be prepared and furnished to the Engineer. Such statement shall include the total tonnage of steel involved, fabrication and welding specifications, list of materials and plant and a description of operations and manpower required for the work. The caisson shall be tested for leakages before being towed to site. Method of floating a concrete caisson, if used, shall also be prepared and furnished to the Engineer which shall include the above mentioned details. Navigational lights shall be installed and maintained on the well immediately after it is placed in position. The well shall be sunk truly vertical to final levels and within the tolerances for tilts and shifts. At least 12 holes of 150 mm diameter shall be formed in the well steining and the
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curb at the time of casting the same for possible anchoring of the well, should the same become necessary due to unanticipated site conditions at the time of final seating of the well. In case these holes are found to be of no use the same shall be plugged with cement grout not leaner than 1:3 cement sand proportions. Kent edging or water jetting may be resorted to for well sinking, wherever necessary. Sinking or loading of the well shall commence only after the steining has been cured for at least 48 hours or as specified in the approved drawings. Pneumatic sinking may have to be resorted to by the Contractor where obstacles are met at the bottom or when there is hard strata which cannot be removed by open dredging. The necessity for pneumatic excavation shall be decided by the Engineer. The design requirements of the pneumatic equipment, safety of personnel and the structure shall comply with the provisions of IS:4138. Generally, blasting shall not be used as an aid for well sinking. However, if unavoidable, prior approval of the Engineer shall be obtained and adequate precautions shall be taken to prevent damage to the well steining. All prevalent laws concerning handling, storing and using of explosives shall be strictly followed by the Contractor. The dredged material shall not be allowed to accumulate near the well. It shall be dumped at not less than 1 km away from the well as directed by the Engineer. The depth of sump made below the well curb shall not exceed 3 m below the cutting edge unless otherwise permitted by the Engineer. In case the well sinks suddenly and with a jerk, the steining of the well shall be examined to the satisfaction of the Engineer to see that no damage has occurred to it. Permissible tilts and shifts in any directions shall be limited to a tilt of 1 in 80 and a shift of 15 cm. If the tilt(s) and / or shift(s) of the well exceeds the specified permissible values, the well so sunk shall be recorded as not conforming to specifications and a sub-standard work. Refer Clause 29.0.2 of Special Conditions of Contract for the penalties imposed for substandard work. Dewatering of wells for sinking shall not be ordinarily resorted to and shall be done with specific instructions in writing from the Engineer. No claim shall be entertained in respect of difficulties experienced due to sand blows during sinking of the well. 4.4.0 Bottom Plug The concrete in the bottom plug shall be designed (in dry condition) to attain the concrete strength as mentioned in the drawing and shall contain 10% extra cement than that required for the same mix placed dry, to cater for underwater concreting.. However, the total cement content shall not be less than 363 kg/cum of concrete with a slump in the range of 150 mm to 200 mm. The thickness of the bottom plug shall extend at least 300 mm above the curb top. All concrete of the bottom plug, placed under water, shall be by tremie method. Concrete placed in the sump or in shear keys formed below the cutting edge shall be filled up by concrete of quality same as that used in the bottom plug at no extra cost. Concreting shall be done in one continuous operation till the dredge hole is filled up to the required height and thereafter sounding shall be taken up to ensure that the concrete has been laid to the required depth. Soundness of the bottom plug shall be tested by dewatering the well unto 5 meters below the surrounding water level and observing rise of water. The rate of rise shall be less than 10 cm/hr. In case the rate of rise exceeds this value, suitable remedial measures shall be taken by the Contractor at his own cost and expense. The testing of bottom plug in any or all wells may be recorded by Owner at their discretion. The lump sum price shall be inclusive of the expenses of conducting this recuperation test(s). To ensure that the sump is actually filled and the level of the top of the bottom plug is at the level required sounding shall be taken at the required number of locations and the volume of concrete in the bottom plug shall be calculated and compared with the quantity.
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Recuperation test on the bottom plug shall not be carried out earlier than 7 days from the date of placing the bottom plug concrete. 4.5.0 Sand Filling A minimum of 3 days shall elapse after the bottom plug has been laid before sand filling of dredge hole is commenced. Clean sand shall be placed and compacted as directed unto the level shown on the drawing or as directed by the Engineer. 4.6.0 Intermediate Plug Intermediate plug shall be provided in designed concrete mix and shall be placed immediately at the required level after scrapping out the sand filling to this thickness. 4.7.0 Well Cap RCC well caps shall be cast in concrete mix not leaner than M35. The well cap shall be designed as a simply supported slab on the steining for all the loads coming on it from the pump house and equipments, but the bond bars of the steining shall be anchored into the well cap to at least 60 mm diameter of the bars. 4.8.0 Tolerances The permissible tilt and shift shall not exceed 1 (horizontal) in 80 (vertical) and the shift at the well base shall not be more than 150 mm in any resultant direction from the approved location of the well For the well steining and well cap the permissible tolerances shall be as follows: a) Variation in dimension + 50 mm - 10 mm
b) Surface irregularities measured with a 3 m straight edge c) Variation of levels at the top 4.9.0 Tests and Standards of acceptance
5 mm
() 25 mm
The materials shall be tested in accordance with the specifications and shall meet the prescribed criteria. The work shall conform to these specifications and shall meet the prescribed standards of acceptance. 5.0.0 5.1.0 Specification for Pile foundations under water Foundation - General Sufficient number of boreholes must be available / carried out in accordance with these specifications at the well foundation location, prior to commencement of the work. The depth of boreholes shall not be less than 1.5 times estimated length of pile in soil but not less than 15 m beyond the probable length of pile, 15 times diameter of pile in weak / jointed rock but minimum 15 m in such rock or 4 times diameter of pile in sound, hard rock but minimum 3 m in such rock. The offshore piles shall be designed for the lateral forces and shall take into account the scouring of the riverbed. All piles shall be located using total station laser operated instrument
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5.2.0
Materials Grade of concrete to be used in cast-in-situ piles shall not be less than M35 and the cement content shall not be less than 400 kg/cum of concrete. Grades of concrete for precast reinforced concrete piles shall not be less than M35. Maximum water cement ratio shall be 0.5 for cast-in-situ piles and 0.45 for precast piles. The minimum slump of concrete for driven cast-in-situ piles shall be 100 mm to 150 mm and that of bored cast-in-situ piles 150 mm to 200 mm. The slump shall not exceed 200 mm in any case. The concrete mix should have homogenous mixture with required workability for the system of piling to be adopted. Suitable and approved admixtures may be used in concrete mix where necessary at no extra cost to the Owner. Where piles are exposed to harmful chemicals or severe conditions of exposure due to sulphate, chloride etc, it may be preferable to opt for higher grade of concrete restricting water cement ratio to 0.45. Special types of cement shall be used where considered appropriate. The other materials used shall be in accordance with Specification no. 6104-ST-SPC590-018.
5.3.0
Cast-In-Situ Concrete Piles Cast-in-situ concrete piles shall be installed by making a bore into the ground by removal of material from it or by driving a metal casing with a shoe at the tip and displacing the material laterally. The metal casing shall be of sufficient thickness and strength to hold its original form and show no harmful distortion after it and adjacent casings have been driven, if any, has been withdrawn. Any liner or bore-hole which is improperly located or shows partial collapse that would affect the load carrying capacity of the pile, shall be rejected or repaired as directed by the Engineer at the cost of the Contractor. Wherever practicable, concrete should be placed in a clean dry hole. Where concrete is placed in dry and there is casing present, the top 3m of the pile shall be compacted using internal vibrators. The concrete should invariably be poured through a tremie with a funnel so that the flow is directed and concrete can be deposited in the hole without segregation. The concrete shall be properly graded, shall be self-compacting and shall not get mixed with soil, excess water, or other extraneous matter. Special care shall be taken in silty clays and other soils with a tendency to squeeze into the newly deposited concrete and cause necking. Sufficient head of green concrete shall be maintained to prevent inflow of soil or water into the concrete. The placing of concrete shall be a continuous process from the toe level to the top of the pile. To prevent segregation, a tube or tremie pipe as appropriate shall be used to place concrete in all piles. To ensure compaction by hydraulic static heads, rate of placing concrete in the piles shaft shall not be less than 6m (length of pile) per hour. For bored cast-in-situ piles the casing shall be small and only at the top. A minimum of 2m length of top of bore shall invariably be provided with casing to ensure against loose soil falling into the bore. The casing /liner shall be driven open ended with a pile driving hammer capable of achieving penetration of the liner to the length shown on the drawing or as approved by the Engineer. Materials inside the casing shall be removed progressively by airlift, grab or percussion equipment or other approved means. Where bored cast-in-situ piles are used in soils liable to flow, the bottom of the casing shall be kept enough in advance of the boring tool to prevent the entry of soil into the casing, thus preventing the formation of cavities and settlements in the adjoining ground. The water level in the casing should generally be maintained at the natural ground water level for the same reasons. The joints of the casing shall be made as tight as possible to minimize inflow of water or leakage of slurry during concreting.
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Boring shall be carried out using rotary or percussion type equipment. Unless otherwise approved by the Engineer, the diameter of the boreholes shall not be more than the inside diameter of the liner. Prior to the lowering of the reinforcement cage into the pile shaft, the shaft shall be cleaned of all loose materials. Suitable spacers shall maintain cover to the reinforcing steel. The diameter of the finished pile shall not be less than that specified and a continuous record shall be kept by the Engineer as to the volume of concrete placed in relation to the pile length cast. Before concreting under water, the bottom of the hole shall be cleaned of drilling mud and all soft or loose materials very carefully. In case a hole is bored with use of drilling mud, concreting should not be taken up when the specific gravity of bottom slurry is more that 1.2. The drilling mud should be maintained at 1.5 m above the ground water level. The minimum embedment of cast-in-situ concrete piles into pile cap shall be 150 mm. Any defective concrete at the head of the pile complete shall be cut away and made good with new concrete. The reinforcement in the piles shall be exposed for full anchorage length to permit it to be adequately bonded into the pile cap. Defective piles shall be removed or left in place as judged convenient without affecting the performance of adjacent piles or pile cap. Additional piles shall be provided to replace the defective piles. The following general requirements and precaution for concreting under water should be followed: a) The concreting of a pile must be completed in one continuous operation. Also, for bored holes, the finishing of the bore, cleaning of the bore, lowering of reinforcement cage and concreting of pile for full height must be accomplished in one continuous operation without any stoppage. b) The concrete should be coherent, rich in cement with high slump and restricted water cement ratio. c) The tremie pipe shall have to be large enough with due regard to the size of aggregate. For 20 mm aggregate the tremie pipe should be of diameter not less that 150 mm and for larger aggregate, larger diameter tremie pipes may be necessary. d) The first charge of concrete should be placed with a sliding plug pushed down the type ahead of it to prevent mixing of water and concrete. e) The tremie pipe should always penetrate well into the concrete with an adequate margin of safety against accidental withdrawal if the pipe is surged to discharge the concrete. f) The pile should be concrete wholly by tremie and the method of deposition should not be changed part way up the pile to prevent the laitance from being entrapped within the pile.
g) All tremie tubes should be scrupulously cleaned after use. 5.4.0 5.4.1 Important considerations for piles Driven Cast-in-Situ Piles Specialist literature and the guidelines from the pile construction industry shall be consulted regarding the method of installation, equipment and accessories for pile driving and recording of data. During installation of piles the final set of penetration of pile per blow of hammer shall be calculated based on the number of blows which depends on the ultimate load capacity of
pile, weight of hammer, height of fall of hammer and taking into account the losses and efficiency. The pile shoes, which shall be of either cast iron conical type or mild steel flat type, shall have double reams for proper seating of the removable casing tube inside the space between the reams. Before commencement of pouring of concrete, it shall be ensured that there is no ingress of water in the casing tube from the bottom. Further adequate control during withdrawal of the casing tube is essential so as to maintain sufficient head of concrete inside the casing tube at all stages of withdrawal. Concrete in piles shall be cast upto a minimum height of 600 mm above the designed top level of pile, which shall be stripped off at the time of construction of pile cap. 5.4.2 Bored Cast-in-Situ Piles While concreting uncased piles, voids in concrete shall be avoided and sufficient head of concrete is to be maintained to prevent inflow of soil or water into the concrete. It is also necessary to take precautions during concreting to minimize the softening of the soil by excess water. Uncased cast-in-situ piles shall not be allowed where mudflow conditions exist. The drilling mud such as bentonite suspension shall be maintained at a level sufficiently above the surrounding ground water level to ensure the stability of the strata, which is being penetrated throughout the boring process until the pile has been concreted. Where bentonite suspension is used to maintain the stability of the borehole, it is essential that the properties of the material be carefully controlled at stages of mixing supply to the borehole and immediately before concrete is placed. It is usual to limit: i) ii) The density of bentonite suspension to 1.05 g/cc The marsh cone viscosity between 30 and 40
iii) The pH value between 9.5 and 12 iv) The silt content less than 1 per cent v) The liquid limit of bentonite not less than 400 per cent. These aspects shall act as controlling factors for preventing contamination of bentonite slurry for clay and silt. The bores shall be washed by bentonite flushing to ensure clean bottom at two stages viz. after completion of boring and prior to concreting after placing of reinforcement cage. Flushing of bentonite shall be done continuously with fresh bentonite slurry till the consistency of inflowing and out-flowing slurry is similar. Tremie of 150 mm to 200 mm diameter shall be used for concreting. The tremie should have uniform and smooth cross-section inside, and shall be withdrawn slowly ensuring adequate height of concrete outside the tremie pipe at all stages of withdrawal. Other recommendations for tremie concreting are: i) ii) The sides of the borehole have to be stable throughout. The tremie shall be watertight throughout its length and have a hopper attached at its head by a watertight connection.
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iii) The tremie pipe shall be large enough in relation to the size of aggregates. For 20 mm aggregate the tremie pipe shall be of diameter not less than 150 mm and for larger size aggregate tremie pipe of larger diameter is required. iv) The tremie pipe shall be lowered to the bottom of the borehole allowing water or drilling mud to rise inside it before pouring concrete. v) The tremie pipe shall always be kept full of concrete and shall penetrate well into the concrete in the borehole with adequate margin of safety against accidental withdrawal if the pipe is surged to discharge the concrete. For very long or large diameter piles, use of retarding plasticiser in concrete is desirable. For large diameter piles, it may be essential to conduct non-destructive pile integrity tests to evaluate integrity of the pile. Where possible, it may be desirable to grout the base of pile with cement slurry under suitable pressure after concrete in the pile attains the desired strength. For this purpose, conduit pipes with easily removable plugs at the bottom end should be placed in the bore along with reinforcement cage before concreting. 5.5.0 Precast Concrete piles Precast concrete piles shall be of the size and shape as shown in the approved drawings. The length of pile shall not normally exceed 25 m. Piles shall be cast with driving point and for hard driving, shall be shod with a metal shoe approved by the Engineer. Care shall be taken that at all stages of transporting, lifting and handling piles are not damaged or cracked. Piles shall be stored at least 300 mm above firm level ground. Spaces shall be left around the piles to enable them to be lifted without difficulty. The order of stacking shall be such that the older piles can be withdrawn without disturbing newer piles. Where piles are stacked in layers the number of layers shall not exceed three. Arrangements for curing during storage if required shall be made by the Contractor. Where a pile is to have another length cast on it during driving, the longitudinal reinforcement shall preferably be joined by full penetration butt-welding. The concrete at the top of the original pile shall be cut down to expose not less than 200 mm of the bars to avoid spalling of the concrete by heat. Where facilities on site are insufficient to make proper butt-welding practicable the joint may be made by lapping. The reinforcement at the head of the pile shall need to be exposed for full anchorage length or 600 mm whichever is greater and the new bars overlapped for this distance. The extension of pile shall be formed to the same cross sectional profile and with the concrete of at least the same strength as that specified for the original pile. The stirrup spacing shall in no case be greater than 150 mm. not more than one extension shall be permitted. In case more than one extension is permitted by the Engineer, only approved mechanical couplers shall be used. Driving shall not be resumed until the strength of the concrete in the extension is at least equal to the specified characteristic strength of concrete in pile and the approval of the Engineer is obtained. Any length of pile surplus to that required for incorporation in the structure shall be cut off neatly and removed during the process it shall be ensured that the projecting reinforcement to be anchored into the pile cap are not damaged. Level reading should be taken on each pile after driving and gain after all the piles are driven. Piles which are found to have risen due to ground heave or as a result of driving adjacent piles, shall be re-driven to the original depth or resistance unless re-driving tests on adjacent piles have shown this to be unnecessary. The pile should be cast in one continuous operation from end to end of each pile. Manufacture of the piles shall conform to Cl.7.1, 7.2 and 7.3 of IS:2911 (Part I Section 3).
Piles shall not be driven in less than 28 days after casting or unless their strength at the time of driving is at least that specified for 28 days. 5.6.0 Driving of piles Piles or their casings shall be driven with any type of drop hammer, diesel hammer or single acting steam or compressed air hammer provided they penetrate to the prescribed depth or attain the designed resistance without being damaged. The minimum weight of the hammer shall be 2.5 t. In case of precast concrete piles the mass of the hammer shall not be less than 30 times the mass of 300 mm length of pile. Details of equipment and the method proposed for driving the piles shall be submitted with the tender for scrutiny and approval of the Engineer. During driving the top of pile shall be protected by a suitable helmet of substantial steel construction. Piles shall be driven from a fixed frame of sufficient rigidity to ensure accuracy of driving within specified limits. the stroke of a single acting or drop hammer shall be limited to 1.2 m unless otherwise permitted by the Engineer. Checks shall be carried out at regular intervals throughout the driving operation to ensure that the pile frame does not exert any undue lateral force on the pile due to restraint within the helmet. If the indications are that a pile shall finish outside the specified tolerances, driving operations on that pile shall cease, the pile shall be withdrawn, the hole filled and the pile re-driven at no extra cost. damaged piles shall be repaired or replaced as directed by the Engineer at no extra cost. The pile shall be driven as accurately as possible to the vertical or to specified batter. Driving a number of friction piles in a group shall proceed outward from the center as otherwise it shall be difficult to drive the inner piles to the same depth as the others. in case of very soft soil, the driving shall proceed from outside to inside, so that the soil is restrained from flowing out during driving operations. If there is a major variation between the depth at which adjacent foundation piles in a group meet refusal, a boring shall be made nearby to ascertain the cause of this difference. If the boring shows that the soil contains pockets of highly compressive material below the level of the shorter pile, it will be necessary to enforce penetration of all the piles to a level below the bottom of the zone which shows such pockets. Piles should be driven to the minimum acceptable penetration shown on the drawings. this may require preboring and / or jetting with the full approval of the Engineer. Preboring shall not extend below 1 m above the founding level and the pile shall be driven to at least 1 m below the prebored hole. When water jetting is used, at least two jets shall be attached to the pile symmetrically when this type of technique is used. Jetting shall be stopped before completing the driving which shall always be finished by ordinary methods. 5.7.0 Pile Tests The bearing capacity of a single pile shall be determined form test loading a pile. The load test on concrete pile shall not be carried out earlier than 28 days from the time of casting of the pile. There shall be two categories of tests on piles, namely initial tests and routine tests. Initial tests should be carried out on test piles for vertical, lateral and uplift loads, which are not to be incorporated in the work. Routine tests shall be carried out as a check on working piles for vertical and lateral loads. The routine tests on piles shall be conducted upto test load of one and a half times the allowable pile capacity by direct loading method. Piles for routine load test shall be approved by the Owner. The number of initial and routine tests
on piles shall be determined by the Engineer depending upon the number of foundations, span length, type of superstructure and uncertainties of founding strata. In any case the initial load tests shall not be less than 2 in number, while the routine load tests shall not be less that 2 per cent of the total number of piles in the structure nor less than 2 in number. Both initial and routine tests may be suitably increased for important structures or cases with large variation in the sub surface strata in accordance with the Engineer. These stipulations hold good for both vertical as well as lateral load tests on piles. The methodology of carrying out load tests and of arriving at safe load on piles shall conform to IS:2911 (Part IV). In case of any doubt of workmanship or load carrying capacity of working piles not subjected to routine tests, or when ordered by the Engineer, or when provided in the contract, load tests on working piles may be supplemented by non-destructive testing. Such tests may include Integrity Testing of concrete in the installed pile and utilization of Pile Driving Analyzer which gives an indication of pile capacity in end bearing and side friction. The Contractor shall submit the scheme for testing pile concrete integrity for Owners approval and test at least 25% of piles. The pile / pile group shall be tested for cyclic plate load test. A report on the pile load tests shall be submitted for the 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 the Contractor shall install additional pile(s) as required and accordingly, pile cap design shall be reviewed and modified, if required, at no extra cost to the Owner. Wherever pile foundations are adopted, a minimum of two pile group shall be provided. 5.7.1 Other requirements For piles in contact with water, MS liner of minimum 8mm thickness shall be provided. Liner shall penetrate adequately into hard soil. The portion of liner above Mean Sea Level / Chart Datum shall be painted outside with a primer coat (zinc chromate) and two finishing coats of bitumastic paint. The rate of painting shall be 1.7 kg / sqm / coat. 5.8.0 Piling record For each pile, a piling record book shall be maintained and submitted daily to the Engineer for approval. The record book shall include for each pile details on : location, reference number (corresponding to the number fixed on the drawing), type and diameter of pile length of the temporary casing date and hour of start and end of each operation - drilling , reinforcement setting, concreting level from which the pile is bored / driven (platform level) level at the pile base top level of concreted pile before cut-off operation used materials (driving or drilling tools, concreting equipments) cleaning results from the bottom of the hole before putting down the reinforcement cage and before concreting.
nature and description of encountered soils poured concrete volume and theoretical volume (measured concrete curves) behaviour, workability, fluidity of concrete, results of compression tests water level within the hole before concreting for driven piles, the refusal corresponding to the last three sets of blows (10 hammer blows) shall be noted for each pile; for one pile from each 20 piles, a driving diagram shall be drawn type of boring chisel, lengths of piles where chisel has been used.
5.8.1
Pile cap Pile caps shall be of reinforced concrete. A minimum offset of 150 mm shall be provided beyond the outer faces of the outer most piles in the group. If the pile cap is in contact with earth at the bottom a levelling course of minimum 100 mm thickness of M 20 grade concrete shall be provided. The attachment of the pile head to the cap shall be adequate for the transmission of loads and forces. A portion of pile top shall be stripped of concrete and the reinforcement anchored into the cap. Manual chipping may be permitted after 3 days of pile casting, while pneumatic tools for chipping shall not be used before seven days after pile casting. The top of pile after stripping shall project at least 150 mm into the pile cap. A layer of surface reinforcement my be provided with a cover of 25 mm to retain the integrity of concrete below the main cap reinforcement which is to be laid 25 mm above the pile top. Concreting of the pile cap shall be carried out in dry conditions.
5.9.0 5.9.1
Permissible Tolerances Precast Concrete Piles a) Variation in cross sectional dimension b) Variation in length : : 5 mm 25 mm
c) Surface irregularities measured with 3 m straight edge d) Bow for length in mm 5.9.2 Driven Piles a) Variation in cross sectional dimension b) Variation from vertical or specified rake :
: :
5 mm Pile length in mm 1000
: 1 in 50
+ 50 mm, -10 mm
c) Variation in the final position of the head in plan : d) Variation of level of top of piles 5.9.3 Bored Piles a) Variation in cross sectional dimension b) Variation from vertical or specified rake :
75 mm 25 mm
: 1 in 50
+ 50 mm, -10 mm
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c) Variation in the final position of the head in plan : d) Variation of level of top of piles 5.9.4 Pile caps a) Variation in dimensions b) Misplacement from specified position in plan : : :
50 mm 25 mm
+ 50 mm, -10 mm 15 mm
c) Surface irregularities measured with 3 m straight edge : d) Variation of levels at the top 5.10.0 Test and Standards of Acceptance :
5 mm 25 mm
The materials shall be tested in accordance with the specifications and shall meet the prescribed criteria. The work shall conform to the specifications and shall meet the prescribed standards of acceptance.
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2.11.3
Technical Specification for Substructure Pier and Pier Cap, Abutment and Abutment Cap SCOPE The work shall cover furnishing and providing of reinforced concrete substructure in accordance with the drawings and as per these specifications or as directed by the Engineer.
1.0.0
2.0.0
CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and methods of testing. Some of the relevant available codes are listed hereunder: IS : 456 IRC : 5 Code of practice for plain and reinforced concrete. Standard Specifications & Code of Practice for Road Bridges, Section IGeneral Features of Design. Standard Specifications & Code of Practice for Road Bridges, Section IILoads and Stresses. Guidelines for the Design & Erection of False Work for Road Bridges.
IRC : 6
IRC : 87 3.0.0
MATERIALS The materials shall conform to specification no. 6104-ST-SPC-590-018
4.0.0
GENERAL A method statement for construction indicating the following shall be submitted by the Contractor for approval of the Engineer, well in advance of the commencement of substructure : i. ii. Sources of Materials Design, erection and removal of formwork
iii. Production, transportation, laying and curing of concrete iv. Personnel employed for exception and supervision v. Tests and sampling procedures
vi. Equipment details vii. Any other point Arrangements for execution under water wherever necessary, shall be included in method statement. Dimensions, lines and levels shall be set out and checked with respect to permanent reference lines and permanent benchmark.
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5.0.0
PIERS AND ABUTMENTS Formwork, concrete and reinforcement for piers and abutments shall conform to relevant sections of these specifications. In case of concrete piers, the number of horizontal construction joints shall be kept minimum. Construction joints shall be avoided in splash zones unless specifically permitted by the Engineer and provided they are treated in accordance with special provisions. No vertical construction joint shall be provided. The work shall conform strictly to the drawings or as directed by the Engineer. In case of tall piers and abutments, use of slipform shall be preferred. The design, erection and raising of slipform shall be subject to special specifications which shall be furnished by the Contractor. The concrete shall also be subject to additional specifications as necessary. All specifications and arrangements shall be subject to the approval of the Engineer. The surface of foundation / well cap / pile cap shall be scrapped with wire brush and all loose materials removed. In case reinforcing bars projecting from foundations are coated with cement slurry, the same shall be removed by tapping, hammering or wire brushing. Care shall be taken to remove all loose materials around reinforcements. Just before commencing masonry or concrete work, the surface shall be thoroughly wetted. In case of solid (non-spill through type) abutments, weep holes as shown on the drawings or as directed by the Engineer, shall be provided. Weep holes shall be provided with 100 mm diameter PVC pipe of 6 kg/cm2 pressure rating. Weep holes shall extend through the full width of the concrete with a slope of about 1 vertical : 20 horizontal towards the draining face. The spacing shall generally be 1m in either direction or as shown in the drawing with the lowest at about 150 mm above low water level or ground level whichever is higher or as directed by the Engineer. The surface finish shall be smooth, except the earth face of abutments which shall be rough finished. In case of abutments likely to experience considerable movement on account of backfill of approaches and settlement of foundations, the construction of the abutment shall be followed by filling up of embankment in layers to the full height to allow for the anticipated movement during construction period before casting of superstructure.
6.0.0
PIER CAP AND ABUTMENT CAP Formwork, reinforcement and concrete shall conform to relevant sections of these specifications. The locations and levels of pier cap / abutment cap / pedestals and bolts for fixing bearings shall be checked carefully to ensure alignment in accordance with the drawings of the bridge. The surface of cap shall be finished smooth and shall have a slope for draining of water as shown on the drawings or as directed by the Engineer. For short span slab bridges with continuous support on pier caps, the surface shall be cast horizontal. The top surface of the pedestal on which bearings are to be placed shall also be cast horizontal. The surface on which elastomeric bearings are to be placed shall be wood float finished to a level plane, which shall not vary more than 1.5 mm from straight edge placed in any direction across the area. The surface on which other bearings (steel bearings, pot bearings) are to be placed shall be cast about 25 mm below the bottom level of bearings and as indicated on the drawings.
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7.0.0
DIRT / BALLAST WALL, RETURN WALL AND WING WALL Concrete and reinforcement shall conform to relevant sections of these specifications. In case of cantilever return walls, no construction joint shall generally be permitted. Wherever feasible, the concreting in cantilever return walls shall be carried out in continuation of the ballast wall. For concrete return and wing wall, the surface of foundation shall be prepared in the same manner as prescribed for construction of abutment. No horizontal construction joint shall be provided. If shown on drawing or directed by the Engineer, vertical construction joint may be provided. Vertical expansion gap of 20 mm shall be provided in return wall / wing wall at every 10 metre intervals or as directed by the Engineer. Weep holes shall be provided as prescribed for abutments or as shown on the drawings. Formwork, reinforcement and concrete in dirt / ballast wall shall conform to relevant sections of these specifications. The finish of the surface on the earth side shall be rough while the front face shall be smooth finished. Architectural coping for wing wall / return wall in brick masonry shall conform to the relevant sections.
8.0.0
TESTS AND STANDARDS OF ACCEPTANCE The materials shall be tested in accordance with these specifications and shall meet the prescribed criteria. The work shall conform to these specifications and shall meet the prescribed standards of acceptance.
9.0.0
TOLERANCES IN CONCRETE ELEMENTS a. Variation in cross-sectional dimensions b. Misplacement from specified position in plan c. Variation of levels at the top : : : : : +10 mm, -5 mm 10 mm 10 mm 5 mm 10 mm
d. Variations of reduced levels of bearing areas e. Variations from plumb over full height f. Surface irregularities measured with 3 m straight edge All surfaces except bearing areas Bearing areas 10.0.0 WEEP HOLE
: :
5 mm 3 mm
Weep holes shall be provided in solid plain concrete / reinforced concrete, brick / stone masonry, abutment, wing wall and return walls as shown on the drawing or directed by the Engineer, to drive moisture from the back filling. Weep holes shall be provided with 100 mm diameter PVC pipe of 6 kg/cm2 pressure rating for structures in plain / reinforced concrete or brick masonry. In case of stone masonry, weep holes shall be 80 mm wide, 150 mm high or circular with 150 mm diameter. Weep holes shall extend through the full width of concrete / masonry with slope of about 1 vertical : 20 horizontal
towards the draining face. The spacing of weep holes shall generally be 1m in either direction or as shown in the drawing with the lowest at about 150 mm above the low water level or ground level whichever is higher or as directed by the Engineer.
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2.11.4 1.0.0
Technical Specification for Superstructure SCOPE The work shall cover furnishing and providing of concrete superstructure in accordance with the drawings as per these specifications or as directed by the Engineer.
2.0.0
CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and methods of testing. Some of the relevant available codes are listed hereunder: IS : 456 IRC : 5 Code of Practice for plain and reinforced concrete. Standard Specifications & Code of Practice for Road Bridges, Section I General Features of Design (Sixth Revision) Standard Specifications & Code of Practice for Road Bridges, Section II Loads and Stresses. Design Criteria for Prestressed Concrete Road Bridges (Post-Tensioned Concrete). Standard Specifications and Code of Practice for Road Bridges, Section III-Cement Concrete (Plain and Reinforced).
IRC : 6
IRC : 18
IRC : 21
3.0.0
MATERIALS Materials shall conform the specification no. 2.17.1
4.0.0
GENERAL A method statement of construction, indicating the following, shall be submitted by the Contractor for approval of the Engineer, well in advance of the commencement of the construction of superstructure : i. ii. Sources of Materials Design, erection and removal of formwork
iii. Production, transportation, laying and curing of concrete iv. Prestressing system, if applicable v. Personnel employed for execution and supervision
vi. Test and sampling procedure vii. Equipment details viii. Any other point Dimensions, lines and levels shall be set out and checked with respect to permanent reference lines and permanent benchmark so that the final product is in accordance with the drawings or as directed by the Engineer.
The work shall conform to the following standard specification besides stipulations in this section with regard to specific type of construction : i. ii. Formwork Concrete and reinforcement Specification No : 2.2, 2.5 & 2.17.1 Specification No : 2.2, 2.5 & 2.17.1
Additionally, some of the common types of superstructure construction shall have features as discussed in this specification 5.0.0 5.1.0 REINFORCED CONCRETE CONSTRUCTION Solid Slabs Where adjacent span of slab has already been cast, the expansion joint and filler board shall be placed abutting the already cast span which shall form the shutter on that side of the new span to be cast. The whole of the slab shall be cast with reinforcement embedded for the road kerb and railings. No other construction joint shall be allowed except with the express permission of the Engineer. Where wearing coat is required to be provided, after the deck slab has been cast, the surface of the slab shall be finished rough, but true to lines and levels as shown on the drawings, before the concrete has hardened. The areas of construction joints shall be treated in the prescribed manner. The top of the slab shall be covered with clean moist sand as soon as the top surface has hardened. Curing shall be carried out as per relevant specification. Where the slab is resting on bearings, the same shall be placed in position in accordance with the drawings, before casting of deck slab. 5.2.0 RCC T-Beam and Slab Provision of construction joint shall conform to the drawings or as per directions of the Engineer. No construction joint shall be provided between the bottom bulb and the web. If not indicated on the drawing, construction joint shall be provided at the junction of the web and the fillet between the web and the deck slab with the permission of the Engineer. The portions of deck slab near expansion joints shall be cast along with reinforcements and embedments for expansion joints. For this purpose, the portion of deck slab near expansion joints may be cast in a subsequent stage, if permitted by the Engineer. The surface finish of the deck slab shall be finished rough but true to lines and levels as shown on the drawings before the concrete has hardened. Care shall be taken for setting of bearings as indicated on the drawings. 5.3.0 Box Girder Box girders may be simply supported or continuous. Simply supported box girders shall have minimum construction joints as approved by the Engineer. In the case of continuous box girders the sequence of construction and location of construction joints shall strictly follow the drawings. The box section shall be constructed with a maximum of one construction joint located in the web below the fillet between the deck slab and web. If permitted by the Engineer, one additional construction joint may be permitted and this construction joint shall be located in the web above the fillet between the soffit slab and web.
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The portions of deck slab near expansion joints shall be cast along with reinforcements and embedments for expansion joints. For this purpose, the portion of deck slab near expansion joints may be cast in a subsequent stage, if permitted by the Engineer. The surface finish of the deck slab shall be finished rough but true to lines and levels as shown on the drawings before the concrete has hardened. Care shall be taken for setting of bearings as indicated on the drawings. 6.0.0 6.1.0 TOLERANCES Precast Concrete Superstructure Variation in cross-sectional dimensions : a) Up to and including 2 m Over 2 m : 5 mm : 5 mm
b) Variation in length overall and length between bearings
shall not exceed 10 mm or 0.1 per cent of the span length, whichever is lesser
c) Permissible surface irregularities when measured with a 3m straight edge or template : 6.2.0 Cast-in-situ Superstructure a) Variations in thickness of top and bottom slab for box girders, top and bottom flange for T-girders or slabs b) Variations in web thickness c) Variations in overall depth or width d) Variation in length overall and length between bearings
5 mm
: : :
- 5 mm to + 10 mm - 5 mm to + 10 mm 5 mm
shall not exceed 10 mm or 0.1 percent of the span length, whichever is lesser
e) Permissible surface irregularities when measured with a 3 m straight edge or template : 7.0.0 TESTS AND STANDARDS OF ACCEPTANCE
5 mm
The materials shall be tested in accordance with these specifications and shall meet the prescribed criteria. The work shall conform to these specifications and shall be meet the prescribed standards of acceptance.
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2.11.5 1.0.0
Technical Specification for Formwork SCOPE Formwork shall include all temporary or permanent forms required for forming the concrete of the shape, dimensions and surface finish as shown on the drawing or as directed by the Engineer, together with all props, staging, centering, scaffolding and temporary construction required for their support. The design, erection and removal of formwork shall conform to IRC:87 Guidelines for Design and Erection of Falsework for Road Bridges and as per IS:456 specifications.
2.0.0
CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and methods of testing. Some of the relevant available codes are listed hereunder: IS : 456 IRC : 87 Code of practice for plain and reinforced concrete. Guidelines for the Design & Erection of False Work for Road Bridges.
3.0.0
MATERIALS All materials shall comply with the requirements of IRC:87. Materials and components used for formwork shall be examined for damage or excessive deterioration before use / re-use and shall be sued only if found suitable after necessary repairs. In case of timber formwork, the inspection shall not only cover physical damages but also signs of attacks by decay, rot or insect attack or the development of splits. Forms shall be constructed with metal or timber. The metal used for forms shall be of such thickness that the forms remain true to shape. All bolts should be countersunk. the use of approved internal steel ties or steel or plastic spacers shall be permitted. Structural steel tubes used as support for forms shall have a minimum wall thickness of 4 mm. Other materials conforming to the requirements of IRC:87 may also be used if approved by the Engineer.
4.0.0
DESIGN OF FORMWORK The Contractor shall furnish the design and drawing of complete formwork (i.e. the forms as well as their supports) for approval of the Engineer before any erection is taken up. If proprietary system of formwork is used, the Contractor shall furnish detailed information to the Engineer for approval. Notwithstanding any approval or review of drawing and design by the Engineer, the Contractor shall be entirely responsible for the adequacy and safety for formwork. The design of the formwork shall conform to provisions of IRC:87. It shall ensure that the forms can be conveniently removed without disturbing the concrete. The design shall facilitate proper and safe access to all parts of formwork for inspection.
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5.0.0
WORKMANSHIP The formwork shall be robust and strong and the joints shall be leak-proof. Balli shall not be used as staging. Staging must have cross bracings and diagonal bracings in both directions. Staging shall be provided with an appropriately designed base plate resting on firm strata. The number of joints on the formwork shall be kept to a minimum by using large size panels. The design shall provide for proper soldiers to facilitate alignment. All joints shall be leak proof and must be properly sealed. Use of PVC JOINT sealing tapes, foam rubber or PVC T-section is essential to prevent leakage of grout. As far as practicable, clamps shall be used to hold the forms together. Where use of nails is unavoidable minimum number of nails shall be used and these shall be left projecting so that they can be withdrawn easily. Use of double headed nails shall be preferred. Use of ties shall be restricted, as far as practicable. Wherever ties are used they shall be used with HDPE sheathing so that the ties can easily be removed. No parts prone to corrosion shall be left projecting or near the surface. The sheathing shall be grouted with cement mortar of the same strength as that of the structure. Unless otherwise specified, or directed, chamfers or fillets of sizes 25 mm x 25 mm shall be provided at all angles of the formwork to avoid sharp corners. The chamfers, beveled edges and mouldings shall be made in the formwork itself. Opening for fixtures and other fittings shall be provided in the shuttering as directed by the Engineer. Shuttering for walls, sloping members and thin sections of considerable height shall be provided with temporary openings to permit inspection and cleaning out before placing of concrete. The formwork shall be constructed with precamber to the soffit to allow for deflection of formwork shall be in addition to that indicated for the permanent structure in the drawings. Where centering trusses or launching trusses are adopted for casting of superstructure, the joints of the centering trusses, whether welded, riveted or bolted should be thoroughly checked periodically. Also, various members of the centering trusses should be periodically examined for proper alignment and unintended deformation before proceeding with the concreting. They shall also be periodically checked for any deterioration in quality due to steel corrosion. The formwork shall be so made as to produce a finished concrete true to shape, line and levels and dimensions as shown on the drawings, subject to the tolerances specified in respective sections of these specifications, or as directed by the Engineer. Where metal forms are used, all bolts and rivets shall be countersunk and well ground to provide a smooth, plane surface. Where timber is used it shall be well seasoned, free from loose knots, projecting nails, splits or other defects that may mar the surface of concrete. Forms shall be made sufficiently rigid by the use of ties and bracings to prevent any displacement or sagging between supports. They shall be strong enough to withstand all pressure, ramming and vibration during and after placing the concrete. Screw jacks or hard wood wedges where required shall be provided to make up any settlement in the formwork either before or during the placing of concrete. The formwork shall take due account of the calculated amount of positive or negative camber so as to ensure the correct final shape of the structures, having regard to the deformation of false work, scaffolding or propping and the instantaneous or deferred deformation due to various causes.
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Suitable camber shall be provided to horizontal members of structure, especially in long spans to counteract the effects of deflection. The formwork shall be so fixed as to provide for such camber. The formwork shall be coated with an approved release agent that shall effectively prevent sticking and shall not stain the concrete surface. Lubricating (machine oils) shall be prohibited for use as coating. 6.0.0 FORMED SURFACE AND FINISH The formwork shall be lined with material approved by the Engineer so as to provide a smooth finish of uniform texture and appearance. This material shall leave no stain on the concrete and so fixed to its backing as not to impart any blemishes. It shall be of the same type and obtained from only one source throughout for the construction of any one structure. The Contractor shall make good any imperfections in the resulting finish as required by the Engineer. Internal ties and embedded metal parts shall be carefully detailed and their use shall be subject to the approval of the Engineer. 7.0.0 PRECAUTIONS i. Special measures in the design of formwork shall be taken to ensure that it does not hinder the shrinkage of concrete. The soffit of the formwork shall be so designed as to ensure that the formwork does not restrain the shortening and / or hogging of beams. The forms shall be removed at the earliest opportunity subject to the minimum time for removal of forms with props retained in position. Where necessary, formwork shall be so arranged that the soffit form, properly supported on props only can be retained in position for such period as may be required by maturing conditions.
ii.
iii. Any cutouts or openings provided in any structural member to facilitate erection of formwork shall be closed with the same grade of concrete as the adjoining structure immediately after removal of formwork ensuring watertight joints. iv. Provision shall be made for safe access, on, to and about the formwork at the levels as required. v. Close watch shall be maintained to check for settlement of formwork during concreting. Any settlement of formwork during concreting shall be promptly rectified.
vi. Water used for curing should not be allowed to stagnate near the base plates supporting the staging and should be properly drained. 8.0.0 PREPARATION OF FORMWORK BEFORE CONCRETING The inside surfaces of forms shall, except in the case of permanent formwork or where otherwise agreed to by the Engineer be coated with a release agent supplied by approved manufacturer or of an approved material to prevent adhesion of concrete to the formwork. Release agents shall be applied strictly in accordance with the Manufacturers and shall not be allowed to come into contact with any reinforcement. Different release agents shall not be used in formwork for exposed concrete. Before re-use of forms, the following actions shall be taken : i. The contact surfaces of the forms shall be cleaned carefully and dried before applying a release agent.
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ii.
It should be ensured that the release agent is appropriate to the surface to be coated. The same type and make of release agent shall be used throughout on similar formwork materials and different types should not be mixed.
iii. The form surfaces shall be evenly and thinly coated with release agent. The vertical surface shall be treated before horizontal surface and any excess wiped out. iv. The release agent shall not come in contact with reinforcement or the hardened concrete. All forms shall be thoroughly cleaned immediately before concreting. The Contractor shall give the Engineer due notice before placing any concrete in the forms to permit him to inspect and approve the formwork, but such inspection shall not relieve the Contractor of his responsibility for safety of formwork, men, machinery, materials and finish or tolerances of concrete. 9.0.0 REMOVAL OF FORMWORK The scheme for removal of formwork (i.e. de-shuttering and de-centering) shall be planned in advance and furnished to the Engineer for scrutiny and approval. No formwork or any part thereof shall be removed without prior approval of the Engineer. The formwork shall be so removed as not to cause any damage to concrete. Centering shall be gradually and uniformly lowered in such a manner as to permit the concrete to take stresses due to its own weight uniformly and gradually to avoid any shock or vibration. Where not specifically approved, the time of removal of formwork (when cement is used without any admixtures at an ambient temperature exceeding 10 degrees Celsius) shall be as under : a.Walls, piers, abutments, columns and vertical faces of structural members
12 to 48 hours as may be decided by the Engineer : 3 days : 14 days 7 days : 21 days
b.Soffits of Slabs (with props left under) c.Props (left under slabs) d.Soffit of Girders (with props left under) : e.Props (left under girders)
Where there are re-entrant angles in the concrete sections, the formwork should be removed at these sections as soon as possible after the concrete has set, in order to avoid cracking due to shrinkage of concrete. 10.0.0 RE-USE OF FORMWORK When formwork is dismantled, its individual components shall be examined for damage and damaged pieces shall be removed for rectification. Such examination shall always be carried out before being used again. Before re-use all components shall be cleaned of deposits of soil, concrete or other unwanted materials. Threaded parts shall be oiled after cleaning. All bent steel props shall be straightened before re-use. The maximum deviation from straightness is 1/600 of the length. The maximum permissible axial loads in used props shall be suitably reduced depending upon their condition. The condition of the timber
components, plywood and steel shuttering plates shall be examined closely for distortion and defects before re-use. 11.0.0 SPECIALISED FORMWORK Specialised formwork shall be required in the case of slipform work, underwater concreting, segmental construction etc. Such specialised formwork shall be designed and detailed by competent agencies and a set of complete working drawings and installation instructions shall be supplied to the Engineer. The site personnel shall be trained in the erection and dismantling as well as operation, of such specialised formwork. In case proprietary equipment is used, the supplier shall supply drawings, details, installation instructions, etc., in the form of manuals along with the formwork. Where specialised formwork is used, close co-ordination with the design of permanent structure is necessary. For slipform the rate of slipping the formwork shall be designed for each individual case taking into account various parameters including the grade of concrete, concrete strength, concrete temperature, ambient temperature, concrete admixtures, etc. In the case of segmental construction, the concrete mix shall be normally designed for developing high early strength so that the formwork is released as early as possible. In order to verify the time and sequence of striking / removal of specialised formwork, routine field tests for the consistency of concrete and strength development are mandatory and shall be carried out before adoption. For specialised formwork, the form lining material may be either plywood or steel sheet or appropriate thickness. Plywood is preferred where superior quality of surface is desired, whereas steel sheeting is normally used where large number of repetitions are involved. 12.0.0 TESTS AND STANDARDS OF ACCEPTANCE The materials shall be tested in accordance with the specifications and shall meet the prescribed criteria. The work shall conform to the specifications and shall meet the prescribed standards of acceptance.
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2.11.6 1.0.0
Technical Specification for Bearings SCOPE This work shall consist of furnishing and fixing bearings in position in accordance with the details shown on the drawings, to the requirements of these specifications or as directed by the Engineer.
2.0.0
CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and methods of testing. Some of the relevant available codes are listed hereunder: IS : 226 IS : 3400 IRC : 83 Code of practice for structural steel (standard quality). Methods of test for vulcanized rubbers. Standard Specification and Code of Practice for Road Bridges, Section IX, Bearings, Part II : Elastomeric Bearings
3.0.0
GENERAL i. Bearing plates, bars, rockers, assemblies and other expansion or fixed devices shall be constructed in accordance with the details shown on the drawings. The bearings may be supplied directly by the Manufacturer to be installed by the Contractor and the Contractor shall install the bearings as part of the contract. In the former case, the Manufacturer shall be associated with the installation of the bearings to the full satisfaction of the Engineer, whereas in the latter case, the Contractor shall be solely responsible for the satisfactory supply and installation of bearing. In the detailed description of the specification, a general reference shall be made to the Contractor or Manufacturer and the interpretation shall be as per terms of contract.
ii.
iii. The Contractor shall exercise the utmost care in setting and fixing all bearings in their correct positions and ensuring that uniformity is obtained on all bearing surfaces. iv. When bearing assemblies or plates are shown on the drawings to be placed (not embedded) directly on concrete, the concrete bearing area shall be constructed slightly above grade (not exceeding 12 mm) and shall be finished by grinding. v. It shall be ensured that the bearings are set truly level and in exact position as indicated on the drawings so as to have full and even bearing on the seats. Thin mortar pads (not exceeding 12 mm) may even be made to meet with this requirement.
vi. It shall be ensured that the bottom of the girders to be received on the bearings are plane at the locations of these bearings and care shall be taken that the bearings are not displaced while placing the girders. vii. Bearings shall be handled with care and stored under cover. 4.0.0 ELASTOMERIC BEARINGS The elastomeric bearing consists of one or more internal layers of elastomer bonded to internal steel laminates by the process of vulcanisation. The bearing shall cater for translation and / or rotation of the superstructure by elastic deformation.
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4.1.0
Raw Material Chloroprene (CR) only shall be used in the manufacture of bearing. Grades of raw elastomer of proven use in elastomeric bearings, with low crystallization rates and adequate shelf life (e.g. Neoprene WRT, Bayprene 110, Skyprene B-5 and Denka S-40V) shall be used. No reclaimed rubber or vulcanized wastes or natural rubber shall be used. The raw elastomer content of the compound shall not be lower than 60 percent by its weight. The ash content shall not exceed 5 percent (as per tests conducted in accordance with ASTM D-297, sub-section 10). EPDM and other similar candidate elastomers for bridge bearing use shall not be permitted
4.2.0
Properties The elastomer shall conform to the properties specified in Table 1.1 Table 1.1 PROPERTIES OF ELASTOMER TEST METHOD, SPECIFICATION IS REFERENCE VALUE OF THE CHARACT ERISTIC SPECIFIED 60 + 5
PROPERTY
UNIT
1. 1.1
Physical properties Hardness
IRHD
IS:3400 (Part II) IS:3400 (Part I) IS:3400 (Part I) IS:3400 (Part X) duration (h) +0 to 24.2 IS:3400 (Part IV) duration (h) 70 Temperature Deg C 1001 Tempe (deg C) 1001
1.2
Minimum Strength
Tensile
MPa
17
1.3
Minimum Elongation at break Maximum Compression Set CR Accelerated Ageing
Percent
400
2.
Percent
35
3.
3.1 3.2
CR Max change Hardness Max change Tensile Strength Max change Elongation
in in
IRHD Percent
+15 -15
3.3
in
Percent
-40
Shear modulus of the elastomer bearing shall neither be less than 0.80 MPa nor greater than 1.20 MPa. The adhesion strength of elastomer to steel plates determined according to IS:3400 (Part XIV) method A shall not be less than 7 kN/m.
For elastomeric bearings (CR) used in adverse climatic conditions the following ozone resistance test shall be satisfied : The ozone resistance of elastomer shall be proved satisfactory when assessed by test according to IS:3400 (Part XX). The strain, temperature, duration and ozone concentration of the test shall be 20 percent, 40 1 degree Celsius, 96 h and 50 pphm by volume respectively. No cracking detected by visual observation at the end of the test shall be considered satisfactory. No specific tests for assessment of low temperature resistance may be deemed necessary. Laminates of mild steel conforming to IS:226 shall only be permitted to be used. Use of any other material like fibreglass or similar fabric as laminates shall not be permitted. The Manufacturers of elastomeric bearings shall satisfy the Engineer that they have inhouse facilities for testing the elastomer for carrying out the following tests in accordance with the relevant provisions of ASTM D-297. a. Identification of polymers (Appendix X-2) b. Ash content test section 34) c. Specific gravity test : to confirm the usage of Chloroprene
to determine the percentage (sub-
: :
(sub-section 15) (sub-section 10)
d. Polymer content test
The Engineer shall invariably get the test (a) performed within his presence or in the presence of his authorised representative to satisfy the requirement. In case of any disputes regarding interpretation of results the Engineer may carry out test as per ASTM S-3452-78 (Chromatography test) at the Manufacturers cost in a recognised test house. The elastomer specimen to conduct the test shall be obtained from the bearings selected at random for destructive test. Remaining part of the test bearing shall be preserved by the Engineer for any test to be done in future, if required. 4.3.0 Fabrication Bearing with steel laminates shall be cast as a single unit in a mould and vulcanised under heat and pressure. Casting of elements in separate units and subsequent bonding shall not be permitted, nor shall cutting from large size cast be permitted. Bearings of similar size to be used in a particular project shall be produced by identical process and in one lot as far as practicable. Phased production shall only be resorted to when the total number of bearings is large enough. The moulds used shall have standard surface finish adequate to produce bearings free from any surface blemishes. Steel plates for laminates shall be sand blasted, clean of all mill scales and shall be free from all contaminants prior to bonding by vulcanisation. Rusted plates with pitting shall not be used. All edges of plates shall be rounded.
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Spacers used in mould to ensure cover and location of laminates shall be of maximum size and number practicable. Any hole at surface or in edge cover shall be filled in subsequently. Care shall be taken to ensure uniform vulcanising conditions and homogeneity of elastomer through the surface and body of bearings. The bearings shall be fabricated with the tolerances specified in Table 1.2. TABLE 1.2 TOLERANCES ITEMS 1 2 3 a) b) 4 a) b) 5 a) b) c) Overall plan dimensions Total bearing thickness Parallelism Of top surface of bearing with respect to the bottom surface as datum Of one side surface with respect to the other as datum Thickness elastomer of individual internal layer of 1 in 200 1 in 100 20 percent (max. of 2 mm) -0, + 1 mm -3 mm, +0 10 percent 1 in 100 TOLERANCES -0, +6 mm -0, +5 mm
Thickness of individual outer layer Plan dimensions of laminates Thickness of laminates Parallelism of laminate with respect to bearing base as datum
The vulcanising equipment / press shall be such that between the platens of press the pressure and temperature are uniform and capable of being maintained at constant values as required for effecting a uniform vulcanisation of the bearing. The moulding dies utilised for manufacturing the bearings shall be so set inside the platten of the press so that the pressure developed during vulcanisation of the product is evenly distributed and the thickness maintained at all places are within acceptable tolerance limits taking into consideration the shrinkage allowance of vulcanizate. The raw compound which has been introduced inside the metal dies for vulcanisation shall be accurately weighed each time and it must be ensured that sufficient quantity has been put inside the die for proper flow of material at every place so that a homogeneous and compact bearing is produced without any sign of sponginess or deficiency of material at any place. Before any vulcanizate of any batch of production is used for producing vulcanised bearings, test pieces in the form of standard slab and buttons shall be prepared in
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accordance with prescribed standards and salient properties tested and recorded regularly against each batch of production to monitor the quality of the products. 4.4.0 Acceptance Specifications The Manufacturer shall have all the test facilities required for the process and acceptance control tests installed at his plant to the complete satisfaction of the Engineer. The test facilities and their operation shall be open to inspection by the Engineer on demand. All acceptance and process control tests shall be conducted at the Manufacturers plant. Cost of all materials, equipment and labour shall be borne by the Manufacturer unless otherwise specified or specially agreed to between the Manufacturer and Engineer. Acceptance testing shall be commenced with the prior submittal of testing programme by the Manufacturer to the Engineer and obtaining his approval. Any acceptance testing delayed beyond 180 days of production shall require special approval of the Engineer and modified acceptance specification, if deemed necessary by him. All acceptance testing shall be conducted by the Inspector with aid of the personnel having adequate expertise and experience in rubber testing provided by the Manufacturer, working under the supervision of the Inspector and to his complete satisfaction. Lot by lot inspection and acceptance shall be made. 4.4.1 Acceptance lot A lot under acceptance shall comprise all bearings, including the pair of extra test bearings where applicable of equal or near equal size produced under identical conditions of manufacture to be supplied for a particular project. The size and composition of acceptance lot shall be got approved by the Engineer. For the purpose of grading levels of acceptance, testing lots shall be classified as follows: i. ii. A lot size of 24 or larger number of bearings shall be defined as a large lot A lot size of less than 24 bearings shall be defined as a small lot
When the number of bearings of equal or near equal size for a single bridge project is large and phased production and acceptance is permitted, the number of bearings supplied in any single phase of supply shall comprise a lot under acceptance. When such phased supply is made, each such lot shall be considered as a large lot for the purpose of acceptance testing. 4.4.2 Levels of Acceptance Inspection The level of acceptance testing shall generally be graded into the following two levels depending on lot size : Level 1 acceptance testing Level 2 acceptance testing Acceptance testing level 1 is a higher-level inspection and shall be applicable to large lots only, less otherwise specified. This shall involve manufacture of two extra bearings for each lot to be used as test bearing and eventually consumed in destructive testing.
Acceptance testing Level 2 shall be applicable to small lots only (i.e. less than 24 lots) for which one extra bearing shall be manufactured. Out of the lot one bearing shall be selected at random for carrying out material tests. This bearing shall be excluded from the lot accepted. Acceptance inspection level 1 shall be specified at the sole discretion of the Engineer taking into account the special importance of the project for small lots also under the purview of special acceptance inspection. The cost of extra bearings, in such cases shall be borne by the user, while the cost of all other materials, equipment and testing shall be borne by the Manufacturer. 4.4.3 Testing Acceptance testing shall comprise general inspection, test on specially moulded test pieces and test on complete bearings or sections for measurement of various quality characteristics detailed below : 4.4.3.1 Acceptance testing level 1 General Inspection 1. All bearings of the lot shall be visually inspected for any defects in surface finish, shape or any other discernible superficial defects. 2. All bearings of the lot shall be checked for tolerances specified in Table 1.2. 3. All bearings of the lot shall be subjected to axial load to correspond to m (i.e. average compressive stress) = 15 MPa applied in steps and held constant while visual examination is made to check for discernible defects like : a. b. c. d. e. Misalignment of reinforcing plates Poor bond at laminate / steel interface Variation in thickness of elastomer layers Any surface defects Low stiffness
Deflection under loads between m = 5 MPa and m = 15 MPa shall be measured and recorded for all bearings with sufficient accuracy ( 5 percent), Variation in stiffness of any individual bearing from the mean of the measured values for all such bearings of the lot shall not be larger than 20 percent (of the mean value). Tests on specially moulded test pieces 1. Test pieces shall be moulded by the Manufacturer with identical compound and under identical vulcanising conditions as used in the Manufacturer of the bearings of the acceptance, lot. The process shall be open to inspection by the Engineer. 2. Test pieces offered for inspection shall be identified by suitable markings and duly certified by the Manufacturer. 3. The quality characteristics to be tested are listed below. The specification references in parenthesis shall define the corresponding specification for test piece, test method and criterion for acceptance. Composition (see Note 1 below) Harness (Table 1.1, 1.1) Tensile strength (Table 1.1, 1.2)
Elongation at Break (Table 1.1, 1.3) Compression Set (Table 1.1, 2) Accelerated Ageing (Table 1.1, 3) Adhesion Strength (Cl. 4.1.0) Ozone Resistance (see Note 2 below) Note 1 For acceptance testing the properties enumerated in Cl. 4.1.0 and specific gravity of elastomer of test pieces from test bearing shall be compared with those for corresponding specially moulded test pieces furnished by the Manufacturer. The following variations shall be deemed maximum acceptable : Specific Gravity Ash Content 0.2 0.5 percent
Hardness (Table 1.1, 1.1) Tensile strength (Table 1.1, 1.2) Elongation at Break (Table 1.1, 1.3) Compression Set (Table 1.1, 2) Accelerated Ageing (table 1.1, 3) Adhesion Strength (Cl. 4.1.0) Note 2 Ozone resistance test can be waived by the Engineer for bearings of CR when satisfactory results of ozone resistance tests on similar grade of elastomer may be available from process control records or development test data furnished by the Manufacturer. Where such process control data are not available or the frequency of testing not deemed adequate, ozone resistance test shall be mandatory for acceptance of bearings of CR. However, such tests may not be insisted for bearings not located under adverse conditions of exposure and where the test on accelerated ageing could be considered as adequate. Process and acceptance control tests for ozone resistance by an independent testing agency shall be acceptable. Tests on Complete Bearings or Sections 1. Two bearings shall be selected at random from the lot as test bearings. bearings shall be excluded from the lot accepted. 2. The following tests shall be conducted on test bearings : Test for determination of shear modulus
These
Test for determination of elastic modulus Test for determination of shear modulus (short term loading) Test for determination of adhesion strength Test for determination of ultimate compressive strength The test specifications and acceptance criteria shall conform to those given in Appendix 2 of IRC:83 (Part II). 4.4.3.2 Acceptance testing level 2 General Inspection This shall conform to the provision in Clause 4.4.3.1 in all respects. Test on Specially moulded test pieces This shall conform to the provisions in Clause 4.4.3.1 in all respects. Test on complete bearings Test for determination of shear modulus shall be conducted using two bearings of the lot selected at random and conforming to relevant provisions of Clause 4.4.3.1. These bearings shall however be part of the lot accepted. The remaining tests stipulated in aforesaid clause shall be carried out on all bearings selected at random, which shall be excluded from the lot accepted. 4.4.4. Special acceptance inspection Special acceptance inspection shall comprise the following : 1. Acceptance testing by an independent external agency with separate or supplemental test facilities provided by it. 2. Acceptance testing on test pieces prepared from the surface or body of the test bearings instead of specially moulded test pieces. 3. Acceptance tests not covered by these specifications but according to the specifications laid down by the Engineer. Special acceptance inspection shall be specified under the following conditions: a. Special contract agreement b. Unsatisfactory evidence of process or acceptance control 4.4.5 Inspection certificate A lot under inspection shall be accepted by the Inspector and so certified, when no deflect is found with respect to any of the quality characteristics tested on samples drawn from the lot according to specifications laid down in Clause 9.2.6 covering general inspection tests on specially moulded test pieces and on complete bearings. In case of any bearing with defect, the lot shall be rejected by the Inspector and so certified. In case any bearing is found to be defective with respect to any quality characteristic, discerned by general inspection tests specified in Cl.4.4.3.1 and Cl.4.4.3.2 test on
specially moulded test pieces and complete bearings as applicable according to Cl.4.4.3.1 and Cl.4.4.3.2 shall nevertheless be completed. If the said lot, rejected by general inspection, satisfies the acceptance criteria in respect of these other tests, the lot and individual bearings found defective shall be clearly identified in the inspection certificate. The Manufacturer shall obtain from the inspector, authorised by the Engineer, immediately on completion of his inspection, an inspection certificate which shall include the details of a lot or lots accepted / rejected by him and records of all test measurements. 4.4.6 Quality control certificate The Manufacturer shall certify for each lot of bearing under acceptance: That an adequate system of continuous quality control was operated in his plant. That the entire process remained in control during the production of the lot of bearings under acceptance as verified from the quality control records / charts which shall be open to inspection of Engineer / Inspector on demand. A certified copy of results of process control testing done on samples of elastomer used in the production of the lot shall be appended and shall include at least the following information : Composition of compound - raw elastomer and ash content, the grade of raw elastomer used (including name, source, age on shelf), test results of hardness, tensile strength, elongation at break, compression set, accelerated ageing etc. A higher level certification of the process quality control shall be called for at the sole discretion of the Engineer in special cases e.g. where adequate inspection of bearings similar to those comprising the lot under inspection produced in the same plant is not available with the Engineer or in case of any evidence of process or acceptance control being deemed unsatisfactory. The higher level certification shall comprise submittal of a complete quality control report as given in Appendix 3 of IRC:83 (Part II) supplementing the quality control certificate. 4.4.7 Acceptance The Manufacturer shall furnish the following to Engineer for the acceptance judgement: 1. Quality control certificate as laid down in Cl.4.4.6. 2. Inspection certificate as laid down in Cl.4.4.5. The Manufacturer shall furnish any supplementary information on the system of quality control and / or process and acceptance control testing as may be deemed necessary by the Engineer. In case of any evidence of process or acceptance control testing being deemed unsatisfactory by him, Engineer at his sole discretion may call for a special acceptance of the lot according to specifications laid down by him, without any prejudice to his right to reject the lot. The entire cost of such supplementary inspection shall be borne by the Manufacturer. The Engineer shall be the sole authority for acceptance of a lot on scrutiny of the certificates along with any supplementary evidence and complete satisfaction therewith. In case of rejection of a lot, the Engineer shall reserve the right to call for special acceptance inspection for the succeeding lots offered for inspection, according to the
specifications laid down by him. The entire cost of such tightened inspection shall be borne by the Manufacturer. 4.5.0 Certification and Marking Bearings shall be transported to bridge site after final acceptance by Engineer and shall be accompanied by an authenticated copy of the certificate to that effect. An information card giving the following details for the bearings, duly certified by the Manufacturer shall also be appended : Name of Manufacturer Date of manufacture Elastomer grade used Bearing dimensions Production batch no. Acceptance lot no. Date of testing Specific bridge location, if any Explanation of markings used on the bearing All bearings shall have suitable index markings identifying the information. The markings shall be made in indelible ink or flexible paint and if practicable should be visible after installation. The top of the bearing and direction of installation shall be indicated. 4.6.0 Storage and Handling Each elastomeric bearing shall be clearly labelled or marked. The bearing shall be wrapped in a cover. They shall be packed in timber crates with suitable arrangement to prevent movement and to protect corners and edges. Care shall be taken to avoid mechanical damage, contamination with oil, grease and dirt, undue exposure to sunlight and weather to the bearings during transport and handling prior to and during installation. 4.7.0 Installation Installation of multiple bearings one behind the other on a single line of support shall be of identical dimensions. Bearings must be placed between true horizontal surfaces (maximum tolerance 0.2 percent perpendicular to the load) and at true plan position of their control lines marked on receiving surfaces (maximum tolerance 3 mm). Concrete surfaces shall be free from local irregularities (maximum tolerance 1 mm in height). Design shall be checked for the actual inclination in seating if larger inaccuracies than those specified are permitted. For cast-in-place concrete construction of superstructure, where bearings are installed prior to its concreting, the forms around the bearings shall be soft enough for easy removal. Forms shall also fit the bearings snugly and prevent any leakage of mortar
grout. Any mortar contaminating the bearings during concreting shall be completely removed before setting. For precast concrete elements, fixing of bearing to them shall be done by application of epoxy resin adhesive to interface, after specified surface preparation. The specifications for adhesive material, workmanship and control shall be approved by the Engineer. Care shall be taken to guard against faulty application and consequent behaviour of the adhesive layer as a lubricant. The bonding by the adhesive shall be deemed effective only as a device for installation and shall not be deemed to secure bearings against displacement for the purpose of design. As a measure of ample safety against accidental displacement, the bearings shall be placed in a recess as shown in Fig. 9 of IRC:83 (Part II).
4.8.0
Seating of Elastomeric Bearings on a Non-Horizontal Plane Installation of elastomeric bearings on a non-horizontal plane shall be as follows : i. Elastomeric bearings shall be delivered with MS backing plate fastened to the bearing from the Manufacturer. Template of 6 mm M.S. plate and of size same as bearing holding base plate with matching holes for the anchor screws shall be used. Anchors shall be fitted to the templates with the anchor screws but with MS washers in place of elastomer washers. The above template assembly shall be fitted in the formwork at its proper location and in a vertical plane.
ii.
iii. After casting of the pedestal and removal of the formwork, the template is to be removed. A. Installation with face plate and without template in-situ casting i. The sub-assembly of elastomeric bearing with MS backing plate shall be fitted to the embedded anchors with anchor screws and elastomeric washers replacing the steel washer. A clearance is required between the stainless steel face of the elastomeric bearing and that of the vertical face of the faceplate with stainless steel top installed on the projection below the soffit. This shall be achieved by inserting removable steel sheeting of thickness as per the drawing, during preparation of the formwork before casting of the superstructure.
ii.
iii. The faceplate with stainless steel top and pack plate shall be assembled with the anchors with elastomeric washers and anchor screws. The assembly shall be fitted in the formwork at its proper location and in a vertical plane. The removable steel shims shall be removed at an appropriate time after the casting of the superstructure. B. Installation with faceplate and with template in-situ casting i. Template of 6 mm MS plate and of size same as face plate with stainless steel top and matching holes for the anchor screws shall be used. Anchors shall be fitted to the templates with the anchor screws but with MS washers in place of elastomer washers. Separate screws shall be used in case of inconvenience of in the length of original anchor screws. The above template assembly shall be fitted in the formwork for the superstructure at its proper location and in a vertical plane. After removal of the superstructure formwork, the template shall be removed.
ii.
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iii. The faceplate with the required thickness of pack plate shall be loosely fitted to the anchors embedded in the projection below the superstructure, with elastomer washers and anchor screws. iv. The sub-assembly of elastomeric bearing with the MS backing plate shall be fitted to the embedded anchors in the pedestal with anchor screws and elastomeric washers replacing the steel washer this time. v. The required clearance between the stainless steel face of the elastomeric bearing and that of the vertical faceplate installed on the projection below the soffit shall be checked. After adjustment of the required working clearance the small gap between the vertical face of the projection below the soffit and the back of the face plate (with pack plates, if any) shall be grouted with epoxy grout.
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2.11.7 1.0.0
Technical Specification for Expansion Joints SCOPE This work shall consist of fabrication and placing of expansion joints as indicated on the drawing and conforming to these specifications or as directed by the Engineer.
2.0.0
CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and methods of testing. Some of the relevant available codes are listed hereunder: IS : 456 IS : 1838 Code of practice for plain and reinforced concrete. Preformed fillers for expansion joint in concrete pavements and Structures. Steel for general structural purpose. Standard Specification and Code of Practice for Road Bridges, Section IX, Bearings, Part II : Elastomeric Bearings.
IS : 2062 IRC : 83
3.0.0
GENERAL The expansion joints shall be designed and duly got approved by the Engineer. It shall cater for expected movement and rotation of the structure at the joints and provide smooth riding surface. It shall also be easy for inspection, maintenance and replacement. Expansion joints shall be robust, durable, watertight and replaceable. Site fabricated expansion joints shall be prohibited. Expansion joints shall be obtained by the Engineer either directly or through the Contractor from approved Manufacturers and be of proven type. For bridges with prestressed concrete superstructure, with individual span length more than 20 m or built with innovative design / construction elastomeric expansion joints of slab seal or strip seal type shall be provided. For slab type of bridges of spans less than 10 m continuous surfacing shall be provided across the expansion gaps, supported on a 20 mm thick plate placed and fixed at the level of the deck slab. For bridges other than those mentioned in above with spans above 10 m, an alternative specification of sliding steel plate joint or filled joints with copper plates may also be adopted if approved by the Engineer, apart from elastomeric expansion joint of slab seal or strip seal type. Vehicular traffic shall not be allowed over expansion joints after its construction for such period as may be determined by the Engineer. Proprietary type deck joints offered by the Contractor in lieu of the type specified shall comply in all respects with the Manufacturers specifications and meet the required range of movements and rotations and be fit for the purpose of ensuring satisfactory long term performance in the bridge.
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Where alternative type proprietary deck joints are proposed by the Contractor, the following information shall be provided. Name and location of the proposed Manufacturer Dimensions and general details of the joint including material specifications, holding down bolt or anchorage details and installation procedures. Evidence of satisfactory performance under similar environmental conditions of similar joints being produced by the Manufacturer.
Any acceptance of alternative types shall be at the sole discretion of the Engineer. Such deck joints shall be installed in accordance with the recommendations and to the general requirements of this specification. Manufacturers
No expansion joint shall be provided only for the width of the carriageway. It shall follow the profile including the kerb and the footway and facia, if provided. The type of expansion joint for the latter may be made different from that used for the carriageway expansion joint. 4.0.0 REQUIREMENTS The requirement criterion shall be separately applicable for the expansion joint proper and the transition zone of attachment to the deck. There are two types of performance requirements for the expansion joint proper viz. from the necessity of the bridge and from the road users e.g. man, animal and vehicle. Performance Requirement with Respect to Bridges The expansion joint shall : Withstand the imposed load including the impact load from live load and other sources. Allow expansion and contraction movement due to temperature, creep, shrinkage and structural deformations. Permit relative rotation in elevation and plan due to the causes as noted above. Be waterproof. Bridge deck expansion joint seals play a critical role in preventing the degradation of the structural components of the bridge system. Without effective joint seals water passes through the bridge deck and works harmfully to corrode steel components and cause deterioration of the concrete. Rainwater gathers various corroding additives from the atmosphere and also from the carriageway. Ensure sealing. In case bridge deck joints are not sealed apart from loss of waterproofing, frit and other forms of road debris may enter the joint. Debris, when impacted with the joint can seriously restrict the movement instead of facilitating the same. In the case of proprietary joints being accepted for adoption, the sealing shall be as specified by them. Ensure long life by being resistant to corrosion Be easy to install Be easy to maintain. Replaceability of expansion joint shall be one of the basic criteria for selection of type of expansion joint.
Be resistant to the materials likely to collect/spill over the deck in its normal service.
Performance Requirement with Respect to User The expansion joint shall : Provide smooth continuity at the top of the deck for riding comfort Be of skid resistant surface Be non-damaging to the rubber tyre Make minimum noise during vehicular crossing Look good aesthetically
Performance Requirement for Transition Zone It is the zone of connection of joint assembly and the adjoining deck. The expansion joint shall : Permit transfer of generated forces without distress, i.e. without getting uprooted. The purpose shall not be served if the bonding is with the wearing coat only. Anchoring must be provided with the deck structural element. Ensure that surface in the transition zone stays undisturbed during long-term service.
5.0.0
STEEL PLATE SLIDING EXPANSION JOINTS In this type of buried joint, the wearing coat shall be made continuous over the joint. The other alternative shall be to keep a gap in the wearing coat, which is filled up with a seal and filler, to be provided in extremely hot areas. Materials for steel plates shall conform to IS:2062.The exposed metallic components shall be galvanised or coated with approved anti-corrosive paint. The thickness shall be 20 mm or so for obtaining satisfactory performance. Plates shall be placed to the line, grade and expansion gap shown on the drawings with any adjustment required for temperature, particular care being taken with the top of the plates. Plates shall be firmly held in place during concreting by methods approved by the Engineer. Any temporary bolts or other fixings, which prevent relative movement of the adjacent parts of the joint, shall be removed as soon as the concrete has set sufficiently to hold the expansion plates in their correct positions. In any case, temporary holts or other fittings shall be removed within 6 hours of placing concrete unless otherwise directed by the Engineer. Care shall be taken to prevent damage to expansion joint plates or its coating. If any damage occurs, the plates and coatings shall be restored by the Contractor to the satisfaction of the Engineer. Plates shall be free of oil, rust, loose paint or other similar material before coating.
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6.0.0
FILLER JOINTS The components of this type of joint shall be at least 2 mm thick corrugated copper plate placed slightly below the wearing coat, 20 mm thick compressible fibre board to protect the edges, 20 mm thick pre-moulded joint filler filling the gap upto the top level of the wearing coat, sealed with a joint sealing compound. The material used for filling expansion joint shall be bitumen impregnated felt, elastomer or any other suitable material, as specified on the drawings. Impregnated felt shall conform to the requirements of IS:1838, and shall be got approved from the Engineer. The joint filler shall consist of large pieces and assembly of small pieces to make up the required size shall be avoided. Expansion joint materials shall be handled with care and stored under cover by the Contractor to prevent damage. Any damage occurring after delivery shall be made good to the satisfaction of the Engineer and at the expense of the Contractor. Joint gaps shall be constructed as shown on the drawings. Surfaces of joint grooves shall be thoroughly cleaned with a wire brush to remove all loose materials and dirt and debris, then washed or jetted out. Pre-moulded expansion joint filler shall not be placed in position until immediately prior to the placing of the abutting material. If the two adjacent surfaces of the joint are to be placed at different times, this type of joint filler shall not be placed until the second face is about to be placed. Sealants shall be installed in accordance with the Manufacturers recommendations and all appropriate requirements for joint face priming. Selants shall be finished approximately 3 mm below the upper surfaces of the joint. Joint materials spilt or splashed onto finished surfaces of the bridge during joint filling operations shall be removed and the surfaces made good to the Engineers approval. No joint shall be sealed until inspected by the Engineer and approval is given to proceed with the work.
7.0.0 7.1.0
ELASTOMERIC SLAB SEAL EXPANSION JOINT Materials Steel inserts shall conform to IS:2062. Use of any other materials like fibreglass or similar material shall not be permitted. Elastomer for elastomeric slab unit (ESU) shall conform to Cl. 915.1 of IRC:83(Part II), compounded to give hardness IRHD 60 5, subject to the following additional stipulations: (i) Chloroprene(CR) only shall be used in the manufacture of elastomeric expansion joints. No reclaimed/natural rubber or vulcanised wastes shall be used. (ii) The chloroprene material used in the manufacture of elastomeric(expansion joints) shall be Neoprene WRT, Bayprene 110, Skyprene B5 or Denka S. 40V. (iii) Chloroprene content of the compound shall not be lower than 60 per cent by weight. The ash content shall not exceed 5 percent (as per tests conducted in accordance with ASTM D-297 for (I) and (ii) above.
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(iv) EPDM and other similar candidate elastomers for expansion joints shall not be permitted. Elastomeric plugs Spacer bars, marked with centre to centre distance of fixing holes Fixing bolts and nuts made of stainless steel Anchor bars comprising hooked anchor stiffeners welded with lower steel inserts and sinusoidal anchor bars welded with horizontal leg of the edge steel inserts. The elaborate anchoring arrangements of steel inserts shall be permanently welded/tied with the steel reinforcement. 7.2.0 Fabrication Steel inserts shall be grit blasted and provided with epoxy paint. Edges of reinforcing steel sections shall be rounded. Expansion joints shall be fully moulded to the required size in one single vulcanising operation including the encasing layers as integral and homogeneous part.
Tolerances of fabrication shall be as follows: (i) Plan dimension > 5 mm (ii) Total height > 3 mm 7.3.0 Supply and Handling The Contractor shall supply all steel reinforced elastomeric expansion joints including bolts, nuts, sealant, plugs and all other accessories for the effective installation of the joints including angled jointing sections for kerbs. Expansion joint material shall be handled with care and stored under cover by the Contractor to prevent damage. Any damage occurring after delivery shall be made good at the expense of the Contractor to the satisfaction of the Engineer. 7.4.0 7.4.1 Installation Expansion joints shall be installed as per approved drawing. Steel inserts, spacer bars, concreting of pockets, fixing of elastomer slab unit and presetting etc., shall be done as per the following: Steel Inserts Deck casting shall be done leaving pockets or recess for steel inserts and anchors of the expansion joint as per drawing. Steel inserts shall be lowered at the appropriate location inside the pocket. The top of the insert shall be flush with the finished level of wearing course maintaining the camber. Spacer bars, duly set appropriately to the month of installation, shall be fitted under proper supervision.
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Anchor rods shall be tied/welded with the existing deck main reinforcement, maintaining level and alignment. Welding between anchor rods and deck reinforcement is preferable. If welding is not possible, strong steel tie wires shall be used for fastening under proper supervision. Spacer Bar Spacer bars shall be used to ensure proper positioning of bolts and also levelling of the steel inserts during fixing of the same with the deck reinforcement and casting second stage concreting in the pocket thereafter. The 2nd stage concreting operation shall preferably be started within 24 hours of fixing the steel inserts. In such cases, spacer bars should be removed just after concreting is finished. If there is a substantial time lag between fixing of inserts and concreting, then any one of the following methods shall be adopted, depending on the support condition: For simply supported bridge resting on simple elastomeric bearings, (with no dowel pins), insert shall be placed in position with spacer bars at every alternate joints. Such joints shall be called restrained joints hereafter. In other words, inserts shall not be fixed simultaneously at two ends of one span. If the above condition is satisfied, inserts with spacer bars shall be kept in position for a substantially longer period at such restrained joints. Spacer bars shall be removed after concreting of such restrained joints and inserts placed in position with spacer bars at the other unrestrained joints thereafter. For bridges resting on other than elastomeric bearings (including bearings with dowel pins at one end), after placing and aligning the inserts and securing the same, the spacer bars shall be removed. Concreting shall be done with great care so that inserts are not dislocated or distorted. While removing the spacer bar after concreting, one must take are to see that the concrete is not damaged during withdrawal of spacer bar. If the spacer bar happens to be snugly fitted, it shall not be pulled by any means, it shall be gas cut in two pieces and then removed. Concreting of Pocket Concreting of pocket shall be done with great care using proper mix conforming to grade similar to that of the deck casting besides ensuring efficient bonding between deck and steel insert. Also proper care shall be given for ensuring efficient bonding with the already cast concrete. Needle vibrators shall not be used. Care shall be taken so that the position of steel insert is not disturbed during vibration. Spacer bar shall be removed within an appropriate time before the joint is required to permit movement. Fixing of Elastomeric Slab Unit (ESU) Special jig shall be used to preset the ESU during installation. ESU (mounted on the jig, if preset) shall be lowered to position. The line and level on the ESU should be adjusted. ESU shall be removed and coated with special adhesive.
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ESU shall be placed in position again, ensuring waterproof joining at required faces. ESU shall be tightened with stainless steel nuts and lock washers in position. Tightened nuts shall be locked with lock washers. Special sealant shall be poured inside the plugholes. The elastomeric plugs shall be pressed in position after applying adhesive on the appropriate surface. ESU shall be fitted in position after completion of wearing course. While completing this part of the wearing course, adequate care shall be taken to ensure a waterproof joining with the already existing wearing course. Pre-setting The main purpose of presetting of the steel inserts at the time of its installation is to ensure as closely as possible the condition that in the long run at the mean average annual temperature, the ESU remains at its nominal state. Major factors responsible for changing the longitudinal length of the bridge superstructure are indicated below: Temperature variation from annual mean Changes due to shrinkage of concrete Changes due to elastic shortening and creep of the prestressed bridge superstructure. Deformation of superstructure and substructure, if any. Resultant changes in expansion gap due to first factor can occur in both directions from any pre-selected mean position whereas changes due to creep and shrinkage are unidirectional such that the expansion gap continuously increases with passage of time. The steel insert unit of expansion joint can be fixed in any month of the year. As stated earlier, the expansion gap between bridge superstructure may vary from time to time; hence the initial fixing distance between fixing points shall obviously depend on the month of installation of steel insert. The c/c distance between stainless steel fixing of bolts as indicated in the drawing can be taken as only nominal. The same shall be modified by presetting depending on : The difference between the mean temperature of the month of fixing of steel insert and the annual average temperature. The elapsed period between the casting and fixing of steel insert for calculating the remnant creep and shrinkage. 7.4.2 Special requirements for installation Prior to construction of bridge deck area adjacent to the joint, the supplier shall provide detailed working drawings showing the location of all bolts, recesses and holes necessary for the installation of the joint. Reinforcing bars in superstructure shall be amended as required to ensure that there shall be no interference in the installation of the joint. All bearing surfaces and recesses, which are in contact with the joint assembly, shall be checked with a straight edge to ensure flatness of profile. No holes shall be drilled for fixing bolts within 7 days of concreting. Holes for the bolts shall be drilled to the size and depth shown on the drawings.
Sections of the jointing making the completed joint shall follow a straight line. The fixing bolts shall not be placed in a position until at least 4 weeks after stressing is completed in post-tensioned box or beam and also structures. Prior to placing sections of jointing, contact surfaces shall be cleaned to remove all grease, tar, paint, oil, mud or any other foreign material that may affect adhesion of the sealant. Sealant shall only be applied to dry contact surfaces. Sufficient sealant shall be applied to the contact surfaces to cause extrusion of sealant when the jointing is fixed in position. Final sealing of the finished expansion joint shall be completed immediately after completion of installation. All exposed ends, joints between units and other areas of possible leakage shall be filled with sealant. All voids between the sides of the jointing and concrete or plates shall be filled with sealant. Bolt cavities shall be cleaned and plugged with neoprene cavity plugs. Prior to placing the plugs sufficient sealant shall be placed in the cavities to cause extrusion of the sealant by the plugs. All excess sealant shall be removed from the jointing and adjacent areas. 7.5.0 7.5.1 Acceptance Test As per Cl. 918.7 of IRC-83 (Part II), necessary quality control certification by the Manufacturer in regard to properties of Elastomer and steel shall be furnished. For severe environment, ozone resistance test as per Cl. 915.2.3 of IRC:83 (Part II), shall be carried out for elastomer. The properties of the elastomer shall conform to Table I of Cl. 915.2 ofIRC:83 (Part II). The acceptance testing for elastomer material shall conform to Cl. 918.4.1.2 of IRC:83(Part II) with additional criteria as stated in Specification 6104-ST-SPC-579-205. 7.5.2 The fabricated expansion joint shall be subjected to the following acceptance tests: Routine test : Each expansion joint shall be tested for at least 100 cycles for a test movement which shall be 10% more than the design expansion / contraction movement. In addition to routine test, one out of every 20-expansion joints shall be subjected to the test movement for 4000 cycles. The lot shall be rejected if the elastomer material shows signs of fatigue or permanent set or distress in the test. The piece shall not be used in the bridge. The type test for abrasion resistance shall be carried out for one joint out of every 20 nos. as per IS:3400 (Part :3) and the standard deviation shall be within 20 per cent. N.B: The Manufacturer shall preferably have in-house testing facility. Otherwise, the testing shall be done by him at his expense at any testing establishment selected by the Engineer. A Manufacturer who cannot carry out the acceptance test shall not be entitled to supply elastomeric slab seal joint.
8.0.0 8.1.0
STRIP SEAL EXPANSION JOINT Components Strip seal expansion joint shall comprise the following items:
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Edge beams This special claw leg profiled member shall be of extruded rolled steel section combining good weldability with notch toughness. Strip seal This shall be of chloroprene with high tear strength, insensitive to oil, gasoline, and ozone. It shall have high resistance to aging. This component, provided to ensure water tightness, shall have bulbous shape of the part of the seal, which is inserted into the groove, provided in the edge beam. The seal should be vulcanised in single operation for minimum full length of joint. Rigid Anchorage This shall be welded to the edge beam at staggered distance. Anchor loops This shall be made of weldable steel connecting the rigid anchorage with deck reinforcement. 8.2.0 Material Edge beams of this special section are at present being directly imported in India. The steel shall conform to steel grade Rst 37-2 of German Standard or equivalent. Chloroprene of strip seal shall conform to Cl. 915.1 of IRC:83 (Part II). The properties of chloroprene shall conform to Table 1. Anchorage steel shall conform to IS:2062. Anchor loop shall conform to IS:2062. Table 1 . STRIP SEAL ELEMENT SPECIFICATION Sealing element is made of chloroprene and must be a extruded section. The working movement range of the sealing element shall be at least 80 mm with a maximum of 100 mm at right angles to the joint and 40 mm parallel to the joint. Property Hardness Tensile Strength Elongation at fracture Tear Propagation strength Longitudinal Transverse Shock Elasticity Abrasion Residual compressive strain (22 h/70 deg C / 30 percent strain) Ageing in hot air (14 days / 70 deg C) Change in hardness Change in tensile strength Change in elongation at fracture Ageing in ozone (24 h/50 pphm / 25 deg C/20 percent strain Swelling behaviour in oil (116 h/25 percent C) ASTM oil no. Volume change Change in hardness ASTM oil no.3 Volume change Change in hardness
Specified Value 63 5 Shore A Min 11 MPa Min 350 per cent Min 10 N/mm Min 10 N/mm Min 25 per cent Min 220 mm Max 28 percent Max +5 shore A Max +5 shore A Max 20 percent Max 20 percent No cracks
Max 5 percent Max 25 percent Max 25 percent Max 20 shore A

Property Cold Hardening Point 8.3.0 Fabrication (Pre-installation)
Specified Value Min 35 deg C
a. Rolled steel profiles for edge beams shall be long enough to cater for a 2-lane carriageway. These shall be cut to size of actual requirements by means of a mitre box saw. Alignment of the cut-to-size steel profiles shall then be made in accordance with the actual bridge cross-section on worktables. For this purpose, the contour of bridge cross-section shall be sketched onto these tables. After the steel profiles are aligned, they shall be chucked to the tables by means of screw clamps and tacked by are welding. b. Anchor plates shall be cut to the required size by gas cutting. These shall be welded to the edge beams. c. Anchor loops shall be bent to the required shape and welded to anchor plates.
d. The finally assembled joints shall then be clamped and transported to the work site. 8.4.0 Handling and Storage a. For transportation and storage, auxiliary brackets shall be provided to hold the joint assembly together. b. The Manufacturer shall supply either directly to the Engineer or to the bridge Contractor all the materials of strip seal joints including sealants and all other accessories for the effective installation of the jointing. c. Expansion joint material shall be handled with care. It shall be stored under cover on suitable lumber padding by the Contractor to prevent damage. Any damage occurring after delivery shall be made good at the bridge Contractors expense to the satisfaction of the Engineer.
8.5.0
Installation The width of the gap to cater for movement due to thermal effect, shrinkage and creep, superstructure deformations (if any) shall be determined and intimated to the Manufacturer. Depending upon the temperature at which the joint is likely to be installed, the gap dimension shall be preset. Taming the width of gap for movement of the joint into account, the dimensions of the recess in the decking shall be established in accordance with the drawings or design data of the Manufacturer. The surfaces of the recess shall be thoroughly cleaned and all dirt and debris removed. The exposed reinforcement shall be suitably adjusted to permit unobstructed lowering of the joint into the recess. The recess shall be shuttered in such a way that dimensions in the joint drawing are maintained. The formwork shall be tight. Immediately prior to placing the joint, the presetting shall be inspected. Should the actual temperature of the structure be different from the temperature provided for presetting, correction of the presetting shall be done. After adjustment, the brackets shall be tightened again. The joint shall be lowered in a pre-determined position. Following placement of the joint in the prepared recess, the joint shall be levelled and finally aligned and the anchor loops on one side of the joint welded to the exposed reinforcement bars of the structure. Upon completion, the same procedure shall be followed for the other side of the joint. With the
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expansion joint finally held at both sides, the auxiliary brackets shall be released, allowing the joint to take up the movement of the structure. High quality concrete shall then be filled into the recess. The packing concrete must feature low shrinkage and have the same strength as that of the superstructure, but in any case not less than m 35 grade. Good compaction and careful curing of concrete is particularly important. After the concrete has cured, the movable installation brackets still in place shall be removed. Rolled up neoprene strip seal shall be cut into the required length and inserted between the edge beams by using a crow bar pushing the bulb of the seal into the steel grooves of the edge beams. A landing to a bead shall be formed in the thickened end of the edges of the seal, which would force the thickened end against the steel beam due to wedge effect when the strip seal is buttoned in place. As soon as the concrete in the recess has become initially set, a sturdy ramp shall be placed over the joint to protect the exposed steel beams and neoprene seals from site traffic. Expansion joint shall not be exposed to traffic loading before the carriageway surfacing is placed. The carriageway surfacing shall be finished flush with the top of the steel sections. The actual junction of the surfacing / wearing coat with the steel edge section shall be formed by a wedge shaped joint with a sealing compound. The horizontal leg of the edge beam shall be cleaned beforehand. It is particularly important to ensure thorough and careful compaction of the surfacing in order to prevent any premature depression forming in it. 8.6.0 Acceptance Test i) ii) All steel elements shall be finished with corrosion protection system. For neoprene seal, the acceptance test shall conform to the requirements stipulated in Table I. It shall also be stretch tested. If a Manufacturer is to supply this type of joint, he will have to produce a test certificate accordingly conducted in a recognized laboratory, in India or abroad.
iii) In view of the importance of the built-up edge beams, special investigation of fatigue 6 strength of this section with anchorages to withstand 2 x 10 load change cycles without showing signs of damage, shall be required. The supplier shall have to produce a test certificate in this regard, conducted in a recognized laboratory, in India or abroad. iv) The Manufacturer shall produce test certificates indicating that anchorage system had been tested in a recognized laboratory to determine optimum configuration of anchorage assembly under dynamic loading. v) The Manufacturer shall satisfy the Engineer that water tightness test for the type of joint has been carried out in a recognised laboratory to check the water tightness under a water pressure of 4 bars. vi) As strip seal type of joint is specialised in nature, generally of the proprietary type, the Manufacturer shall be required to produce evidence of satisfactory performance of this type of joint. 9.0.0 TESTS AND STANDARDS OF ACCEPTANCE The materials shall be tested in accordance with the specifications and shall meet the prescribed criteria. The work shall conform to the specifications shall meet the prescribed standards of acceptance.
JHABUA POWER LIMITED 1 X 600 MW + 1 x 660 MW JPL SEONI Project Specification for River Water Intake System
ANNEXURE 2.1
BORE HOLE DETAILS AT INTAKE SITE
Doc. No. 3109142-ME-SPC-108-001-Rev C Volume II Detailed Technical Specification
Section 2.0
JHABUA POWER LIMITED 1 X 600 MW + 1 x 660 MW JPL SEONI Project Specification for River Water Intake System
ANNEXURE 2.2
TRAIL PIT DETAILS ALONG PIPE CORRIDOR
Doc. No. 3109142-ME-SPC-108-001-Rev C Volume II Detailed Technical Specification
Section 2.0
VOLUME II
SECTION 3 TECHNICAL SPECIFICATION FOR MECHANICAL ITEMS
Section 3
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Mechanical Items
SECTION 3 TECHNICAL SPECIFICATION FOR MECHANICAL ITEMS CONTENTS
DESCRIPTION
PAGE NO.
3.1 - RAW WATER PUMPS 3.2 - DOUBLE GIRDER EOT CRANE 3.3 - STOP-LOG GATES & COARSE SCREEN 3.4 - VALVES 3.5 - SPIRALLY WELDED M.S. PIPES 3.6 - AIR CONDITIONING & VENTILATION SYSTEM
3 12 25 33 45 73
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Mechanical Items
SECTION 3 DETAILED TECHNICAL SPECIFICATION FOR MECHANICAL ITEMS 3.1 RAW WATER PUMPS
1.0.0
GENERAL INFORMATION This section presents the general guidelines and details of pump and associated equipments to be procured under the scope of this package.
2.0.0
CODES AND STANDARDS The design, manufacture and performance of the various mechanical items as specified hereinafter, shall comply with the requirements of the following codes and standards and shall include all the latest amendments subsequent to the year of publication as mentioned below. IS-5120/1977 IS-5639/1970 IS-5659/1970 IS-6536/1972 IS-9137/1978 ISO 3555/1977 BS 5316/1977 Part 2 ISO 2548/1973 BS 5316/1976 Part 1 API-610/1989 PTC 8.211965 IS: 1710 : : : : : Technical requirements for Rotodynamic special Purpose pumps. Pumps for handling chemicals & corrosive liquids. Pumps for process water. Pumps for handling volatile liquids. Code for acceptance tests for centrifugal, mixed flow and axial flow pumps - Class 'C'.
: Acceptance test for centrifugal, mixed flow and axial flow pumps -Class 'B' tests. .
- Do -Class 'C' tests. : Centrifugal pumps for general refinery services. Standards of the Hydraulic Institute of USA (1983). : Power Test Codes -Centrifugal pumps. : Specification for pumps - Vertical turbine mixed and axial flow for clear cold water.
In case of any contradiction with the above standards and annexure, the stipulations in the annexure shall prevail and shall be binding on the bidder. 3.0.0 PERFORMANCE REQUIREMENT Raw Water Pumps Performance requirements for the pumps shall be as guided in Data sheet A 1.1 enclosed with this section. 3.0.0 Pumps shall preferably be designed to have the best efficiency at the specified duty point. The pumps shall be suitable for continuous operation at any point within the "Range of Operation" as stipulated in the Annex 1.1 attached with this section. Pump shall preferably have continuously rising head-capacity characteristics from the specified duty point towards shut-off point, the maximum being at shut-off to enable parallel operation. The first and second critical speeds of the pumps in the coupled condition shall not be less than 50% above operating speed. The rotors shall be dynamically balanced for the above condition or runaway speed, whichever is higher. Under all circumstances, the 'range of operation' of the pumps shall exclude any unstable
3.1.0 3.2.0
3.3.0
Mechanical Items
operating zone of the head-capacity curve. 3.4.0 Wherever specified in the Data Sheet A attached to this section. Pumps of each category shall be suitable for parallel operation. The head vs. capacity, the BHP vs. capacity characteristics etc. shall be identical to ensure equal load sharing and trouble-free operation of any pump when the other pump(s) working in parallel with it trip. The Vertical pump-motor sets shall be designed in such a way that there is no damage due to the reverse flow through the pump which may occur due to any improper operation of the system. The drive motor shall be capable of bringing the pump to its rated speed in the normal direction from the point of maximum possible reverse speed when power to the motor is restored External head that is imposed on the pump under reverse flow condition to be considered by Bidder shall be 15% of rated head and the specific abnormal condition. However, pumps shall be provided with non-reverse ratchet to restrict rotation in one direction only. The Bidder shall note that the pump characteristic as obtained during performance testing of pump shall not deviate from the characteristic curve furnished during tender stage particularly with regard to the operating point and shut off head and steepness of the curve beyond the duty point. Bidder shall furnish the speed-torque curves for pump. Bidder shall clearly indicate the maximum duration for which the pump can be operated under shut off condition. Motor Rating 3.10.0 Minimum 116% of duty point requirement and also to meet the maximum power requirement over the operating range at 52.5 Hz frequency. Adequate for maximum pump shaft input power required over the entire range including the shut off point. Adequate for the pump shaft input power required during single pump operation in the event of tripping of the other pumps operating parallel.
3.5.0
3.6.0
3.7.0 3.8.0 3.9.0
The pump set along with drive motor shall run smooth without undue noise and vibration. Acceptable peak to peak vibration limits shall be generally guided by the Hydraulic Standards of USA. The Bidder under this specification shall assume full responsibility of the operation of the pump and the motor as one unit. DESIGN AND CONSTRUCTION REQUIREMENTS Raw water pumps Pump type Pumps shall be of vertical shaft, submerged suction, self lubrication type (water) design, complete with bowl, column, discharge head and drive assembly, etc. If the water quality is found to be unsuitable for self lubrication, the Bidder shall provide an arrangement for filtering and use the same water as external water for lubrication. Water for lubrication shall be taken from the discharge pipe. It shall then be filtered and its pressure reduced to be used for lubrication of shaft bearings & cooling of stuffing box.
3.11.0
4.0.0 4.1.0 4.1.1
4.1.2
Discharge head The pump discharge head arrangement shall be as indicated in the pump data specification sheet. The pump installations contain an expansion joint located immediately at the pump discharge, and hence are subjected to an additional thrust. The foundation bolts and base plate shall be capable of absorbing all the thrust which shall be based as a pressure equal to shut off head.
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Mechanical Items
4.1.3
Column Pipes Column Pipes shall be flanged and bolted and shall be complete with bolts, nuts, & gaskets. The standard lengths of the column pipe pieces shall be dictated from considerations of ease of handling and as per IS: 1710 column pipes shall be designed for full internal vacuum.
4.1.4
Bowl assembly suction bell, Suction strainer The bowl assembly shall consist of rotating impellers which are housed in stationary bowls having guide vanes. The bowl shall also include the bearing housing of the bottom pump shaft to bearing. The bowls shall provide smooth water passages and shall be hydraulically designed to minimize radial thrust. Pumps shall be provided with an adequate dimensioned suction bell to stream line the intake of water into the bowl assembly.
4.1.5
Impeller The impeller shall be of closed type and shall be of non overloading characteristic. The pump shaft shall have provision for adjusting the impeller position in a vertical direction from an accessible location preferably from the housing of thrust bearing. The impeller adjustment mechanism must take into consideration the extension of the line shaft caused by hydraulic down thrust, the weight of shaft and impeller.
4.1.6
Impeller shaft, Line shaft & Head shaft Shaft size selected shall take into consideration the critical speed which should be considerably away from the operating speed and the runaway speed. The impeller shaft shall be guided by bearings provided in each bowl or above and below the impeller shaft assembly. The butting faces of the shaft shall be machined square to the assembly and the shaft ends shall be chamfered on the edges. The line shaft couplings shall preferably be of muff type. Replaceable shaft sleeves shall be furnished, at applicable locations, particularly under stuffing boxes and other locations where it is subject to wear. Pump shaft shall be connected to the motor shaft by a heavy flexible coupling.
4.1.7
Bearings Impeller shaft, line shaft and head shaft bearings: Adequate number of properly designed bearings shall be furnished. The bearings located above the minimum water level shall be self lubricating type, "Thordon make".
4.1.7.1
Thrust Bearings: Thrust bearings (tilting pad / tapered roller, anti-friction type) shall be furnished separately for pump and motor for taking the entire pump thrust arising from all probable conditions of continuous operation and also at the shut off condition. It shall be centrally pivoted suitable for reverse rotation. The thrust bearing shall be designed on the basis of 40,000 working hours minimum, for the load corresponding to the shut off condition. The bearing shall also be sized for a 25% margin over the thrust occurring at shut off condition. It shall be conveniently located for access and easy maintenance. The bearings shall be lubricated by grease or oil. The design shall be such that the bearing lubricating oil/grease does not contaminate the liquid being pumped. Provisions shall also be made in the pump assembly such that dust or the pumped liquid may not enter the thrust bearing housing. Cooling of thrust bearing, if necessary, shall be done by liquid tapped from the discharge of the pump itself. The bearing enclosure shall be provided with temperature indication and alarm. Lubrication system shall be designed in such a way that there will not be any damage to the bearing while coasting down to stop in the event of a total power failure.
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Mechanical Items
4.1.7.2
Pump-motor supports, Base plates, etc. The pump and motor shall have a common support. The necessary supporting frame, base plates, mounting plates, foundation and anchor bolts, nuts, etc., as required shall be supplied under this specification. The base frame of the pump shall be levelled and grouted during the erection stage in order to avoid fresh levelling each time the pump is dismantled.
4.2.0
Ventilation Axial fans The Axial fan shall be designed for: a) b) c) Fan type: Tube Axial / Propeller. The impellers have blades of an aerofoil design. The speed of the fans shall be 1500 rpm for impeller diameter 450 mm or less and 1000 rpm for impeller diameter above 450 mm.
Each Axial fan comprises of fan, fan motor, inlet and outlet cone (for Tube axial), filters (supply air fans), cowl with bird screen, gravity dampers (exhaust fan), grouting frame, cadmium plated fixed bolts and supporting arrangement. The wall mounted supply air fan shall be of axial flow type with cast aluminium impellers with blades of aerofoil design The fan unit shall be complete with air filters and casing shall be of galvanized sheet steel construction. The wall mounted exhaust fan is of axial flow type with cast aluminium impellers with blades of aerofoil design. The fan is directly driven through three phase induction motor. Wall mounted exhaust fans for toilets are driven by single phase motor. The fan casing is of galvanized sheet steel construction. Pre Filter The pre-filter section shall be washable HDPE filter panels suitably arranged in holding GSS frames having a minimum efficiency of 90% down to 10 micron size and velocity across the filters shall not be more than 2.5m/s.The pressure drop across the filter shall be restricted to 5 mm of wg in clean condition and 7.5 mm of wg at dirty conditions. 5.0.0 INSPECTION AND TESTING Raw water Pumps 5.1.0 At Manufacturers Works 1. The Bidder shall conduct all tests required to ensure that the equipment furnished shall conform to the requirements of the specification in compliance with the requirements of the applicable codes. The particulars of the proposed tests and the procedures for the test shall be submitted to the Purchaser/Consultant for approval before conducting the tests. All materials, castings and forging shall be of tested quality and certificates made available. If mill certificates are not available, the Bidder shall arrange for physical and chemical testing at his own. The general performance testing of the pumps shall be carried out as per the requirement of HIS / IS: 9137 in presence of Purchasers representative. In addition to the above, all major components shall be subjected to various material, inprocess, dimensional, hydrostatic and NDT tests. Necessary test certificates to this effect shall be furnished to the Purchaser. All pressure parts shall be subjected to hydrostatic testing at a pressure of 1.5 times the design pressure for a period not less than 1 hour. Inspection shall also include dimensional check of pump and motor duly mounted on the
2. 3.
4. 5.
6. 7.
Mechanical Items
base plate, in accordance with the General assembly drawing. Unless otherwise specified, the following minimum tests have to be performed and shall be witnessed by the Purchaser or by their authorized representative or by both together. 1. 2. 3. 4. 5. 6. 8. 1. 2. 3. 4. 5. 9. 10. 11. Hydrostatic test Performance test Shop inspection test Dynamic balancing of rotating assembly. Strip off test after the performance test Other tests (if any) as described in the inquiry and order. Zero flow Minimum continuous stable flow Midway between minimum continuous flow and rated flow Rated flow Maximum continuous stable flow.
The pump shall be tested at minimum five points:
Minimum submergence test at maximum flow for vertical turbine pumps. Pressure gauges / pressure transmitter shall be calibrated prior to start of test. Job motor shall be used for testing and the rating of the motor shall not exceed 150% of power that may be consumed while running at duty point with water or power at VFO condition, whichever is higher. Vibration measurement shall be conducted for two points; minimum continues stable flow and rated flow. As far as possible weld repairs on all castings shall be avoided. However, if the same is unavoidable, radiography must be carried out after such repair and the test report shall be submitted to the inspecting authority for approval. But Cast Iron components are not allowed for repair. Testing shall be conducted using the job motor. All rotating components of the pumps shall be subjected to dynamic balancing test. Performance test shall be conducted to power the entire range of operation of the pumps to check their satisfactory performance, free from vibration, balance and proper ceiling of the stuffing box. Pumps shall be capable of operating from shut off point to a max flow of 10% over the point of intersection between system resistance curve and pump H-Q curve. All NDT shall be performed in accordance with ASME Sec. V. Filler material that will deposit weld metals with a composition and structure as near as that of the material being welded shall be used. All welding electrodes shall be got approved by the Purchaser. The electrodes shall be dried before use. Any procedure for the repair of the defects in the weldments and all other materials shall be submitted to the Purchasers/Consultant for his approval prior to any repairing being done. Pipe butt welds shall be examined by liquid penetrate for the root and final passes. 10% of Butt joint welded by each welder shall be checked by RT. 10% of Fillet welds shall also be similarly examined by PT. The tests shall be carried out as per ASME sec V. Acceptance criteria shall be ANSI B31.1. Reports of all shop tests shall be submitted to the Purchaser/Consultant prior to dispatch for review and approval.
12. 13.
14. 15. 16.
17. 18. 19.
20.
21.
22.
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6.0.0
INSPECTION AND TESTING AT SITE Raw water pumps
6.1.0 6.1.1
Test at Site After completion of erection and/or installations and before start-up, each equipment and all its appurtenances shall be thoroughly cleaned, and then inspected in the presence of Purchasers representative. It is responsibility of the successful Bidder to check the correctness, soundness and completeness of installation and acceptability for start. After pre-commissioning operation the Raw water pumps and its associated system will be put in trail run for a period of 15 days. During the trail run the vertical turbine pumps and its associated system will be subject to a reliability run for 72 hours uninterrupted. During the trail run logbook will be maintained to note the various performance data, the malfunction, output deficiency and the short comings etc. The malfunctioning, short comings and deficiencies shall be rectified by the successful Bidder to the satisfaction of the Purchaser at no extra cost. The objective of test run shall be to ascertain that the following are within the permissible limits and the operation is satisfactory. Performance of the Raw water pumps Vibration, noise level Bearing temperature Performance of lube oil system Motor winding temperature Any other parameters considered necessary
6.1.2
6.1.3
6.1.4
6.1.5
Tests shall be conducted as per HIS / IS: 9137. Instruments required for measuring the above parameters shall be furnished by the manufacturer. Any other pre-commissioning and field test not included in the above list and which are specified in the relevant standards, Electricity Rules, Code of practice shall be carried out at no extra cost to Purchaser. Also, if the Purchaser wishes any particular test is to be repeated or freshly carried out, the same shall be done by the successful Bidder without any extra cost. The reports on the site tests shall be submitted to Purchaser by the Bidder.
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Mechanical Items
ANNEX 1.1 SPECIFIED DESIGN DATA FOR RAW WATER PUMPS Clause No. 1.1.0 1.2.0 1.3.0 1.4.0 1.5.0 1.6.0 1.7.0 1.8.0 1.9.0 1.10.0 1.11.0 1.12.0 1.13.0 1.14.0 2.0.0 2.1.0 2.2.0 Service Equipment name Pump type Duty Location Design Temperature No. of pumps installed No. of pumps working Parallel operation Stand by Type of internal element Max. rated speed Seal Acceptable noise level rpm Nos C Nos. Nos. Description A. GENERAL River water Raw water pumps Vertical mixed flow Continuous Indoor 50 3 2 Yes 1 Pull out 1500 Gland Packing Not greater than 85 dBA at a distance of 1.5 m from outline of equipment Unit Data
PUMP PARAMETERS Design capacity of each pump Total discharge head (with losses) Range of operation M3/hr MWC 167 (Minimum) % Pumps shall be capable of operating from shut off point to a max. Flow of 10% over the point of intersection between system resistance and pump H-Q curve. 1970 kW (Bidder shall confirm) To limit specific speed to 1500 and ensure adequate NPSH under all conditions. 3000
2.3.0
2.4.0 2.5.0
Motor rating Pump Speed
KW rpm
3.0.0
LIQUID DATA
Mechanical Items
Clause No. 3.1.0 3.2.0 3.3.0 4.0.0
Description Liquid handled Specific gravity Ambient Temperature DESIGN AND CONSTRUCTION FEATURES Pump type Impeller type Type of lubrication Shaft enclosing tube Column pipe connection Discharge arrangement head
Unit
Data River water 1.0
33
4.1.0 4.2.0 4.3.0 4.4.0 4.5.0 4.6.0 4.7.0 4.8.0 4.9.0 4.9.1 4.10.0 4.11.0 4.12.0 5.0.0 5.1.0 5.2.0 5.3.0 5.4.0 5.5.0 5.6.0 5.7.0
Vertical mixed flow wet pit type Closed Self lubrication No Flanged Above pump floor slab According to ANSI B16.5 150# Separately on pump and motor Tilting pad / Tapered Roller Mitchell / SKF / FAG be 25% margin over the thrust occurring at condition, and for a period of 40,000 hours Flexible To be provided
Flange drilling standard Location of thrust bearing Type of thrust bearing Thrust bearing make Thrust bearing designed for to
Type of coupling (between pump & motor) River ratchet Mechanism MATERIAL OF CONSTRUCTION Suction bell Bowl Bowl liner Impeller Impeller shaft Intermediate shaft Head shaft
2% Ni CI to IS 210, Gr. FG 262 2% Ni CI to IS 210, Gr. FG 262 2% Ni CI to IS 210, Gr. FG 262 SS 304 SS 410 SS 410 SS 410
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Mechanical Items
Clause No. 5.9.0 5.10.0 5.11.0 5.12.0 5.13.0 5.13.1 5.14.0 5.15.0 5.16.0 5.17.0 5.18.0 5.19.0 5.20.0 5.21.0
Description Intermediate shaft sleeve Column pipe Discharge head Intermediate shaft coupling Line shaft bearing (above minimum water level) Line shaft bearing (below minimum water level) Motor stool Pump and motor coupling Gland Stuffing box Gland packing Fasteners assembly in pump
Unit
Data Hardened SS 316 Carbon steel (IS: 2062) Carbon steel (IS: 2062) SS 410 Thordon Cutless rubber in SS shell. Carbon steel (IS: 2062) CS / Forged Cast iron to IS:210 Gr. FG 260 Cast iron to IS: 210 Gr. FG 260 Impregnated Teflon SS for fasteners submerged in water and alloy steel for other fasteners Carbon steel (IS:2062) Minimum 116% of duty point requirement and also to be the maximum power requirement over the operating range at 52.5 Hz frequency.
Base plate /sole plate Motor rating
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Mechanical Items
3.2 1.0.0
DOUBLE GIRDER EOT CRANE GENERAL This section is intended to specify the detailed technical requirements of double girder EOT cranes, electric hoist and its associated equipment, to be provided by the bidder and covers the minimum requirements for design, engineering, manufacture, inspection, shop testing, erection at site, testing and commissioning as per well established engineering practices, safety codes and other relevant codes and standards. The crane shall be complete in every respect and suitable for safe, reliable and continuous operation. All materials and equipment shall be provided as required to make a complete, properly functioning installation and shall conform to the highest standards of engineering and design and workmanship. However, compliance with this specification shall not relieve the Bidder from the responsibility of furnishing equipment / system to meet the specified conditions and satisfied working of Equipment.
2.0.0
SCOPE The scope includes Design, fabrication, supply, installation, testing at factory and at site and commissioning of the double girder EOT crane of required capacity confirm with pump vendor for Intake well pump house. These cranes & hoist shall be reliable & trouble free.
The span of cranes shall be derived based on the final building layout with considerations to clearances and hook approach. 2.1.0 CODES AND STANDARDS The design, manufacture, erection and testing of the cranes shall conform to the latest editions of the following Codes and Standards along with their amendments: IS 325 IS 800 IS 807 IS 2062 IS 2266 IS 2327 IS 3177 Three Phase Induction Motors. Code of practice for use of structural steel in General Building construction Code of Practice for Design, Manufacture, Erection and Testing (Structural Portion) of Cranes and Hoists. Hot Rolled Low, Medium and High Tensile Structure Steel Steel Wire Ropes for General Engineering Purposes. Straight Sided Splines for Cylindrical Shafts with Internal Centering-Dimensions, Tolerances and Verification. Code of Practice for Electric Overhead Travelling Cranes and Gantry Cranes other than Steel Works Cranes.
Mechanical Items
IS 13834 IS 15560 IS 3938 IS 6547
(Part-5) Cranes - Classification: Overhead travelling and portal bridge cranes Point Hooks with Shank up to 160 Tonne Specification Specification for Electric wire rope Hoists Specification for Electric Chain Hoists
2.2.0
SCOPE OF SUPPLY Scope of supply consists of supply of all materials including installation, commissioning & testing at site, but not limited to the following: Electric operated crane shall consist of but not limited to the following:
i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xvi) xvii) xviii) xix) xx) xxi) xxii) xxiii)
Box type girder, end carriages & trolley frame Long travel runway rails (ISMB & ISMC etc.) with machined clamps, bolts, & nuts, end stops with spring/rubber buffers & wheel stops Trolley runway rails with machined clamps, bolts, nuts, end stops with spring/rubber buffers & wheel stops Lifting hook, wire ropes, rope drum, sheaves, equalizing sheaves & bottom block & top block assemblies Totally enclosed gearboxes Drive motors with variable voltage variable frequency drives for all motions Brakes (all motions) for fail-safe operation PVC insulated shrouded type DSL with copper conductor & spring loaded current collectors with fixtures Flexible trailing cable system mounted on retracting support for hoist drives & for cross travel motion Controllers, resistors, control panel & distribution panel Necessary cabling Protection devices & indicating devices such as limit switches, resistors, insulators, safety switches, etc Lighting fixtures & accessories for cranes Earthing of all electrical equipment in crane Protective guards, necessary fasteners, screws & other fixtures Supply of adequate quantity of consumables required for the job at site Initial fill of various lubricants A set of essential spares for three years of trouble free operation A set of start-up spares required during erection, testing, trial operation & commissioning A set of all required maintenance tools & tackles List of essential spares, start-up spare & maintenance spare Operators Cabin and Pendant control system
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Mechanical Items
3.0.0 3.1.0
DESIGN REQUIREMENTS General The design, manufacture and testing of double girder cranes mechanical and electrical components shall conform to IS 3177. Structural design shall conform to IS 807. Long Travel, Cross Travel and Hoist shall be electrically operated.
3.2.0
Bridge Girder The crane bridge shall be of double girder box type as per the data sheet provided for each crane. The size of girder & strength of the plate used shall be such that it has enough strength to carry the rated load without causing undue stress or deflection as per IS 807. The design should ensure that deflections in the steel structure do not affect the drive-unit alignment and stresses arising due to vertical & lateral forces with impact to which they are subjected to. Each girder shall carry a rail on which a wheeled trolley shall run. Mountings shall be designed to facilitate easy removal of the wheels, bearings and journals. The maximum vertical deflection of the main girder due to live load at rest with the crab positioned at the centre of the span, shall be limited to the 1/900 of the span positioned with datum line for deflection by placing the crab on extreme end of the crab span. The entire bridge girder shall be radio graphically tested as per code along with other structural welded parts. The structural plats shall conform to IS 2062. Bridge & trolley shall be provided with suitable platforms. The platforms shall be surrounded by suitable hand railings to facilitate easy access & maintenance of equipment placed on the trolley & bridge. The mechanical end stoppers (spring buffers) shall be provided for effectively arresting the motion of bridge & trolley. They should be fitted rigidly on the gantry beams for the crane bridge & on the bridge girder for the trolley at all the four corners. The mechanical wheel stoppers are also desired for LT & CT for additional safety.
3.3.0
End Carriage End carriages connected with bridge girder at the both ends shall be made from structural steel & it shall be designed as per IS 807/800 for the rated load on the crane. End carriage design shall be such that it facilitates easy removal of the wheels for maintenance. Suitable jacking pads shall be provided for maintenance & easy removal of crane wheels. The wheels shall be double flanged machined on their treads to match the runway rail section. Wheel base & structural frame of the end carriages shall be designed & connected with bridge girder in such a way that the equipment remains square & skewness is prevented.
3.4.0
Travelling Trolley Trolley frames shall be fabricated from rolled structural steel sections. It shall be designed as per IS 807 / IS 800 for the rated load on the crane. The trolley shall be provided with platforms made out of the chequered plate with openings for ropes, sheaves etc. Hand railings shall be
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provided all around the platform. Suitable jacking pads shall be provided for maintenance & easy removal of wheels. 3.5.0 Rope Drum Rope drum shall be either fabricated or seamless pipe of required diameter & thickness to withstand the rated load. It shall be designed as per IS 3177. Drums shall have machined groove, right & left of a proper size for the rope used. Grooving shall be of adequate length, to handle entire rope required to make the specified lift plus the two dead laps at each anchor point, without overlapping, as per IS 3177. The allowable stress on rope drum should be as per IS 800 / IS 807. In case of welded drum, same shall be stress relieved. If the rope drum is fabricated from plate, the plate shall be ultrasonically tested & welded butt joints shall be 100 % radio graphed.
3.6.0
Hoist Rope Hoist rope shall be flexible & with steel core. The rope shall be fastened to the drum with an attachment having strength at least equal to that of the rope. Rope shall be of sufficient length so that minimum two full pass shall remain on drum at extreme low position of the hook. Reverse bends, cross bends & kinks shall be avoided. The size of wire rope shall be one size higher than that having breaking strength considering factor of safety of minimum 6.0 as per IS 3177, weight of the lower pulley block & weight of the wire rope. Hoisting rope shall comply with IS-2266. Wire rope will be of best plough steel, fiber core, 6 x 37 or 6 x 36 constructions.
3.7.0
Sheaves Rope sheaves shall be of cast steel or fabricated steel with anti-friction bearings. Sheaves shall be fully guarded to prevent rope coming off. Maximum fleet angle from drum to lead sheave in the load block or in between individual sheaves shall not exceed the IS specified value except at highest elevation the fleet angle may increase slightly.
3.8.0
Gears Gears shall be cut from solid cast or forged steel blanks or shall be of stress relieved welded steel construction. Pinions shall be of forged carbon or heat treated alloy steel. Split gears shall not be used. Gears and pinions shall be totally enclosed for all motions and must be dust proof and prevent oil leakage. Gear boxes shall have oil bath type for lubrication. Gear boxes shall have covers split horizontally for inspection & rigid construction as per IS : 4460 & stress relieved casing as per IS : 3177. The gears shall be machine cut helical / spur type confirming to relevant IS & shall run in an oil bath. The helical / spur gear & pinions shall have hardness not less than 300 BHN made from carbon alloy steel. The shaft shall rotate in anti-fraction type ball / roller bearings. The final reduction shall be achieved through pinion reduction duly protected with steel metal coverings.
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Necessary level gauge for indicating oil level, Drain plugs, Lifting lugs and guards shall be provided. 3.9.0 Wheels & Rails The wheels shall be of EN 9 forged steel & shall be ultrasonic tested. The wheels shall be mounted in such a manner as to facilitate ease in removal & replacement. The rails for CT shall conform to IS : 3443. Bridge & trolley track wheels shall be of forged steel double flanged with L type bearing housing as per IS:3177. The hardness of the wheel rim shall be as per IS: 3177. The wheels shall be mounted in such a manner as to facilitate easy removal & placement. 3.10.0 Hooks & Hook Blocks The hook shall be compact in nature. The hook shall be capable of swiveling & designed to turn easily on thrust bearings with seal arrangement. The hook shall be provided with spring loaded locking arrangement for locking the swiveling action at each 90 of rotation as & when required. The hook shall be of trapezoidal C shank hook type having higher shank length. The hook shall be ultrasonic, physical, chemical, proof load tested. The heat treatment certificate shall also be provided. Freely, swiveling & supported on entrust bearing & protection shroud shall be provided to enclose the bearings.
3.11.0
Bearings Bearings shall be roller type except that motor bearings shall be of ball or roller type only. For rope drums, LT & CT drives, self-aligned roller bearings shall be used. All anti-friction bearings shall be of approved brand. Bearing housings shall be of split type or so designed to permit easy removal of the shaft. The design shall be such that there is no ingress of dust to enter & oil or grease should not leak out from it. Drip pans shall be provided to accept accidental leakage & drippings.
3.12.0
Guards All gear wheels, pinions shall be completely encased. Effective guards shall be provided for rotating shafts, couplings, chain drives, all moving parts on the bridge & cross trolley & sheaves of hook blocks. i) ii) All exposed couplings, shafts, gear wheels, pinions, drives etc. shall be safely encased & guarded. The sheaves of hook blocks shall be guarded to prevent trapping of hand between a sheave & the in-running rope.
3.13.0
Walkways & Ladders Safe means of access shall be provided to all places where maintenance/ inspection works are required to be carried out. Access walkways of minimum 750 mm clear inside width with hand railings on both sides of bridge girders for the full span length for inspection & maintenance of
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the crane shall be provided. Walkways shall be of chequered plate or non-slip steel surface of minimum 6 mm thickness. Walkways shall be of rigid construction & be designed to sustain a distributed live load of adequate rating. The hand railings shall consist of 32 mm NB pipe in two tiers. Toe plate shall be 8 mm thick & shall project 100 mm above the walkway platform. Ladder shall be provided to reach the girder rail level from the floor level. Ladder shall be 450 mm clear in width with 300 mm centers spaced of rungs 3.14.0 Greasing & Lubrication System Centralized grease lubrication unit with hand operated grease pump shall be provided for antifriction bearings. One unit shall be provided on bridge platform for line shaft antifriction bearings & another unit shall be provided on trolley for top sheave & drum antifriction bearings. Oilgrease collection tray shall be provided for the hoisting arrangement in the trolley to prevent spillage. Trolley Trolley frame shall be rigidly held together by means of bolts. Trolleys shall be suitable for running on I section bottom flanges 3.15.0 OPERATIONAL FEATURES: Cabin operated. The crane operation shall be operated either from operators cabin or with the help of a pendant from operating bay at any time. The operators cabin shall be located at one end of the crane. It shall have permanently mounted crane controunits. The cabin shall have operation comfort, unrestricted aerial and floor view, adequate illumination, proper ventilation and head clearance. The cabin shall be close type fabricated from 20 SWG Aluminium sheets, 2 metre height, single shutter full height air tight entry door, with 600 mm width access platform with railing on entry to cabin side. The floor plate shall be non-skid chequered type. The viewing windows shall be located on two sides (normal to main girders) and full view single shutter fixed glass windows shall be located on the remaining two sides (parallel to main girder) of the cabin. The approach ladder to cabin access platform for further entry to cabin through its door shall be fabricated from 20 mm NB heavy class C pipes. The cabin shall have a. Revolving and adjustable operators seat with back rest suitably cushioned. b. A 300 mm sweep, 230 V guarded fan. c. Fluorescent tube illumination. d. Alarm gong, 230 V AC. e. Switches sockets, cable work for above in the cabin. f. Mortise lock, lockable with key in the door shutter. g. Louvers at floor level and ceiling level for cross ventilation on all sides. h. Thick rubber mattress insulation for floor. i. Any other features which may be required from operation safety and control point of view.
Mechanical Items
4.0.0 4.1.0
CONTROLS & CONTROL SYSTEM Crane shall be operated with floor operated push button pendent, through independent movable pendent & capable of withstanding rough handling without being damaged & shall be effectively secured & earthed. The pendent shall be of light weight (non-metallic less than 2 Kg) & of latest design. The pendent shall be hanged from the T track with trolley system to have its position irrespective to crab location. The control panel shall be of CRCA of 14 SWG thick & powder coated with acceptable shade.
4.2.0
Emergency stop (Mushroom type), stop, start & directional changes shall be accomplished by reversing magnetic contactors, by push buttons operating a control circuit. In case the push buttons shall be spring-loaded & shall return to off positions when released. They shall be suitably inter-locked such that the push buttons of two reverse motions (hoist up & down etc.) can not be simultaneously operated. All push buttons shall be illuminating type.
4.3.0
The weight of the pendent shall be supported independently by means of chain or wire ropes. If the pendent is of metal, it should be effectively earthed at two places.
4.4.0
Adequate guards shall be provided to prevent accidental contact of pendent rope or chain with down shop leads.
4.5.0
Command to brake shall be given through VFD. However, there shall be timer in the circuit, which will cut off the supply to brake irrespective of command from VFD.
5.0.0
PAINTING All surfaces of crane structure shall be cleaned thoroughly and sand blasted. All oils and greases shall be removed prior to painting. One shop coats of EPOXY primer (60 micron) and two coats golden yellow (@ 125 micron) shall be provided at the suppliers works. Minimum DFT (Dry Film Thickness) shall not be less than 150 micron.
6.0.0
SPECIAL TOOLS AND TACKLES For all major equipment, the VENDOR shall provide appropriate structural steel
members/bracket for mounting various handling devices which are necessary for the components erection and maintenance. The VENDOR shall indicate and include in his scope of supply all the necessary tools/tackles, appliances and lifting devices for the effective maintenance and servicing of the equipment and its components. Maintenance tools and tackles supplied shall be new and unused. The dispatch of tools, tackles and lifting devices shall be synchronized with the dispatch of the related system/equipment. The VENDOR shall supply all tools and tackles clearly marked with its size and/or purpose. They shall not be used for erection purpose. Each set of tools and tackles shall be suitably arranged in fitted boxes of mild steel construction. The taps, stocks and dies shall be kept in approved mild steel boxes with components for individual items. If the weight of any box and its contents is such that it can not be conveniently carried it shall be supplied on steerable rubber tyre wheels. Each tool box shall be fitted with a lock and two keys and shall be painted
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with suitable color and clearly marked in white letters, with the name of the system/equipment for which the tools and tackles are intended. The tools and tackles with the appropriate boxes are to be handed over to the Owner at the time of issue of the taking over certificate. 6.1.0 List of Maintenance Tools and Tackles S. No. 1 2 3 4 5 6 7 8 9 10 Description Tool box D/E Spanners required sizes Grease gun Oil can Screw driver of required sizes Nose plier Insulated plier Hammer 2 lbs Allen key required sizes Hydraulic jack Qty 1 set 1 No 1 No 1 set 1 No 1 No 1 No 1 No 1 set 1 No
7.0.0
TESTING AND INSPECTION The supplier shall submit the QA plan to the Owner / Consultant for the approval. The particulars of the proposed test and the procedures for the test shall be submitted to the owner/consultant for approval before conducting the test. All materials, castings and forging shall be of tested quality & certificates made available for approval. If mill certificates are not available, the Bidder shall arrange for physical & chemical testing at his own cost. The crane shall be subjected to full load, overload tests as per IS: 3177. a. b. c. Welds for major load bearing components like bridge, end trucks, trolley, frames etc. shall be examined as follows: All butt welds in the load carrying members such as girder, end carriages, crab structure, hook block etc. shall be 100 % radio graphed. All butt, T-joints and fillet welds shall be checked by dye penetrate test for root and subsequent each pass of welding. The particulars of the proposed tests and the procedures for the test shall be submitted to the Owner/Consultant for approval before conducting the tests. The tests shall be conducted on the motors as per Indian Standards IS:325 and IS:4029 and routine test and type test certificates of the motors shall be submitted to the Purchaser/Consultant for review.
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Reports of all shop test shall be submitted to the Purchaser/Consultant prior to despatch for review and approval. Following tests to be conducted and certificates shall be furnished by the supplier and approved by the Owner/Consultant. a. Manufacturers test certificates for physical properties and chemical compositions of structural steels, hooks, wire ropes, rope drums, wheels, gears and pinions, shafts and axles etc. b. c. d. e. f. g. h. i. j. 8.0.0 8.1.0 Functional test report for all bought out components. Radiography test reports of butt welds. Test reports of DP inspection of fillet, butt and T- joint welds. Ultrasonic test for all forgings, shaft, pinion, gears, castings, roper drum, hook, cross head etc. Functional test of crane at no load condition. Rated and overload deflection test of the crane. Insulation test for all electrical equipments and continuity test for all cables. Type and routine tests for motors. Test certificates for brakes and other bought out components.
PERFORMANCE TEST Guarantee requirements In addition to compliance with the requirements of the Specification, the Bidder shall meet the specific guarantees of performance as required and as stated in the Schedules of Guaranteed Performance. All tests shall be carried out in accordance with the IS 3177 or equivalent relevant international standards unless otherwise specified or approved by the Owner. Performance test will be carried out, within 30 days from the date of commissioning.
8.2.0
Guarantee Test Procedure The guaranteed performance figures of the equipment shall be proved by the Bidder during these Performance and Guarantee Tests. Should the results of these tests show any decrease from the guaranteed values the Contractor shall modify the equipment as required to enable it to meet the guarantees. In such case, Performance and Guarantee Tests shall be repeated within one month, from the date the equipment is ready for retest and all cost for modifications including labour, materials and the cost of additional testing to prove that the equipment meets the guarantees shall be borne by the Contractor. The equipment shall be guaranteed to meet performance requirements required by this specification and rectification shall be carried out until satisfactory results are obtained. The owner reserves the right to reject the equipment should the performance values fall short of those indicated in the schedule of Technical data sheets. In case of such option of rejection being exercised by the Owner shall replace the equipment
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which shall meet the guaranteed values. The Bidder shall furnish a detailed performance test procedure and a programme well in advance for approval by the Purchaser / Owner.
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ANNEX 2.1 SPECIFIED DESIGN DATA SHEET FOR CRANE A) Sl.No. 1 2 3 EOT CRANE Description Design, fabrication and testing of the crane IS 807 & IS 3177 confirm to standard / code number Duty Class Operation from M 7(Bidder to confirm) Hoisting, lowering, forward & reverse for CT&LT power ON/OFF and emergency ON/OFF with key by Pendent push button 20 T - Minimum, (Bidder shall confirm to handle 1.2 times of the heaviest component) Data
3.1 4 4.1 4.2 4.3 5 6 7 8 9 10
Capacity Material of construction Trolley frame Gears (Trolley) Lifting hook (Swivel) Rope Drum & sheaves Wire rope (codes / construction) Gears Factor of Safety LT / CT wheels Operating speeds with full load
Cast steel / Mild steel cast steel / Forged steel Shank C. IS 15560 Forged steel. Safety latch and swivel lock pin. IS 3177 with minimum 1 spare groove, hook is at highest position. IS 2266 / 6 x 36 or 6 x 37 multi strand construction Fibre core. IS 3681/4460 As per IS 3177 Not less than 5 C 55 Mn 75 IS:1570 / cast steel with min. hardness 300-350 BHN Full speed. Inching facility shall be provided for Hoisting motion Electric Electric
10.1 Longitudinal bridge travel 10.2 Trolley travel 11 Brake - Type - Hoisting - CT -LT
Electro Hydraulic thrustor / Electro magnetic brake One per each drive One per each drive One per each drive
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Sl.No.
Description
Data 150% rated torque for hoisting 125% for CT & LT Festoon cable arrangement/Down Shop Lead (DSL)s
11.1 Braking capacity 12 13 Power Conductors Limit switches - Hoisting - CT -LT 14 Fire extinguisher
Rotary gear & gravity (1+1) lever type lever type CO2 type.
B) Sl.No. 1 2 3 3.1 3.2 3.3 3.4
ELECTRIC HOIST Description Standards Trolley type Material of construction Trolley frame Gears (Trolley) Lifting hook (Swivel) Rope drum / MOC Rolled structural steel. cast steel / Forged steel Shank C. IS 15560 Forged steel. Safety latch and swivel lock pin. As per IS 3938 / Grooving shall be lift length plus 2 dead laps at each anchor point. / either cast or welded to sustain concentrated loads resulting from rope pull. solid cast / forged steel blanks Forged carbon or heat treated alloy steel. Extra Flexible with lubricated hemp core 6x36 or 6x37 / right hand ordinary lay construction. Forged / cast steel / and single flanged to suit standard I beam section. From floor by means of pendant push button controller suspended from hoist Hook- Hoist and Lower Trolley travel To and Fro, Start and Stop, emergency ON/OFF with key. As per IS / Not less than 5 Single flanged
Data IS 3938 / Class-II Electric operated
3.5 3.6 3.7 3.8 4 5 6 7
Gears Pinion Wire Rope Trolley wheel Operation Pendant push button Factor of safety Trolley wheel Type
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Sl.No. 8 9 Motor CDF
Description 40% 150% rated torque ACEM / DCEM One per each drive One per each drive
Data
Brakes - Type - Hoisting - Trolley travel Limit switch - Hoisting - Trolley travel
10
To be provided 1 No. (Over hoisting and over lowering) 1 No. (Two extreme ends of trolley travel.)
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3.3 1.0.0 1.1.0
STOP-LOG GATES & COARSE SCREEN GENERAL This section is intended to specify the constructional and operational requirement of Stop-log gates.
2.0.0
SPECIFIC TECHNICAL REQUIREMENTS Stop-Log Gates The clear size of the stop log gates shall be equal to the clear opening size of the wall. Structural design of Stop-Log gate shall conform to IS: 5620 and IS: 4622 (latest) & other relevant IS codes. Maximum water level for designing the stop-Log gates shall be taken as water level of the river indicated in the tender drawing. The stop-log gate shall be fixed at different levels based on the water levels indicating in the tender drawing. Filling valves shall be provided in gates to balance the water pressure before lifting the gate. All other Stop-Log gates shall be operated under balanced condition (i.e., when water is on the one side and no water on the other side). The stop-Log gates shall be operated by means of an Electric Hoist. Suitable common lifting beam shall be provided by Bidder to operate the Stop-Log gates for each location. Coarse screen The Coarse screens are provided to prevent the wooden logs, shrubs and large debris, solid substance or floating material to enter into the flows and further not to damage the Pump House
3.0.0 3.1.0
DESIGN AND OPERATING REQUIREMENTS The stop-log units shall be designed in accordance with the provisions of IS: 5620: 1985 and IS: 4622 (latest revision) in general. The stop-log gate set of Upstream and Downstream of settling basin should be made in identical interchangeable units. The gates will be designed corresponding to the maximum water level as indicated elsewhere in the specification and wave effect with full hydrostatic pressure with the down stream completely empty.
3.1.1.1
Earthquake effect shall also be considered and allowed in the design in accordance with IS: 1893. The design shall be checked for additional force due to horizontal and vertical seismic coefficient as indicated in General Conditions of Contract. An increase of 33 percent over the normal allowable stresses may be allowed for the structural members and 25 percent for bolts and nuts etc. for earthquake condition.
3.3.0
The permissible stresses in various components shall not exceed those specified under Appendix B of IS: 5620 for wet conditions, (accessible) column and those mentioned in these specifications.
3.4.0
Clear marking to be done for identifying each set easily.

Mechanical Items
3.5.0
All the units shall have music note type side seals and bottom seal. The skin plate and bottom seal clamp plate shall be suitably chamfered to prevent damage to bottom seal.
3.6.0
Suitable drain holes shall be provided on all the horizontal girder webs and horizontal stiffeners. Each stop-log unit shall be provided with suitable guide shoes. Lifting points should be suitable for the automatic engaging and disengaging hooks provided on the lifting beam. Two (2) suitable guide rods equidistant from centre shall also be provided on the units at the webs of the top horizontal girders to match the guide bush (pipe) provided at the bottom of the lifting beam to facilitate lowering of lifting beam correctly to engage the stop-log.
3.7.0 3.8.0 3.9.0
The stop-log unit shall be required to be raised/ lowered at a speed of 1 to 2 meters per minute. In closed position, the stop-log assembly units shall be completely water tight with design water head. The stop-log assembly and its accessories shall be so designed that the stresses in the different members due to dynamic loads during closing and opening operations and static loads in the closed position do not exceed the permissible stresses. The frames and anchors shall be designed as per Clause 6.0 of IS: 5620:1985. The bearing plates shall be of mild steel and surface shall be machined. This shall slide on the machined structural steel plates provided on embedded parts.
3.10.0 3.11.0
The Coarse screen structures are little higher in size than that of the size of Stop Log Gate. The Coarse screens are provided in the slot, one-above the other. In short, they can be placed in tiers, say two tier, three tiers etc. The coarse screen set shall be provided with identical interchangeable units.
3.12.0
The Coarse screen units shall be designed in accordance with the provision of IS: 4622, IS: 5620 and other relevant IS codes. Maximum water level for designing in the coarse screen shall be taken as High Flood Level of the River
3.13.0 3.14.0
The permissible stresses in various components shall be as indicated in IS: 4622 or 5620. Coarse screen unit shall have stainless steel seal plates of IS: 6911. These seal plates will slide over another, the cup and cone arrangement shall be provided. These can also be termed as Dowel & Cup arrangement.
3.15.0
The coarse screen units or as called as panels are being lifted and lowered with the help of Lifting Beam by EOT Crane/Hoist as required.
3.16.0
The coarse screen panels shall be operated, lifted or lowered at the speed of 1 m/sec
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4.0.0 4.1.0
ARRANGEMENT OF STOP-LOGS The stop-log gate assembly shall consist of a skin plate provided on downstream side and shall be supported on horizontal girder and vertical stiffeners. Each stop-log gate assembly unit shall have required no. of bearing pads supported by end vertical girders. The bearing pad shall transfer the thrust to concrete through the embedded parts. Suitable lifting attachments, guiding stems shall be provided.
4.2.0
The side seals shall be music note rubber seals with solid bulbs and bottom seal shall be wedge type.
4.3.0
Suitable no. of guide shoes on each side of the unit shall be provided to check side and lateral movement of the units and to restrain the same within specified limits.
4.4.0
The side and bottom seals should have perfect leak proof jointing, and the side seal bulbs should be in a true vertical plane.
4.5.0
The end vertical girders shall have suitable inclined cut at bottom, so that only skin plate and bottom seal rest on bottom seal seat.
5.0.0 5.1.0
DESIGN AND CONSTRUCTION The stop-log assembly units and guiding parts shall consist of the following component parts and shall involve the design of these components: a. b. c. d. Stop-Log unit leaf consisting of skin plate horizontal and vertical girders/plates, end Vertical girders, lifting points, guide stem, guide shoes and bearing pads. Seals and accessories e.g. clamp plates, nuts and bolts etc. Guides Track and side seal seat assemblies.
5.2.0
The gate leaf and its components shall be designed in accordance with clause 6.1 of IS: 5620:1978 and IS: 4622 (Latest revision). The maximum deflection of stop-log unit shall be limited to 1/800 of span (centre to centre of bearing pads). The unit leaf shall also be checked for additional forces due to earthquake.
5.3.0
Structural steel construction suitable bearing pads shall be provided and the bearing surface shall be machined.
5.4.0 5.4.1
Seals Music note type solid bulb seals for side seals and wedge type bottom seals shall be furnished complying with clause 6.3 of IS:5620:1985, stainless steel AISI-316 bolts shall be used for
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clamping. The minimum seal comp. shall be 3 mm. Seals shall be so fixed as to ensure a positive water pressure between the seal and the gate and shall bear tightly on the seal seat to prevent leakage. The side seals should be in single piece of suitable length. However, use of moulded corner seal pieces shall be preferred. Friction forces shall be computed as per IS: 5620:1985. 5.4.2 The bottom rubber seal shall be so provided as not to have any leakage past the gate when the gate is in deflected position due to full water pressure. The side and bottom seals on the gate should also be joined in such a manner that there is no leakage at the seal joints when the gate is in closed position. 5.4.3 Track cum-side seal seat assembly shall consist of rolled structural steel/plate sections, which shall form the base over which stainless steel plate shall be welded/ screwed to present a smooth surface to bearing pads and seals. The bearing stress in concrete should not exceed 40 kg/cm. 5.4.4 Guides shall consist of structural steel plate anchored to embedded steel by bolting/welding. The guide shall be tapered at top for easy entry of unit. 5.4.5 The coarse screen panels shall consist of frame channel i.e. ISMC of designed section and shall be rigidly welded. 5.4.6 5.4.7 For intermediate support the horizontal steel plate or channel shall be welded. Designed sized trash bars manufactured from MS plate shall be welded over the U/S face of coarse screen. These trash bars are equi placed and shall help to prevent the logs, debris, floating material etc. 5.4.8 Lifting Lugs or lifting brackets are welded on top of frame channel, in such way that C.G. of the total coarse screen is balanced, while lifting and lowering. Lifting lug or lifting brackets shall be designed as to use common lifting beam for handling stop log gate & coarse screen of same location. 5.4.9 Guide brockets are provided on either side of the panel so as to facilitate the easy and correct travel of coarse screen in the slot. 5.4.10 sufficient stiffeners are provided to make the frame sturdy and balanced.
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6.0.0 6.1.0
COMMON LIFTING BEAM FOR STOP-LOG GATE & COARSE SCREEN PAIR AT EACH LOCATION BASED ON THE SITE CONDITION The lifting beam shall be designed in such a way that same lifting beam shall be used for handling Stop-Log gate unit and Coarse screen unit of same location.
6.2.0
The lifting beam shall be made from rolled structural steel I-beam/channel sections or fabricated from angle iron frames. The depth of lifting beam/frame should be sufficient to prevent bending of lifting beam in between the side guides. It shall have suitable guide shoes at both ends. Suitable guide bushes corresponding to guide stems on stop-log units and Coarse screen shall be provided for correct engagement with the Stop-Log unit and Coarse screen for each location.
6.3.0
Two (2) automatic engaging and disengaging type hooks with counterweights etc. shall be provided corresponding to lifting lugs on the units, for grappling and up-grappling of stop-log assembly & Coarse screen units under water.
6.4.0
It should be assembled in shop and its operation specially that of automatic engaging and disengaging hook shall be checked for its correct operation.
6.5.0
The lifting beam shall be designed to cater the following requirements: a. b. c. d. Double point lifting shall be envisaged in the design of lifting frame. The depth beam/frame shall be normally 0.6 of its length. However, this may be reduced with suitable end arrangement preventing bending of frame in the guides. Counter-weights shall be provided for automatic grappling and ungrappling. The hook made out of plate shall be checked for automatic grappling and ungrappling and shall be suitably designed for the load of heaviest stop-log unit and Coarse screen pair at each location with adequate margin of impact, sticking of stop-log units and Coarse screen etc. The pin of hook shall be suitably designed for load for which hook is being designed. e. The top pin of the lifting frame/beam shall be designed for the load of lifting frame, load of stop-log unit and Coarse screen pair at each location with adequate margin of impact, sticking of stop-log unit and Coarse screen etc. f. Two (2) guides on either side with their bottom chamfered shall be provided for guiding the lifting frame into the slot and clearances of guide and guide shoes shall be kept the same as adopted in the stop-log units and Coarse screen pair at each location. g. h. The pilot shall be provided at the bottom of lifting frame to prevent rotation of stop-log gate & Coarse screen units during handling. The lifting frame shall be checked for its verticality and for satisfactory operation of grappling and ungrappling of its hook.
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7.0.0
CONSTRUCTION MATERIALS All materials used in the fabrication of stop-log gate shall be of high grade, free from defects and imperfections and shall be of the highest standard commercial quality suitable for intended use. Radiographic examination or magnetic particle testing or other comparable tests will be required for determining the soundness of steel castings and shall be conducted if asked for by the Owner. The material of various components for intended application is as below: All mild steel surfaces exposed to water environment shall be coated with epoxy paint. Sl .No. 1 2 Component Parts Stop-log gate leaf Stop-log gate frames and 1st stage embedded parts 3 2nd stage embedment Wheels (the hardness of cast steel wheel 4 track surface shall be kept 50 points higher than that of wheel tread) 5 6 7 8 9 10 11 12 Wheel axles, wheel track steel Seals Bearings Seal seats Lifting pin Guide Guide shoe Counter sunk bolts IS : 1030 IS : 11855 4 Cr 19 Ni IS : 2062 IS : 2062 IS : 6603 IS : 6603 IS : 2062 IS : 1030 IS : 1570 Reference IS : 2062 IS : 2062
8.0.0 8.1.0
ERECTION TOLERANCES The erection tolerances in various components of stop-log assemblies, lifting beam etc. shall be in accordance with IS: 5620:1985 and other relevant Indian Standard Codes and shall conform to the best engineering practice. It is the responsibility of the Bidder to ensure that his embedments are correctly aligned when civil work is carried out at site.
9.0.0 9.1.0
LEAKAGE TESTS OF STOPLOG GATES Leakage tests shall be carried out with the stop-log gates lowered onto the sill. Before the observation for leakage, the stop-log gate shall be raised and lowered about one meter several times in order to dislodge any debris that might have lodged in the side and bottom seals. The leakage shall then be measured and it should not be more than 5 litres/ minute / metre of length of seal under maximum head.
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10.0.0 10.1.0 10.2.0 10.3.0 10.4.0 10.5.0 10.6.0 10.7.0 10.8.0 11.0.0 11.1.0 11.2.0 11.3.0 11.4.0
SHOP TEST AND FACTORY INSPECTION FOR COARSE SCREEN It is also ensured that all the channels are correctly cut in size. The trash bars are straightened are in size. Correct size welding is done. The frame work is achieved as per requirement. The panel C.G. is maintained. The spacing between Trash bars is correctly maintained as per requirement. Overall dimensions are meeting with the slot dimensions. The Dowels or cup and cone arrangement is in correct dimensions, so as to keep the coarse screens one over another and to facilitate the easy movement in the embedded slot. PERFORMANCE TESTS See that the Coarse screen panels are smoothly entering in to the slots and easily taken out. Lifting hooks are correctly engaging and disengaging while lowering & lifting. Panels are correctly resting over the seal beam and moving over the trash plate, seal plate, so also moving over the guide tees. Center of Gravity (C.G.) of each point unit is achieved.
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ANNEXURE 3.1 TECHNICAL DATA SHEET FOR STOP-LOG GATE & COARSE SCREEN Sl.No. A. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 7.1 7.2 7.3 7.4 7.5 8.0 9.0 10.0 11.0 Type Design code Flow Fluid to be handled Velocity of fluid (design) (m/s) Quantity Sump details - No. of pump components - Intake Well bottom level - Pump room floor level - Minimum water level - Maximum water level Maximum overall height of single unit of gate assembly Material of construction for stop log gate Hoist and lowering arrangement Type of hoist to be provided As per requirement & Bidder to design. Carbon Steel to IS 2062, Gr.B Hoist with lifting beam Manual 3 Description Data Sheet for Stop-log gate Stop-log IS:5620 3300 m/hr (Max) River water 0.3 As per requirement. Data
B) 1.0 2.0 3.0
Data Sheet for Coarse screen Type Liquid in Service Design Code Static type River Water IS: 4622, IS: 5620 & other relevant IS codes As per Drawing (Shall verify by the bidder) 3300 m/hr (max) Two Nos 0.3 m/sec. 100mm x 12mm SS 304 At the inlet to the River water intake well
4.0 5.0 6.0 7.0 8.0 9.0 10.0
Total no. of Coarse screen Flow of fluid through screen No. of Guide ways per Coarse screen Velocity of water through Coarse screen Size of Screen Material Location
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3.4 VALVES 1.0.0 INTENT OF SPECIFICATION This specification is intended to cover design, manufacture, fabrication, testing, supply including transportation and delivery at site in properly packed condition, Erection, testing and commissioning of valves, fittings and specialties etc.
2.0.0
CODES & STANDARDS The codes and standards shall be as per valve specification sections enclosed herewith as per specified data sheet. The latest edition of following codes and standard shall be used. ANSI B16.34 ANSI B16.10 ANSI B16.5 ANSI B16.25 API 598 API 607 API 608 AWWA-C 504 AWWA-C 207 BS -5351 MSS-SP-25 MSS-SP-55 MSS-SP-53 MSS-SP-54 : : : : : : : : : : : : : : Steel valves, flanged & Butt-welding ends. Face-to-face & End-to-end dimensions of ferrous valves. Steel pipe flanges & flanged fittings. Butt-welding ends, Testing of valves. Fire test for soft seated ball valves Metal ball valves - Flanged and butt welded ends. Rubber seated Butterfly valves. Steel pipe flanges for water works service. Steel ball valves for petroleum industry. Standard marking system for valves, fittings, flanges etc, Quality standard for steel castings for valves, flanges etc. visual method. Quality standard for steel castings & forgings for valves, flanges etc. magnetic particle examination method. Quality standard for steel castings for valves, flanges etc. - radio-graphic examination method.
In case of any contradiction with aforesaid standards and the stipulations as per technical specification, later shall prevail.
3.0.0
TECHNICAL REQUIREMENT The method of manufacture, dimensions, tolerances, etc. shall be as per latest edition of the relevant standards indicated in the corresponding valve classification /specification. Deviations, if any, shall be clearly highlighted in the offer.
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Valves shall be as per internationally recognized standards. Flanges shall be machined on faces and edges to ISO 7005, IS 6392 or BS 4504. This shall be finalised during detail engineering. Valves shall be double flanged type and the face shall be parallel to each other and flange face should be at right angles to the valve centerline. Back side of valve flanges shall be machined or spot faced for proper seating of the head and nut. Valve shall be suitable for frequent operation as well as operation after long periods of idleness in either open or closed position. The valve stem, thrust washers, screws, nuts and all other components exposed to the water shall be of a corrosion resistant grade of stainless steel. Valves shall be free from sharp projections. 3.2.0 Duo Jet Air Valve The Single chamber DI duojet air valves shall be with body and cover in Ductile Iron of Grade GGG 40. All internal parts such as float, shell etc., all cover bolts, of austenitic alloy steel, Dn 50 Float of HOSTAFLON and Gaskets and seals of EDPM. The valve shall be painted with Epoxy powder coating (EP-P) inside and outside colour blue RAL 5005. The Air Valve shall be fixed in position at the summits of pipe line as directed by the Engineer. The air valve connections shall be carried out as per the standard specification and Engineer. They shall be fitted by means of flange joints or screwed joint to the pipe line. The Air Valve and the joints shall be tested hydraulically to a minimum pressure as per testing clause of piping work. The testing shall be done along with the testing of pipe line.
3.3.0
Butterfly valve / Sluice Valve Sluice / butterfly valves shall be Soft sealing Gate with body bonnet of ductile iron of wedge fully rubber lined with EPDM of grade W 270 (approved for drinking water) and seals of NBR and the valves should be of vacuum tight and 100% leak proof with face to face dimensions as per BS 5163-89 / IS 4846-2000 / DIN 3202 F4 with Replaceable stem nut and all the valves should be with Electrostatic epoxy powder coating both inside and outside with pocket less straight thro' body passage. Valve will be capable of burried applications with out chamber Construction. The wedge will have plastic rectangular sliding block which ensures smooth travelling of the wedge and
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reduces the torque and wear and tear. The stem sealing will not be of gland packing type and the sealing is by 3 O ring system which ensures 100% leak tightness. The body of the valve shall be grade GGG40 and the wedge fully lined with EPDM rubber. The stem shall be stainless steel with brass nut. Each pump shall be provided with a butterfly valve / Sluice valve in the delivery pipe. The butterfly valve / Sluice valve shall be flanged water works pattern, eccentrically pivoted and shall be electrically actuated. The actuators shall be suitable for opening and closing against the maximum head realized under operating conditions and any necessary spur or other gearing and links etc. shall be incorporated. The actuator motor shall be complete with limit switches, interlock switches for remote control and also contact for close, open, in operation and percentage opening position indications. The actuators shall be suitable for operation with DOL starting on 415 V, 3 phases, 50 Hz. A.C. power supply. Necessary arrangement with hand wheels shall be provided for emergency manual operation with suitable interlocking mechanism to prevent the actuator operation when the valve is being operated manually and vice versa. Horse power of motor shall be adequate with at least 50% margin over maximum power required to unseating the valve against line pressure equivalent to valve rating specified in Schedule or normal operation whichever is higher. Butterfly valve, suitable for flange bolting individually to flanges of pipe and pump with the disc to form a section cut through a sphere, working in conjunction with a cone shaped seating in body and suitable seal ring fitted to the disc, with the help of retaining ring and stainless steel screws shall be conforming EN593.. Local operation switches near the valves should invariably be provided for operation of the valves. The valve should be subjected to seat and body test in accordance with the manufacturers works. This test shall be carried out in presence of customer or his representative. Before delivery, test certificates shall be furnished in triplicate. The valve seat shall be of integrally cast or replaceable design. When the valve is fully closed, the seal shall seat firmly so as to prevent leakage. The seat surfaces shall be machined smooth to provide a long life for the seal. All fasteners shall be set flush so as to offer the least resistance possible to the flow through the valve. Valves shall be suitable for throttling purpose if required in exceptional circumstances.
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All valve spindles and hand wheels shall be positioned to give good access for operational personnel. Valves shall be provided with enclosed gear arrangement for ease of operation. The operation gear shall be such that they can be opened and closed by one man against an unbalanced head 15% in excess of the maximum specified rating. Valve and any gearing shall be such as to permit manual operation in a reasonable time and not exceed a required rim pull of 400 N. All hand wheels shall be arranged to turn in a clockwise direction to close the valve, the direction of rotation for opening and closing being indicated on the hand wheels. Manually operated Butterfly valve shall also conform to above specification.
3.4.0
Electric actuator All local controls shall be protected by a lockable cover. Each actuator shall be adequately sized to suit the application and be continuously rated to suit the modulating control required. The gearbox shall be oil or grease filled, and capable of installation in any position. All operating spindles, gears and head stocks shall be provided with adequate points for lubrication. The valve actuator shall be capable of producing not less than 1 times the required valve torque and shall be suitable for at least 15 minutes continuous operation. The actuator starters shall be integrally housed with the actuator in robustly constructed and totally enclosed weatherproof housing. The motor starter shall be capable of starting the motor under the most severe conditions. The starter housing shall be fitted with contacts and terminals for power supply, remote control and remote positional indication, and shall also be fitted with internal heaters so as to provide protection against damage due to condensation. Heaters shall be suitable for single phase operation. The heaters shall be switched ON when the starters are OFF and shall be switched OFF when the starters are ON. Each starter shall be equipped as follows : a. b. c. d. AC electric motor Reduction gear unit (with thrust bearing if required) Torque switch mechanism Limit switch mechanism
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e. f. g. h. i. j. k. l. m. n.
Hand wheel, for manual operation Valve position indicator Hand-Auto lever with suitable locking arrangement Valve position transmitter Reversing contactor starter complete with overload relays of suitable range and adequately rated control fuses Actuator with integral starter shall have selection between local/remote operation Local control switch/ push buttons 415 V/240 V AC control transformer A white lamp for supervision of main supply to be provided locally A potential free contact shall be provided to annunciate over-load trip/main supply failure on remote panel. If used for inching operation, same shall have position feedback transmitter.
The following shall be included as standard feature for valve actuators a) Two (2) DC interposing relays for matching the low voltage of remote commands with the control voltage. b) The motor shall be specially designed for valve operation, combining low inertia with a high torque and with linear characteristics. c) Each electric-motor operator shall be provided with a hand-wheel with handle for manual operation. The hand-wheel shall be automatically declutched when the electric motor is operating, but shall be capable of being engaged at other times by positioning the clutch lever. The electric operation shall override the manual operation. d) All motor operators shall be provided with visible local valve position indicators mounted on the operator assembly itself. e) The torque switch shall function to stop the motor on closing or opening of the valve, or upon actuation by the torque when the valve disc is restricted in its attempt to open or close. A minimum of two (2) torque switches, one for closing direction and one for opening direction shall be provided. f) The non-adjustable limit switches shall stop the motor and give indication when the disc has attained the fully open or close position. g) All wiring connections from the various switches shall be brought out on to separate terminal box mounted on the valve, having liberal space for wiring and making connections. h) The terminal box shall be suitable for outdoor use and shall be weatherproof and dust tight.
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Reversing Contactor starters for valve Actuators a) The reversing starters shall comprise forward and reverse contactors, electrically interlocked with each other. b) The terminal overload relays provided with the reversing starters shall be three element, positive acting, ambient temperature compensated, time lagged thermal overload relay with adjustable settings. The setting range shall be properly selected in accordance with the rating of the motor. c) d) Thermal overload relays shall be hardest type. STOP push button of the starter and hand reset device shall be separate from each other. e) Overload relay reset push button shall be brought out to the front and made easily accessible. f) Overload relay shall be provided with at least one NO and one NC or one change-over contact. g) The minimum continuous current rating of the contactors shall be 16 Amps for all actuator valve motors upto 6 kW. 3.4.0 Non-return valve The valve shall be suitable for mounting on a horizontal pipeline and flow direction shall be clearly embossed on the valve body. Valves shall possess high speed closing characteristics and be designed for minimum slam condition when closing. Dual plate check valves shall conform to API 594 and API 598. They shall have metal to metal sealing. The spring action shall optimize the equal closing rates of each plate especially when the friction coefficients are uneven due to one plate resting upon one another. The plates shall not drag on the seat while opening. The plates shall not vibrate under full or partial flow condition. In case of the nozzle check valve, the disc shall be correctly positioned at all times to achieve fully non-slam closure. The spring shall be fully shielded from the flow stream by the central flow diffuser.
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Tilting disc non-return valve shall incorporate a double offset shaft with a variable angle tilt disc configuration. Sealing shall be metal to metal. The disc shall be stable and shall not vibrate under full or partial load conditions. Valves shall be provided, in addition to others, feet and jacking screws. Hinge pins / shaft shall preferably be square in section to ensure positive location of flaps and provide for secure fixing. 3.4.1 Materials of Construction Sr. Component Material
a) b) c) d) e) Note :
Body and Doors/Disc/Plate Body Ring / Door Ring Hinge pin Spring Bearings
DI Stainless steel ; ASTM A743 CF8MBS970 Gr. 304 S11 Stainless Steel ; BS 970 431 S29 Spring Steel Teflon
The closing timing of non return valve shall be based on surge analysis study. These timings shall be required to be noted by the successful bidder and the valves will be required to be designed accordingly.
4.0.0
INSPECTION AND TESTING All valves and specialties shall be subjected to the tests indicated in the corresponding valve class/specification data sheet section and as per Approved QAP. Tests shall be conducted at manufacturer's works, conforming to the relevant standards, and all test certificates shall be submitted to Owner/Consultant for approval before despatch of material. Valves shall be subjected to the following tests. Visual inspection test as per MSS-SP 55. Magnetic particle and radiography, as indicated in the valve specification class. Hydrotest as per -relevant specified standards. The following test certificates shall be submitted for approval of Owner/Consultant before despatch of material.
o o
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Material test certificate for chemical & mechanical properties with heat numbers as required by the Engineer-in-charge. CCOE certificates with relevant stamping on the valves if required shall be furnished where applicable. Chemical composition, physical properties, tests, dimensions & tolerances, heat treatment and marking shall conform to applicable codes/standards/specifications. Any deviation shall be highlighted on a separate sheet by the Tenderer in the quotation itself.
No material shall be despatched without the approval of Owner/Consultant. During testing there shall be no visible evidence of structural damage to any of the valve component. Motorized valves shall be tested with their actuators, with a differential head equivalent to their maximum working pressure, to prove that the actuators are capable of opening and closing the valves under maximum unbalanced head condition within the specified opening or closing period. The following test shall be carried out for butterfly valves: a. b. c. d. e. Seat leakage test at rated pressure Body hydrostatic test at 1.5 times the rated pressure/ two times rated pressure Disc strength test at body test pressure Valve operation with and without actuator Crack opening test under tension
The following test shall be carried out for sluice valves: a. b. c. d. Seat leakage test at rated pressure Hydrostatic test at 1.5 times the rated pressure Valve operation Open end test
The following test shall be carried out for non-return valves: a) Seat leakage test at rated pressure b) Body hydrostatic test at 1.5 times rated pressure/ two times rated pressure c) Operation
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5.0.0
SPECIAL INSTRUCTION TO BIDDER Bidder has to submit a detailed Technical data sheet and schedule of guaranteed data as per the standard data sheet format of manufacturer for each type of valves.
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ANNEX 4.1 SPECIFIED DESIGN DATA I. S. No. 1.0 1.1 1.11 1.2 1.3 1.4 1.5 1.6 1.61 1.7 1.8 1.9 2.0 2.1 2.2 3.0 3.1 3.2 3.3 3.4 3.5 3.5.1 3.5.2 3.6 4.0 4.1 GENRAL SIZE Pressure (PN) QUANTITY VALVE OPERATION LIMIT SWITCH REQUIREMENT SERVICE VALVE CENTER LINE ELEVATION OPERATING FLOOR ELEVATION FLUID HANDLED INSTALLATION DESIGN & CONSTRUCTION CODE/ STANDARD CONNECTING PIPE DETAILS PIPE O.D. PIPE THICKNESS DESIGN DESIGN PRESSURE FOR VALVE BODY WHETHER DSN. FOR VACUUM DESIGN MAX. DIFF. PRESS. FOR DISC, SHAFT, OPERATOR SIZING ETC. DESIGN TEMPERATURE FLOW RATE THROUGH VALVE NORMAL MAXIMUM WHETHER DIRECTION FLOW IN BOTH m3/hr. m /hr.
3
Butterfly Valves (ELECTRIC) DESCRIPTION UNIT (NB) Bar Nos. 600 / 1200 / As required 25 bar (Bidder shall confirm) As required ELECTRIC OPERATED / MANUAL REFER NOTE : A RIVER WATER INTAKE PUMP DISCHARGE LINE M m LATER LATER RIVER WATER SUITABLE FOR INSTALLATION IN ANY POSITION AWWA C 504 / BS EN 593, FLANGED, DRILLING TO AWWA C-207 CL-D mm mm 600 / 1200 / As required As per the design DATA/PARTICULARS
bar (g) Full Vacuu m bar (g)

O
25 (Bidder to confirm) YES 25 (Bidder to confirm) 50 3909 YES
PERFORMANCE REQUIRMENT VALVE OPERATING TIME UNDER MAX. DIFF. PRESSURE

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S. No. 4.1.1 4.2 5.0 5.1 5.2 5.3 5.4 5.5 5.7 6.0
DESCRIPTION OPENING/ CLOSING TIME LEAKAGE MATERIAL OF CONSTRUCTION VALVE BODY VALVE DISC VALVE SHAFT BODY SEAL APPLICABLE) DISC SEAT RINGS BEARINGS COUNTER FLANGE DETAILS RINGS (IF sec litre/hr.
DATA/PARTICULARS BIDDER TO FURNISH ( REFER NOTE: B ) ZERO (Bidder shall be provided DI valve) DI DI SS-BS 970 Gr.431S29 SS-BS 970 Gr.431S29 EPDM RUBBER TEFLON BIDDER TO FURNISH( REFER NOTE: D)
NOTES: A) B/F VALVE SHALL BE PROVIDED WITH 4 LIMITSWITCHES. LIMIT SWITCH SHALL BE 2 NUMBERS OPEN AND 2 NUMBERS CLOSED IN THE ADJUSTABLESETTING BETWEEN FULLY OPEN AND FULLY CLOSED POSITION .EACH LIMIT SWITCH SHALL HAVE 2 NORMALLY CLOSED(NC) & 2 NORMALLY OPEN(NO) POTENTIAL FREE CONTACT. OPENING / CLOSING TIME FOR ACTUATED VALVES SHALL BE REVIEWED AND CONFIRMED BASED ON THE SURGE ANALYSIS DURING DETAILED ENGINEERING BIDDER TO SUPPLY STUD BOLTS AND NUTS FOR THE REQUIRED NUMBER OF TAPPED HOLES ON VALVE BODY. THICKNESS OF COUNTER FLANGE SHALL BE APPROVED LATER AFTER PIPING ANALYSIS NON RETURN VALVE : 600NB / 1200 NB RATING confirm) :25 bar (Bidder shall
B) C) D) II. SIZE
QUANTITY : As required VALVE DESCRIPTION CONSTRUCTION BODY BONNET DISC SEAT RING HINGE PIN COVER STUD BOLT COVER NUTS COVER GASKET RENEWABLE CASTING BOLTED
ENDS : FLANGED - FLAT FACE TO B16.5 MATERIAL (DI valve shall be provided) DI DI DI SS ASTM A743 CF6MBS970 Gr.304 S11 SS BS 970 431 S29 A193 Gr. B7 A194 Gr. 2H SPIRAL WOUND SS304 WITH NON- ASBESTOS FREE FILLER
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OTHERS TYPE END TO END DIMENSIONS PRESSURE RATING & TEMPERATURE DUAL CHECK PLATE
ASME B16.10 ASME B16.34 API - 598 REQUIRED DN400 ABOVE PRESSURE PARTS REQUIRED Kg PSIG (kg/cm (g)) BIDDER TO FURNISH FOR AND
TESTING STANDARD RADIOGRAPHY REQUIREMENT
DP/ MP TESTING ACCESSORIES WEIGHT HYDROSTATIC TEST PRESSURE NOTES:
1. CHEMICAL, MECHANICAL TEST CERTIFICATES, DP/MP TEST CERTIFICATES,FIRE SAFE TEST CERTIFICATES, ETC. 2. BIDDER TO SUPPLY COUNTER FLANGE ALONG WITH FASTENERS AND GASKETS. III. SIZE DUO JET AIR VALVE : 200NB RATING : 25 bar (Bidder shall confirm) ENDS : FLANGED - FLAT FACE CONSTRUCTION CASTING MATERIAL DI Stainless steel (1.4301); DN 50 float of Hostaflon Stainless Steel EPDM Rubber [Grade- W 270] Stainless Steel Electro static epoxy powder coating min. 250 microns thickness, colour RAL 5005 Blue.
QUANTITY : As required VALVE DESCRIPTION BODY FLOAT SHELL GASKET & SEAL SCREWS SURFACE PROTECTION
NOTES: 1. CHEMICAL, MECHANICAL TEST CERTIFICATES, DP/MP TEST CERTIFICATES,FIRE SAFE TEST CERTIFICATES, ETC. 2. BIDDER TO SUPPLY COUNTER FLANGE ALONG WITH FASTENERS AND GASKETS.
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3.5 -
SPIRALLY WELDED M.S. PIPES
1.0.0
SCOPE Designing, supplying & laying of MS pipe of 1200mm dia and 14mm minimum thickness satisfying the water hammer requirements as per the specification and conforming to IS 3589 & AWWA-M 11 for about 12.0 km (approximate) long from intake pump house to plant boundary and additional length of pipeline from plant boundary to the raw water reservoir inside the plant as required and also consider the buckling load for design the pipe thickness. M.S. pipes shall be procured from the reputed manufacturer and the pipe shall conform to IS 3589/ 2001. The pipes shall bear ISI mark. The test certificate furnished by the manufacturer should be produced. This Standard specification applies to seamless and welded carbon steel pipes for water Supply works. This specification covers the manufacture, supply, testing and delivery of spirally welded mild steel pipes (steel grade Fe 410) suitable for sleeve joints for pumping mains and for butt joints in case of gravity main with lining and coatings. The contractor shall furnish all fittings and special pieces required for curves, tees, branches, air valves, scour and sluice valves as ordered by the Engineer. Specials shall suit the respective internal dia MS pipes to withstand required test pressure and suit air valves, scour valves and sluice valves and conform to the details furnished in the Bid Documents.
2.0.0
CODES AND STANDARDS Unless specifically mentioned otherwise the design, workmanship, quality, properties of materials and methods of testing shall be in accordance with the latest editions/ amendments of all applicable codes and standards as published by the Bureau of Indian Standards and those published during the progress of the contract. IS: 3589:2001 IS 5822 : 1994 IS 15337 : 2003 IS: 1608:2005 IS: 2328:2005 IS: 3803 (Part I) 1989/ ISO 2566 Steel Pipes for water and sewage (168.3 to 2540mm outside diameter) works Code of practice for laying of electrically welded steel pipes for water supply Coal tar based anticorrosion tape for protection of underground mild steel pipelines Methods for tensile testing of steel products (Second Revision) Method for flattering test on metallic tubes (First Revision) Method for elongation conversions for steel: Part I. Carbon and low alloy steels (Second Revision)
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IS: 4711: 2008 IS: 4736: 1986 IS: 814 : 2004 3.0.0 GENERAL
Method for sampling of steel pipes, tubes and fittings Hot-dip zinc coatings on mild steel tubes (First revision) Electrodes used for welding of steel plates
The laying of pipelines shall commence only after the bottom of the trench at various points have been levelled as shown in the typical cross section drawings. The Centre line shall be excavated to correct depth, slope and width at all points. The pipes shall be carefully laid to the alignment, levels and gradients as per the IS code and as per instruction of Engineer in charge. The trench shall be excavated wide enough under the sockets to cater for working space that is required for jointing pipes. When it crosses under a road, the pipe shall be fully encased in concrete as shown on the typical cross section drawings. The Contractor shall take precautions to maintain always a minimum cushion of earth over the pipes as indicated in the drawings. After each section of the pipelines has been laid, the joints shall be allowed to set properly and shall be inspected and tested as directed by the Engineer. Backfilling of the trench shall be carried out only after the approval of the Engineer. After testing, the trench shall be backfilled with selected earth in layers of 150 mm, watered and thoroughly rammed. All pipes, water mains, cables etc. met within the course of excavation shall be carefully protected and supported. All piping works shall be executed by a licensed or authorized supervisor and shall be in accordance with the requirements of relevant codes. Pipes shall be free from all defects including indentations, delamination, bubbles, pinholes, cracks, pits, blisters, foreign inclusions and resin starved areas that due to their nature, degree, or extend detrimentally affect the strength and service ability of the pipe. The pipe shall be as uniform as commercially practicable in color opacity, density and other physical properties. For items such as earthworks, excavation, concrete, brick work, stonework, painting etc. relevant specifications for these shall apply, unless other wise specified. Any damage caused to pipes, fittings etc. during execution of the piping works shall be made good by the Contractor at his own cost to the satisfaction of the Engineer.
4.0.0
QUALITY ASSURANCE The quality shall comply with, but not limited to the requirement of applicable codes and standards.
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5.0.0
SUBMITTALS The Contractor shall submit to the Engineer samples of all materials, fittings and appliances for approval well in advance of starting the work. All materials, fittings and appliances used in the work shall conform to the approved samples. The contractor should furnish the test certificate issued by the manufacturer. The Engineer shall have the power to test the MS pipes for its quality standards in his laboratory/ other reputed Laboratory, the manufacturers test certificate inspection certificate should be produced by the contractor for the pipes used in the works The Engineer shall verify, in addition to the test certificate, whether the pipes are as per IS code, by visual examination, diameter, weight, wall thickness, flexibility, color etc.,
6.0.0
QUALITY OF MATERIALS The pipes shall be manufactured with the steel produced by the open heart or electric furnace or one of the basic oxygen processes. Other processes may be used by agreement between the purchaser and the manufacturer. The pipes shall be manufactured by one of the following process. Any of the following process shall be employed for sleeve and butt welding. i) Seamless Pipes: - The pipe shall be manufactured by using a seamless process and shall either be hot or cold finished. ii) Electric Resistance Welded Pipes: - The pipes shall be manufactured from plate, sheet or strip welded continuously by the passage of an electric current across the abutting edges longitudinally or spirally. The finished pipes shall not include welds used for joining lengths of the hot or cold, flat rolled strips prior to tube forming. The external weld bead shall be removed completely. iii) Submerged Arc Welded Pipes: - The pipes shall be manufactured from plate, sheet or strip with either a single or double longitudinal seam or a spiral seam and welded across the abutting edges by an automatic submerged arc welding process using at least two runs, one of which shall be on the inside of the pipes. All electrodes shall conform to IS: 814-2004. Irrespective of the dimensions calculated for the most adverse conductor of loading, the steel plate thickness shall not be less than that approved design, drawing & specification, branch or scour outlet. The plate thickness for the wall of a branch or outlet shall also be not less than one half of the thickness of plate in the barrel of the fittings. Tests carried out whenever a significant change is made in the design, composition or process of manufacturing and/or at a specified frequency in order to establish the suitability and performance capability of the pipes.
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The outside diameter and thickness of the pipes shall be specified as IS: 3589, the nominal mass per meter run of the pipes against each dimension also as per IS: 3589. The other sizes not included in the IS Code may be supplied as specified by the owner. The materials used in the manufacture of steel fittings shall comply with the following requirements Joints:Wire Mesh: - Wire mesh for reinforcement of interior and exterior gunuite shall be electrically welded wire fabric or woven wire fabric and specially crimped or otherwise if furring to hold the reinforcement 10 to 13mm away from the surface on which it is applied. The wire mesh shall weigh not less than 12.5 kg/ b sq.m. The reinforcement shall be free from paint other coating material, loose soil, dirt or excessive rust etc, Steel Sheets: - Steel sheets shall conform to the IS: 2061or its latest revision. Electrodes: - Electrodes for welding shall conform to the IS: 814-1963 or as amended. The pipe shall have a joining system that shall provide for fluid tightness for the intended service condition. Dye penetration/ radiographic testing shall be carried out as per BIS for steel fittings. 7.0.0 LINING The specification shall comply with, but not limited to the requirement of applicable codes and standards. The inside and outside coating for the pipe material shall be as per the design criteria of IS codes or as per owner decision. 7.1.0 Liquid-Epoxy coating systems Unless otherwise specified by the owner, the coating and lining systems may be consists of any of the following 3 types: (1) Two-Part, chemically cured epoxy primer and one or more coatings of a different two-part, chemically cured epoxy topcoat. (2) Two or more coats of the same twopart, chemically cured epoxy coating, in which case the first coat shall be considered as the prime coat. (3) A single coat of a two-part, solvent free, chemically cured epoxy coating. The coating used shall be based on liquid, chemically cured epoxies. The curing agent may be an amine, amine-adduct, or polyamide and the epoxy may be modified with the coal rat, phenolic or other modifiers. Materials with used in both the primer and finish coats shall be products of one manufacturer.
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Unless otherwise specified by the owner, the minimum Dry Film Thickness (DFT) provided shall be at 406 m. After curing but prior to burial, the coating system shall be a continuous film, free of thin spots and other imperfections as a defined and shall pass electrical inspection. The pipe coating shall be applied in accordance with the manufacturers recommendations. Application by airless spray or centrifugal wheel equipment is preferred. 7.1.1 Pipe preparation Cleaning: - Prior to abrasive blast cleaning, surfaces shall be inspected and, if required, cleaned according to remove oil, grease, or other foreign matter. Only approved solvents that do not leave a residue shall be used. Preheating to remove oil, grease, mill scale, water and ice may be used provided all pipe is preheated in a uniform manner to avoid distorting the pipe. If abrasives or other loose foreign matter has entered the interior of the pipe, then clean, dry oil free compressed air shall be used to remove the loose foreign matter in a manner that does not adversely affect the cleaned surface. Alternatively, vacuum cleaning or other methods may be used in place of compressed air. The exterior and interior pipe surfaces shall be abrasive blast cleaned to achieve a near white metal surface. Abrasive blasting and coating shall only be performed when the metal temperature is more than 3C above dew point. The exterior and interior pipe surfaces shall be inspected for surface imperfections, such as slivers, scabs, burrs, weld spatter and gouges shall be removed by grinding. 7.1.2 Pipe Ends for Non-Welded Field Joints When rubber gasketed joints or mechanical couplings are used the coating shall extend to the ends of the pipe. The coating thickness on the pipe surfaces that receive rubber scaling gaskets shall not exceed what is recommended by the manufacturer of the coupling. However the coating systems DFT shall not be less than 406m. The temperature of the mixed coating material and of the pipe at the time of application shall not be lower than 10C 7.2.0 Fusion-bonded Epoxy coating (Void) The epoxy powder shall consist of a one-component, fusion bonded material consisting of epoxy resin, curing agents, catalysts, fillers, colorants, flow control agents, and ultraviolet light resistant agents that when applied to the preheated substrate, will uniformly coalesce and cure to produce homogeneous film that complies with the requirements of this standard. Application capability, when applied by electrostatic spray, fluidized bed or air spray to the preheated article and subsequently cured the epoxy powder shall produce a uniform protective coating.
Mechanical Items
7.2.1
Pipe coating application When both an internal and external coating are to be applied, it is preferable to preheat the pipe to the specified temperature and apply the internal coating first, immediately followed by the external coating, since elevated temperatures are required during processing, fusion bonded epoxy coating must be applied prior to the application of other coating or lining unless those coatings and linings are resistant to the processing heat. Surfaces to be coated shall be free from mud, mill lacquer, wax, coal tar, asphalt, oil, grease, chlorides, or any other deleterious material. Prior to blast cleaning, surfaces shall be inspected and if required, precleaned, to remove oil grease, and loosely adhering deposits. Heating to removal oil, grease, mill scale, water and ice may be used provided the pipe section, is preheated in a uniform manner to avoid distortion. The cleaned exterior and interior pipe surfaces shall be inspected for adequate surface preparation. Surface imperfections such as silvers, burrs, weld spatter and gouges shall be removed by hand filling or grinding to prevent holidays in the applied coating. Pipe sections with coating defects, such as particle coating, unbounded coating, or inadequate film thickness, shall be reprocessed starting with surface preparation procedures. The weld area shall be heated to a temperature not to exceed 260C using a circumferential induction heating coil of sufficient size, width and power to provide the required heat in the weld zone and 55mm back under the fusion bonded pipe coating. Immediately after heating, the weld shall be coated with a powder coating. The welded joint coating shall overlap the original pipe coating by no less than 25mm. The exterior of field welded joints may be coated with hot applied tape, cold applied tape, liquid epoxy, or heat shrinkable coatings.
7.3.0 7.3.1
Coal tar based Anticorrosion Tape coating Scope This specification covers the material and application requirements for coal tar based anticorrosion tape for protection of underground Mild steel pipelines up to operating temperature of 50 deg C as per IS 15337-2003.
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7.3.2
General Equipment and accessories required for tape coating shall be in good operating conditions. Adequacy of equipment and accessories shall be approved by Engineer-in-charge. Necessary arrangements for power supply, testing and inspection facilities, Field and laboratory tests and other utilities shall be made for completion of the job. Manufacturers recommended / Trained supervisor and skilled applicator shall be engaged by the contractor for application, inspection and quality assurance.
7.3.3
Material Materials for coal tar tape coating shall conform to the following specifications. The following are the salient features of coal tar tape coating materials. a) Primer
The primer shall be resin based synthetic primer containing only unmodified chlorinated rubber and small amount of coal tar pitch of same quality used for making coal tar tape and have the following characteristics: i. ii. iii. iv. Flash point (Abel) deg C, Min Viscosity (Flow time at 20C by No.4 flow cup) in second Volatile matter (100-1 10C) Loss of mass, by percent, Max Drying time, minutes (Tack free) : 23 : 35-60 : 75 : 5-15
It shall be a liquid that can be applied without heating and shall produce an effective bond between the surface to be protected and subsequent coating of coal tar tape. Primer shall not settle in the container to form a cake that cannot be mixed easily by hand stirring. Primer shall have good spraying and/or brushing properties and a minimum tendency to produce bubbles during application. The primer and the coal tar tape shall be compatible to each other and the primer shall pass the adhesion test after 72 hours as specified in IS 15337. b) Coal Tar (Hard pitch)
The coal tar (hard pitch) component shall be produced from coal that has a minimum heating value of 13000 Btu/lb (7.223 x 1()6 cal/kg) on a moisture and mineral matter free basis and has been carbonized in a slot type coke oven at a temperature of not less than 900C. Coal tar component shall comply with the requirement as given in the following Table.
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Softening Point Specific Gravity at 25 deg C Ash Content Penetration at 25 deg C / 100 g / 5s Filler percent b)
65 to 121 deg C 1.3 + 0.05 0.5 % (Max) 1 to 20 mm x 10-1/4 20 35 w/w
Fabric
The fabric shall be made of inorganic fibre. The tape made of inorganic fibre shall have glass fibre mat / tissue reinforced with glass yarn. The inorganic fabric shall be thin, flexible and uniform mat, composed of glass fibre in an open structure bonded with a suitable inert material compatible with coal tar. The mat shall be reinforced with continuous filament glass yam at approximately 10 mm pitch in the longitudinal direction. The following are the salient features of fabric. Weight Thickness 40 gm / m2 (Min) 0.30mm (Min)
Breaking load in longitudinal direction:
2.28 kN/m When related to pressure difference across the sample, the glass fibre fabric shall have
Porosity
porosity of not less than 0.6 mm and not more than 1.9 mm, maximum of water at an average air velocity of 61m/min (1 m/s) The fabric shall be unaffected under load in hot coal tar at 288C for 1 min. It shall not shrink lengthwise or width wise No cracking shall take place when bent over a mandrel of 3 mm radius through 90 after immersing in water for l0 to 15 min
Temperature Resistance
Pliability Test
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c)
Coal tar tape
When heated for wrapping on to the surface to be protected, the tape shall be able to withstand the tensile force employed to obtain a tightly wrapped voids free coating without tearing. The tape shall comprise of coal tar component as specified above supported on fabric as specified in fabric specification. The tape shall be thoroughly coated and completely covered on both sides with coal tar. The tape shall have sufficient pliability (flexibility) at 35C so as to unwind from the roll without dis-bonding the coal tar component from the fabric. The tape shall comply with the requirements as given below. Physical Properties of Tape Characteristic Softening point, of coal tar component, deg C Needle penetration of coal tar component at 25C/100 g / 5 s, mm Filler content, w/w percent Breaking load in the longitudinal direction for the following thickness of tape, N/mm: a) 2.0 mm b) 3.0 mm c)4.0 mm (To be measured at 20C to 30C for summer composition) Service temperature of tape Adhesion test on applied tape on steel pipe Cathodic dis-bondment test with applied tape on steel plate Solubility of coal tar based tape in petrol 50 deg C As per IS 15337 Disbonding shall not be more than 5 mm radius from the edge of the 6 mm holiday Average loss in weight shall be 5 percent maximum in 24 h shall be supplied in suitable width as agreed to Width between the manufacturer and the purchaser with tolerance of 5 mm. Thickness 4.0 mm with a tolerance of 10 percent. 1.5 kg / m2 / mm of thickness with a tolerance of 10 percent. 3 4 5 Min requirement 65 1 20 Max requirement 121 20 35
Mass
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d) Filler The characteristic of the filler used shall be as given in below. Characteristic Fineness, percent w/w, Min Loss on ignition at 800 deg C, percent, w/w, Max Min requirement 90 shall pass w/w, through mesh size of75 microns 10
7.3.4
Application of Wrapping tape a) Surface preparation
The surface of the pipe shall be thoroughly cleaned and shall be free of dirt, grease, oil rust, scale or other foreign matter. It shall also be thoroughly dried before application of primer. The pipe shall be cleaned by anyone of the following methods. a) b) Grit/shot blasting with Suitable combination of grits and" shots to obtain dense angular surface profile, and Mechanical cleaning. All the oil and grease present on the metal surface should be removed using a suitable solvent or cleaning rags before grit shot blasting or mechanical cleaning. Any other foreign matter which cannot be removed by blasting or mechanical cleaning shall be removed by other suitable means. The surfaces of the exposed base metal presenting a greyish matter appearance except that slight shadows; streaks or discolouration caused by rust stains or mild scale oxides. Blasted surfaces which rust before applying the primer coat should be again cleaned by wire brushing or emery "paper. If the rust formation is heavy, that is, if the pipes have been exposed overnight without priming, the same shall be ore-blasted once again before priming. Adequate moisture separators should be used so as to remove oil and moisture from the air supply of the blasting unit effectively. After-cleaning the pipes shall be effectively protected and maintained free from all oil, grease and dust that may fall on the pipes from outside sources till the tape is wrapped. b) Primer application
One coat of primer shall be applied on blast cleaned surface by brush or spray to achieve complete wetting of the surface as recommended by the manufacturer. In case the pipe surface is wet during application of primer the surface should be made dry. The primer shall be allowed to become touch dry prior to tape application. Primer and tape shall be supplied by the same manufacturer. If the primer coat is found to be unsatisfactory, the pipe shall be primed again.
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c)
Wrapping
Take the tape rolls out of the packing boxes and leave in the sun for at least 30 min before application. The tape can be hot applied using a suitable and compatible primer. The tape is slightly warmed on the side containing more coating compound with either a blow lamp or a gas flame to soften the coating compound. Care shall however be taken to ensure that the compound does not melt. The tape shall then be spirally wrapped while maintaining tension around the surface of the pipe. The tape shall be applied radially if the pipe diameter is large. The adhesion test shall be carried out only after minimum 72 hrs of curing time. An overlap of 12.5 mm is recommended for single wrapping. If the tape is being applied in cold weather, the surface of the pipe shall be preheated until it is warm to the touch and the traces of moisture are also removed. The primer shall then be applied and allowed to dry. If required by the user, the surface of the coated pipe can be covered up with craft paper when the pipeline is exposed for more than 5 days to in open ultra violet (UV) light (sun light). Blackness of the coated surface can be removed by the above methods which will reduce excessive heating of the coating arising out of absorption of solar radiation; particularly where sun is very strong and the coated pipe remains over ground for long.
7.3.5
Inspection and testing The following inspection and testing shall be carried out at manufacturers end / at site by the Owners representative third party inspection agency. The properties and materials shall be tested and inspected mutually decided by the owner / consultant and manufacturer. All the test and procedure shall be conformed to the IS 15337:2003 i. ii. iii. Adhesion test Holiday test Direct impact test In addition the tape shall also be subjected to the following test at least once in year iv. v. Cathodic disbonding test and Microbiological test
8.0.0
TESTING OF MATERIALS All materials shall be properly tested at the contractors expense in accordance with specification. The contractor shall supply free of cost any required specimens of materials for testing by the Engineer at any time during the manufacture of pipes and fittings.
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8.1.0
Fabrication of fittings The manufacture of fittings shall be carried out in a workman like manner by the first class labour be in all cases, be of high grade and carefully performed. Manufacturers equipment for all specials, such as welding, flamed cutting and other operations shall be of a standard and quality necessary to produce specials meeting the specification. Equipment, in general, shall be in good condition and shall be modern as judged by the standards of the industry. The longitudinal seams of fabricated specials shall be butt welded, shop girth seams shall be butt welded or lap joined welded. All edges cut to size shall be uniform and smooth. Those edges to be welded that are prepared by flame cutting, shall be free from scale and slag accumulations. Edges of plates to be jointed by an automatic welding machine shall be formed to the shape required for the particular welding process and automatic welding machine is employed in carrying out the agreed procedure. Edges of plates to be jointed by manual welding shall be formed to the shape required by the purchaser in accordance with the drawings. The resulting edges for welding shall be uniform throughout the entire length of the plate and shall be to a straight line. Minor defects in the welds of electric welded pipe such as sweats or leaks, unless otherwise specified shall be repaired at the discretion of the manufacturer with the approval of the Engineer. Repairs of this nature shall be made by completely removing the defect, cleaning the cavity and then welding. The workmanship involved in the repair is subject to approval of the Engineer. Special sections having a butting plates of different thickness shall have the heavier plate sufficiently beveled so that the apex of the weld groove shall correspond with that of the lighter plate. All lap breaking, rolling, cleaning of plate surfaces to be welded and fittings up operations, as well as the qualification of welding operators, welding procedure, automatic welding, manful welding and correction of welds in specials shall be in accordance with the relevant to IS code. Reshaping special after it is manufactured shall be done by rerolling or by pressure. Reshaping of pipe by excessive hammering or dropping shall not be permitted. Flanged pipes of varying length and diameter shall be externally coated and internally lined with mortar. Dimension of the flanges, welding details and welding procedure shall be in accordance with the relevant IS code. Flanges shall be welded to a section of the pipe before matching.
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Flanged branches shall be fabricated in accordance with the general specification and to the Employer requirements. Wall opening shall be formed by welding fabricated structural steel of approved design to the steel cylinder and shall be lined internally and coated externally. Flanged branches for air and scour valves shall be welded into pipe in the required position. The branch for an air valve shall be vertical and at right angle, to the longitudinal axis of pipe. The invert of the branch for a scour valve shall be horizontal and at right angle to the axis of pipe and shall align with the invert of the barrel of the main pipe. All flanges shall be machined to standard thickness, square to the axis of the pipe and the bolt hole shall be drilled evenly off centre and true to the pitch. Dimension of the flanges, welding details and welding procedure shall be in accordance with the relevant to IS code. Bends to provide change of alignment in main laying shall be manufactured to suit the site condition from completed and tested pipes by angle cutting the barrel or by such other standard procedure and rewelding bends shall be socket and spigot and lined internally and coated externally as given in the specification. Tapers shall be manufactured out of steel plates and lined internally and coated externally. The tapers shall be suitable for connections to the sluice valve or flanged tail piece on one side and to pre stressed concrete pipe on the other side. Stiffner rings shall be provided to afford rigidity to pipe. The walls of steel fittings including branches and scour outlets incorporated in the fittings shall be sufficiently thick to ensure that during the hydrostatic pressure test, the stress in the steel shall not exceed 75 per cent of the minimum yield point for steel, provided that, when installed under the specified surge and operating under internal pressure upto the specified working head, the stresses in the steel shall not exceed 60 per cent of the minimum yield point for the steel. Not withstanding anything said, elsewhere, the manufacturer shall furnish the thickness of the steel plate used and other relevant details and shall get the approval for these details from the Engineer, before fabrication. The weight of M.S. pipes, specials etc. shall be only without inside lining and outside coating.
9.0.0
LAYING AND JOINTING OF MS PIPES The specification for laying and jointing shall generally conform with relevant IS Code.
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The type of joints and ends of pipes shall be specified by the purchaser. The types of joints and ends recognized under this standard are: i) Plain ends or bevelled ends for butt welding unless otherwise agreed, bevelled ends shall be bevelled to an angle as mentioned in Fig.3A, 3B and Fig.4 in IS 3589, or unless otherwise specified by the engineer. The root face shall be 1.6 0.8mm. (The root face of the bevel may be prepared by hand fitting, if required.) ii) Joints with sleeves joint or swelled and plain end for welding.
Pipe with sleeve welded joints shall be supplied with the plain and parallel end and sleeve and tapered to approximately 3mm per 100mm. The ends shall be sized and gauged so as to ensure that the plain end will freely enter the sleeve and thereafter be capable of being forced home. All sleeves shall be made so that the plain end shall enter the specified minimum depth given in below table. The contractor shall take necessary action to inspect while manufacturing and ascertain that the sleeve and plain end comply with the requirements of the specification. Depth of sleeve, X and Clearance Y for welded pipes Dimensions mm 50 60 75 Clearance Y between the plain ends, mm max Designation of pipes and fittings:Pipes and fittings will be classified according to their diameter, working head and they shall be marked as shown below. 1. 2. 3. 4. 5. 6. 7. Name of manufacturer Date of manufacture Internal diameter of pipe Test pressure Permissible working head Effective length of the pipe Serial Number 1321 upto 2540 6 Outside Diameter of Pipe mm 168.3 upto 406.4 457 upto 1219 1321 upto 2540 168.3 upto 1219 Tolerance mm 6 6 6 4
Recessed markings will not be permitted
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10.0.0
INSPECTION All works and material under specification will be rigidly inspected during all phases of manufacture and testing and such inspection shall not relieve the contractor of this responsibility to furnish materials and perform work in accordance with this specification. The contractor shall notify the Engineer in charge concerned in advance of production of materials and fabrication thereof in order to arrange for mill and shop inspection. The Engineer in charge may reject any or all fittings (i) that are of the material specified, that are not fabricated in accordance with the outlined procedure and (ii) that doe not obtain the prescribed test results, condition of fittings and tolerances set forth in the relevant IS drawings and specification. The Engineer shall have free access to these parts of all plants that are concerned with the furnishing of materials of the performance of work under this specification. The contractor shall furnish the inspector reasonable facilities and space without charge for inspection, testing and obtaining of any information he desires in respect of the character of material used and progress and manner of the work. Inspection of Coating The entire procedure of applying the protective coatings will be rigidly inspected from the time the bare fittings are fabricated until the fittings are coated and tested. If any time it is found that the procedure of applying the coating materials is not in accordance with relevant specification, all such coatings shall be rejected. Samples of coating materials will be collected at random and tested and if any sample is not found to conform to the specifications, fittings coated with such materials will be rejected.
11.0.0
TESTING OF PIPE LINE Each valved section of the pipe shall be slowly filled with clean water and all air shall be expelled from the pipe line through hydrants, air valves and blow-offs fixed on the pipeline. Before starting the pressure test, the expansion joints should be tightened.
11.1.0
Pressure Test The field test pressure to be imposed should be not less than the greatest of the following a. b. c. 1 time the maximum sustained operating pressure. 1 time the maximum pipeline static pressure, and sum of the maximum static pressure and surge pressure subject to the test pressure.
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Where the field test pressure is less than two-thirds the test pressure, the period of test should be at least 24 hours. The test pressure shall be gradually raised at the rate of nearly 0.1 N/mm2 per minute. If the test pressure measurements are not made at the lowest point of the section, an allowance should be made for the static head between the lowest point and the point of measurement to ensure that the maximum pressure is not exceeded at the lowest point. If a drop in pressure occurs, the quantity of water added in order to re-establish the test pressure should be carefully measured. This should not exceed 0.1 litre per mm of pipe dia per km of pipeline per day for each 30 m head of pressure applied. Where the pipe line is tested in section, two or more welded joints at each gap may not get tested under pressure. Special care should be taken in making these welds and these joints should be kept under observation during the commissioning of the system
11.2.0
Pressurization Each valved section of pipe shall be filled with water slowly and the specified test pressure, based on the elevation of lowest point of the linear section under lest and corrected to the elevation of the test gauge, shall be applied by means of a pump connected in to the pipe in a manner satisfactory to the Engineer in charge. Under the test pressure no leak or sweating shall be visible at all section of pipes, fittings, valves, and welded joints. Any defective pipes, fittings, valves discovered in consequence of this pressure test shall be removed and replaced by sound material and the test shall be repeated until satisfactory of the Engineer in charge.
12.0.0
SURGE PROTECTION SYSTEM AND SURGE ANALYSIS The Contractor shall carry out comprehensive steady state hydraulic analysis and pressure (transient) surge analysis on the complete pumping system at the pumping stations and along the pipelines under all operating conditions. The surge analysis shall be undertaken by independent specialist using a proven computer programme. The surge analysis shall identify the most adverse transient operational conditions. The analyses shall include but not be limited to the following conditions: Complete power failure to the pumping station with all duty pumps running at maximum capacity. Start up of the pumps under the specified control system Shut down of the pumps under the specified control system
o o
Mechanical Items
In addition to the delivery pipeline the surge analysis shall include consideration of the length of pipeline(s) between the pumping stations and the pressure vessel(s), and the suction condition(s). The objective of the surge analysis is to recommend surge protection equipment which ensures maximum and minimum pressures under all conditions within the allowable surge rating of the pipelines as indicated below Maximum pressures shall not exceed the capabilities of the pipes and fittings on the system. Minimum pressures in the system shall not fall below atmospheric pressure and subsequently rise above atmospheric pressures again during the same transient event. Pressures below atmospheric pressure will only be permitted as the systems drain down through supply connections during extended periods of pump shutdown. The recommended solutions should include sensitivity checks to show that it is still valid with possible variations in system parameters such as wave speed, friction factor and system demands. The solution should include but not be limited to the following recommendations: Size and details for delivery air pressure vessel (Surge Vessel) Details for controlling the air volume in the above vessels Details and alarms for monitoring the air volume in the above vessel. Recommendations for controlling slam on the pump delivery non-return valve that may adversely affect the lifetime or operation of the valve and the system.
The Contractor shall however determine the actual required capacity during detailed engineering, according to the transient surge analysis. In addition to surge vessels of total capacity stipulated above, the Contractor shall install at least one standby surge vessel of the same type and size as the proposed ones. Such surge vessel shall provide stand by capacity in a case of releasing one of duty vessel for maintenance. The Contractor shall furnish the surge analysis report to Engineer for approval. The report shall include computer printouts and graphs showing maximum and minimum pressure envelopes. The report shall also include time-flow and time pressure plots at critical points. Surge protection may be by pressure vessel or feed tank, but flywheels to add to the pump rotating inertia shall not be used. Surge Vessels shall be compressed air type, designed, constructed, installed and tested as detailed elsewhere in the Specification. Surge vessel(s) shall be installed near, as practically possible, to the pumping station.
Mechanical Items
13.0.0 13.1.0
ONSHORE BURIED PIPING WORKS Scope of work This specification covers the requirements in respect of materials, workmanship quality for supply, fabrication, inspection, testing, and laying of onshore buried pipes.
13.2.0
General The Contractor shall provide all labour, materials, plant, equipments, temporary works, constructional plant, fuel supply, transportation and all miscellaneous items all in strict accordance with the specifications. The nature of work shall generally include clearing, grading, stripping / marking, excavation, backfilling, disposal, dewatering, road & drain cutting, rectification of damaged structure due to excavation, laying of RCC hume pipe or culvert under road railway track, canal / drains etc. as the case may be. Crossings shall be made by open cut excavation. However, steel-cased boring if permitted, shall be made below existing canals, rail crossing and for highway over bridge wherever required. Contractor shall restore original ground profile and include all concreting reinforcement, formwork, erection of miscellaneous steel (i.e. steel inserts, bolts etc.) if required, to erect the pipe, all crossings and bends, pockets and all other miscellaneous items required to complete the work including the requirement of right of way and access thereto, restoration of work areas etc. The Bidder shall inspect and examine the sites and its surroundings and shall satisfy himself before submitting his tender as to the nature of ground and subsoil and nature of the site, the quantities and nature of work and material necessary for the completion of the works and the means of access to the site, the accommodation he may require and in general shall himself obtain all necessary information as to risks, contingencies and other circumstances which may influence or affect his tender. No extra changes consequent on any misunderstanding or otherwise shall be allowed. The Bidder is advised to get himself fully acquainted with the site conditions, approach to work site, etc. before submitting his bid. Owner shall not provide any approach to work site and the same has to be arranged by the Contractor at his own cost. The Contractor is required to perform his construction activity within the width of acquired land set aside for construction of pipeline or within the right-of-way area as decided by the Owner. The pipeline shall be buried either in the embankment or shall be buried in the natural ground. Areas for laying the pipeline may be available in segments and Contractor has to cater the same without any extra cost.
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The tender drawings provide a general idea about the work to be performed under the scope of this contract. These are preliminary drawings for bidding purposes only and are by no means the final drawing or show the full range of the work under the scope. Work has to be executed according to the drawings prepared by the Bidder and approved by Engineer. 13.3.0 Construction requirement and access to work areas The Contractor shall notify to the Engineer well in advance during work progress, the method of construction for crossing road, pipeline, cable, railway, canals and other existing obstacles. The Contractor shall not commence work on such crossings before having obtained approval from the authorities and land Owners concerned to the satisfaction of the Engineer. The work at crossings shall meet, at all times, requirements and conditions of the permit issued by the Authorities concerned. In the absence of any specific requirements by Authorities, Contractor shall comply with Engineers instructions. Where the work area comes within the area of influence of high voltage electrical installations, the Contractor shall propose and provide adequate safety measures for all personnel working. No work is allowed in such areas without the Engineers prior approval. 13.4.0 Work areas - Reference marker The Contractor shall also establish all required lines and grades necessary to complete the work and shall be responsible for the accuracy of such lines and grades. Prior to clearing operations the Contractor shall : 1. 2. 3. Install Bench Marks, Intersection Points and other required survey pillars. Markers in the centreline of the pipeline at distances of maximum 100 m for straight line sections and maximum 10 m for horizontal bends. Set out a reference line with respect to pipeline centreline at a convenient location. Markers on reference line shall be at a distance of maximum 100 m for straight-line sections and maximum 10 m for horizontal bends.
13.5.0
Clearing and Grading Any obstacle, which may hinder the construction and laying of the pipeline along the pipeline route, shall be removed. All stumps, if met with, shall be removed for a continuous strip, with a width equal to trench top with plus two m on either side, centered on the pipeline centerline. All stumps, timber, bush, undergrowth and roots cut / removed from the work area shall be disposed of in a manner and method satisfactory to Engineer, and Government Authorities having jurisdiction. In no case shall it be left to interfere with the grading and laying operations.
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Whenever stumps are removed and a hole is left in the ground, Contractor shall back-fill the hole and compact it to prevent water from gathering in it and making a big hole. The Contractor shall grade the pipeline work area as required for proper installation of the pipeline, for providing access to the pipeline during construction, and for ensuring that the pipeline is constructed in accordance with the latest Engineering and construction practices. The Contractor shall grade sharp points, to allow the pipe to be bent and laid within the limits set forth in these specifications, and shall drill or excavate any rock or other material which cannot be graded off with ordinary grading equipment in order to make an adequate working space along the pipeline. No temporary / permanent deposit of any kind of material resulting from clearing and grading shall be permitted in the approach to roads, railways, streams, ditches, drainage ditches and any other position which may hinder the passage and / on the natural water drainage. In the case of natural or artificial deposits of loose soil, sand, heaps of earth, or other fill materials, these shall be removed till stable natural ground level is reached so as to ensure the construction of the pipeline trench in stable ground. Wherever the pipeline work area runs across, through or alongside farmyards, built-up areas, groups of trees, groves, horticultural spreads, gardens, grass-field, ditches, dikes, roads, paths, railways or any other area with restrictions of some kind, the Contractor shall work with all caution necessary for digging the pipeline trench and constructing the pipeline. In the said places the Contractor shall carry out the works in such a way that damage resulting from the pipeline construction is kept to a minimum. Provision of Detours The Contractor shall make all necessary arrangements to permit the passage of its men and equipment. It is understood that the Contractor has recognised restrictive features of the work area and shall provide the necessary detours and execute the works without any extra cost of Owner. Public travel shall not be inconvenienced nor shall it be wholly obstructed at any point. The Contractor, at his own cost, shall furnish and maintain watchman, detours, lanterns, traffic lights, barricades, signs, wherever necessary to fully protect the public. The Contractor shall be responsible for moving his equipment and men across or around watercourses. This may require the construction of temporary bridges or culverts. Temporary bridging or access, if required for crossing watercourses, shall be constructed. The Contractor shall ensure that such temporary works shall not interfere with normal water flow, avoid
Mechanical Items
overflows, keep the existing morphology unchanged and shall not unduly damage the banks of water courses. No public ditches or drains or canals shall be filled or bridged for passage of equipment until the Contractor has secured written approval of the authorities having jurisdiction over the same. The Contractor shall furnish a copy of such approval.
Work Area Damages The Contractor shall confine all his operations within limits of the work area. Any damage to property within and outside the work area shall be restored or settled at the Contractor expenses. The Contractor shall promptly settle all damage claims. Should the Contractor fail to do so, the Owner shall give written notice to the Contractor and if the Contractor does not settle such claims within seven days after such notice, the Owner shall have the authority to settle claims from the account of the Contractor. 13.6.0 13.6.1 Pipe line trench Location Contractor shall excavate and maintain the pipeline trench on the centreline of the pipeline taking into account the curves of the pipeline. The free working space shall conform to IS:5822. Generally it shall not be less than 150 mm on either side or one third of diameter of the pipe flange whichever is greater. Irrespective of the diameter of pipes for all trenches deeper than 90 cm, the minimum width shall be 75 cm. The trench shall be excavated so as to provide minimum cover of 1000 mm between the top of the pipe and finished grade, or as shown in approved drawings. In steep slope areas before commencing the works, proper barriers or other protection shall be provided to prevent the removed materials from rolling down slope. On slopes wherever there is danger of landside, the pipeline trench shall maintained open only for the time strictly necessary. In certain slope sections before the trench cuts through the water tables, proper drainage shall be ensured both near and trench and the work area in order to guarantee soil stability. All sewers drain, ditches and other natural waterways involved in the execution of the works shall be maintained open and functional. The same applies to canals, irrigation canals, pipe
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lines and buried facilities crossed by the trench for which temporary pipelines shall be laid, if required, and proper temporary installations provided.
13.6.2
Extra Depth and Clearance At points where the contour of the earth may require extra depth to fit the minimum radius of the bend as specified, or to eliminate unnecessary bending of the pipe according to customary good pipeline practice, or where a deep trench is required at the approaches to crossings of roadways, rail rails, rivers, streams, drainage ditches, and the like, the Contractor shall excavate such additional depth as may be necessary. The Contractor shall excavate to additional depth where the pipeline approaches and crosses other pipelines, sewers, drain pipes, water mains, telephone conduits, and other underground structures, so that the pipeline may be laid with at least 50 cm free clearance from the obstacle, or such greater minimum clear distances as may be required by Authorities having jurisdiction. Where the pipeline crosses areas, which specifically require greater than normal depths of cover, the trench shall be excavated to extra depth in accordance with the Right-of-Way Agreements or as required. Where rock or boulders are encountered, the trench shall be trimmed to a depth of at least 100mm below the level at which the bottom of the barrel of the pipe is to be laid and filled with sand of adequate depth to give the curved seating.
13.6.3
Grades, Bends and Finish of Trench The trench shall be cut to a grade that shall provide a firm, uniform and continuous support for the pipe. Bends shall be made in the pipe at significant changes in grade of the trench. The Owner reserves the right to set the grade of the trench and locate the bends if so desired, in which case the Contractor shall excavate, at no extra cost, the trench and bend the pipe to such a grade. Number of field bends to lay the pipe to conform to the general contour of the ground and maintain a normal cover shall be kept to a minimum. This can be accomplished by cutting the trench slightly deeper at the crest of ridges and by gradually deepening the trench in approaches to crossings.
13.6.4
Encroachments and working near other utilities In locations, where pipelines have to be laid in the body of a road, canal, dyke, etc. or other locations under jurisdiction of Government / Public Bodies, the Contractor shall perform such work without extra compensation, according to the requirement of concerned Authorities. When it becomes necessary that the Contractor has to resort to hand digging, well point dewatering, sheet piling or any other special construction method in these areas, no extra compensation
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shall be paid. Contractor shall contact the Authorities concerned in order to become familiar with their requirements. In locations, where the pipeline has to be laid more or less parallel to existing pipeline, cable and / or other utilities in the work areas, the Contractor shall perform the work to the satisfaction of the Owner / Authority of the existing pipeline cable / utility. In such locations the Contractor shall perform work in such a way that even under the weather and flooding conditions, the existing pipeline/utilities shall remain stable and shall neither become undermined nor have the tendency to slide towards the trench. Contractor shall be liable for any damage occurring to other pipelines, underground structures / utilities. 13.6.5 Protection of Trench The Contractor shall keep the trench in good condition until the pipe is laid, and no claim is to be made to the Owner for reasons of its caving either before or after pipe is laid. All timber, sheet-piling jacks or other materials that may be necessary to shore the trench, in order to prevent caving are to be furnished and removed by the Contractor. The Contractor shall dewater, if necessary, using well point system or other suitable systems, shore or do as required excavating the trench, installing the pipe in it and backfill the trench in accordance with these specifications at no extra cost to Owner.
13.6.5.1 Protection of underground utilities and special methods The Contractor shall obtain plans and full details of all existing and planned underground services from the relevant Local Authorities /Owner and shall follow these plans closely at all times during the performance of work. The Contractor shall be responsible for location and protection of all underground lines and structures. Temporary under-pinning or any other type of supports and protective devices necessary to keep the interfering structure intact shall be provided by the Contractor at his own cost and shall be of such design as to ensure against their possible failure. Despite all precautions, should any damage to any structure / utility etc. occur, the Owner / Authority concerned shall be contacted by the Contractor and repair shall forthwith be carried out by the Contractor at his expense under the direction and to the satisfaction of Engineer, the concerned Owner / Authority. If the Contractor fails to repair the same in reasonable time, the Owner reserves the right to have the repair executed at the cost of the Contractor.
Mechanical Items
13.7.0
Backfilling Backfilling with the excavated material shall be done in suitable layers of 200 mm, well watered and rammed to avoid any setting afterwards. Each layer shall be consolidated to a density equal to 90% of the standard proctor density or greater as determined by relevant IS Code or equivalent standards. Backfilling shall be done by excavated earth. The backfilling material shall be free from stone, concrete etc. Backfilling shall not be done until the pipe and appurtenances have the proper fit and the pipe is following the trench profile at the required depth. Backfilling of trench in watercourses shall be carried out as per the relevant specifications. Backfilling shall be carried out immediately after the pipeline has been laid the trench, inspected and approved by the Engineer, so as to provide a nature anchorage for the pipeline, thus avoiding long exposure of coating to high temperature, damaging actions of adverse weather conditions, sliding down of trench sides and pipe movement in the trench. In general, the trench shall be dry during backfilling. The surplus material shall be neatly crowned directly over the trench and the adjacent excavated areas on both sides of the trench to such a height, which shall, in the opinion of the Engineer, provide adequately for future settlement of the trench backfill during the maintenance period and thereafter. Surplus material, left from this operation shall be disposed off to the satisfaction of Engineer beyond the work area to a place suitably identified by the Contractor himself at no extra cost to the Owner. Where gravel, lumps of hard soil or like materials are encountered at the time of trench excavation, sufficient earth, sand or select backfill materials shall be placed around and over the pipe to form a protective cushion extending at least to a height of 150 mm above the top of the pipe, Select backfill materials for padding that are acceptable to Engineer shall be soil, sand clay or other material containing no gravel, or lumps of hard soil. Engineer shall direct whether such padding material would be taken from elsewhere. All these works shall be carried out by the Contractor at no extra cost to Owner. When the trench has been dug through driveways or roads, all backfills shall be executed with sand or a suitable material as approved by the Engineer and shall be thoroughly compacted. In certain case, special compaction methods, such as moistening or ramming of the backfill in layers may be required by the Engineer. Any public or private authority having jurisdiction over a road, street or drive way may require that the surface of the backfill be graveled with crushed rock or some other purchased material and the road shall be repaved. In such instances, the Contractor shall comply with said requirement at no extra cost to Owner.
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Mechanical Items
Trenches excavated in embankments which is the property of railways or which are parts of main roads shall be graded and backfilled in their original profile and condition. If necessary, new and / or special backfill materials shall be supplied. The materials required may include gravel, special stabilization materials or stabilized mixtures. However, special processing and / or compacting methods shall require the approval of Engineer and / or competent authorities. At the end of each days work, backfilling shall not be more than 500 m behind the head end of lowered-in-pipe, which has been padded and approved for backfill. The backfill shall be maintained against washouts etc., until the completion and final acceptance of the work by Engineer. The Contractor shall furnish materials and install breakers in the trench in steep areas (slope generally 10% and more) for the purpose of preventing erosion of the backfill. The type of breakers installed shall be as per the approved drawing. Breakers shall be constructed of grout bags filled with a mixture of 4:1 (sand : cement) at the Engineers direction. The Contractor may purpose other method such as foam dams etc., which shall be subject to approval by the Engineer. Such work shall be at no extra cost to the Owner. When backfilling the trenches, the sloping terrains or steep areas, where in the opinion of the Engineer the backfill may be washed out of the trench, sheet piling or other effective water breakers across the trench shall be provided. This is to divert the flow of water away from the trench into normal drainage followed before laying of the pipeline. In no case, the water is to be drained via the trench or via channels other than those followed before the line was laid. The Contractor shall leave the pipe uncovered at certain locations to allow the Engineer to survey the centerline of the pipe and the level of the pipeline in the backfilled trench. Temporary markers shall be installed during backfilling to locate the pipeline axis. markers shall then the replaced with permanent pipeline markers. 13.8.0 Permanent markers Permanent pipe line markers made of concrete (of grade M20) shall be installed at every 1.0 km and at every bend / turning point. The markers shall be 500 mm wide and 75 mm thick and shall project 1200 mm above ground level the marker shall be grouted in 1:4:8 cement concrete mixture to correct line, level and direction all-along the pipe line. The work also includes necessary excavation for grouting of marker, cleaning, painting etc. The Contractor shall furnish drawing of marker to the Engineer for his approval before installation of the same. The mark shall show name of the Owner, chainage of pipeline, invert level of pipe, direction of flow, etc. These
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Mechanical Items
13.9.0
Clean-up and Restoration of work areas The Contractor shall restore the work areas and all sites used for the construction pipelines, water crossings and other structures in accordance with the instructions of the Engineer.
13.9.1
Disposal All surplus and defective materials supplied by the Contractor and all trash, refuse and spoiled materials shall be collected and disposed off by the Contractor. The work areas shall be cleared of all rubbish, broken skids, empty cans, cardboard, sacks, stumps, trash, and leftover construction material. All burnable matter shall be burned, but only after obtaining appropriate permits for such burning. If burning is not allowed, the Contractor shall haul the clean-up material to an approved dumping area. All scrap metal and unburnable material shall be disposed off, in an appropriate manner, but never be buried in the work areas. Surplus soil can be removed from the Owners plot only after authorisation by Engineer. All dumping fees connected with the disposal of materials shall be to the account of the Contractor. All loose stones and rock exposed by the construction operations and scattered over the work areas or adjacent ground shall be removed and transported to a location considered suitable by the Land Owner and / or Tenant, or by authorities having jurisdiction, for satisfactory disposal. For gravel or other hard material, which may be buried in the trench, the provisions of the specifications shall apply with the understanding that the use of the land by the landowner and / or tenant shall not be interfered with.
13.9.2
Temporary Structures All auxiliary structure such as bridges, culverts, sheet piling, posts, signs etc., which were erected or installed by Bidder as temporary measure, shall be removed.
13.9.3
Repair of Damages Damages to roads, bridges, and private property shall be repaired by the Contractor. All fences and other structures, which are damaged during construction, shall be restored to original condition. Slopes, watercourse sides or banks, which have been partially or totally demolished during the execution of the works, shall be properly consolidated and restored without waiting for their naturals consolidation and settling.
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Mechanical Items
All boundary stones, which have been moved or removed during the work, must be reset in their original location to the specification of the Land Owner concerned. On completion of clean up, the work areas shall be restored to such stable and usable condition as may be reasonably consistent with the condition of the work areas prior to laying the pipeline. The Owner shall be completely indemnified and held harmless by the Contractor from any and against all claims, demands, losses, expense etc. that may arise on this behalf. The Engineer may require from the Contractor signed releases from Land Owners regarding satisfactory indemnification and restoration of their lands. If, in the opinion of the Engineer, the sod in pasture land has been damaged by vehicles and wheel tracks are visible, the work areas shall be tilled with a dise-harrow or rotary cultivator several times. The damaged sod shall be firmly cut up and thoroughly mixed through the topsoil. In general, the work areas have also to be ripped. After this procedure no closed-in layers must be found and sufficiently loose topsoil 25 to 30 cm thick must be present. The whole procedure must be approved by the Engineer. Subsequently, the entire work areas, which are part of pastureland, shall be prepared for seeding and fertilized according to the instructions of the Engineer. A sapling of any plant / free uprooted or cut during construction shall be planned along the route as per the direction of the Engineer and in accordance with the forest preservation Act, 1981. The cost of sapling and its plantation shall be to the Contractors account.
13.10.0
Cutting and removal of paving / Water Bound Macadam road Whenever it is permitted by Authorities and / or Owner to open cut a paved / WBM road crossing, or where the line is routed within the road pavement, the Contractor shall remove the paving in accordance with the restrictions and requirements of the authorities having jurisdiction there of or as directed by the Engineer. After laying the pipeline, backfilling shall be immediately performed and all the area connected with the works shall be restored. Throughout the period of execution of such works, the Contractor shall provide and use warning signs, traffic lights or lanterns, barricades, fencing, watchman etc. as required by the local authorities having jurisdiction and / or Owner. For all roads, paths, walkways etc. which are open-cut, the Contractor shall provide temporary diversions properly constructed to allow the passage of normal traffic with the minimum of inconvenience and interruptions. The paving / WBM shall be restored to its original condition after the pipeline is installed.
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Mechanical Items
13.11.0
Minor Water Course Crossings For Minor water crossings a standard drawing shall be prepared by the Contractor or a separate detailed approved drawing for individual crossing shall be prepared for approval of the Owner. Whenever minor water crossings in the work area are to be crossed, the Contractor shall install temporary bridges and comply with provisions as laid down in this specification. In crossings of water courses with either moderate flow rate or of torrential nature with marked and unpredictable flooding, adequate survey shall be carried out before starting the work with the object of determining what precautions are necessary and the most favourable period for executing the work. In case of crossing of watercourses for which no special methods of laying are required, a pipe section of a suitable size as per the approved drawings shall be assembled and subsequently laid.
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Mechanical Items
3.6 1.0.0
AIR CONDITIONING & VENTILATION SYSTEM GENERAL This section is intended to cover Technical specification for Air conditioning & Ventilation system. The specified items shall be designed, engineered, manufactured, inspected, shop tested, erected at site, tested and commissioned to well establish engineering practices, safety codes and other relevant codes and standards. Compliance with this specification shall not relieve the Bidder of the responsibility of furnishing material and workmanship to meet the specified conditions.
2.0.0 2.1.0
SYSTEM DESCRIPTION Split type air conditioning system The control room in the intake well shall be air conditioned using split type air conditioning system.
2.2.0
Supply Ventilation system Switch gear room Fresh air is supplied through a wall mounted fan-filter unit comprising of tube axial fan, intake louver, cowl, bird screen, short ducting and pre filters, complete with supports and hardware. The air from the room shall be exhausted through gravity dampers.
2.3.0
Simple exhaust ventilation system Pump Room & Toilet The above room shall be provided with wall mounted axial flow exhaust fans complete with drive motor, cowl with bird screen and gravity dampers. Fresh air to the above areas shall be provided through wall/ door mounted intake louvers or through infiltration.
3.0.0 3.1.0
EQUIPMENT DESCRIPTION Split Type Air-Conditioning System The major component of split type airconditioner system is: i) Indoor unit comprising of: DX -Cooling coil Blower Coarse filter ii) Outdoor unit comprising of: Compressor Condenser.
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Mechanical Items
DX Dehumidifying & coil unit: The DX coil shall be standard staggered tube arrangement with seamless copper tube and aluminium plate fin mechanically bonded to copper shall be sized with following specification: Face velocity Tube OD minimum Wall thickness Blower Coarse Filter : : : : : 2.5 m/sec 10mm 0.5mm The Blower shall be DIDW forward curved belt driven fan of suitable capacity and static pressure. Coarse filter shall be washable dry panel filter having an efficiency of 90 % down to 20 microns and suitable for handling the units air quantity The compressor of split unit shall be Scroll type compressor (of R22). Condensers shall be fin-tube type seamless copper tubes and aluminium plate fin mechanically bonded to copper and shall be sized with following specification: 2.5 m/sec 10mm 0.5mm
Compressor Condenser
: :
Face velocity Tube OD minimum Wall thickness
: : :
The Condenser fan shall be of high efficiency propeller type 3.2.0 Axial fan The Axial fan shall be designed for: a. b. Fan type : Tube Axial / Propeller. The speed of the fans shall be 1500 rpm for impeller diameter 450 mm or less and 1000 rpm for impeller diameter above 450 mm. Each Axial fan comprises of fan, fan motor, inlet and outlet cone (for Tube axial), filters (supply air fans), cowl with bird screen, gravity dampers (exhaust fan), grouting frame, cadmium plated fixed bolts and supporting arrangement. The wall mounted supply air fan shall be of axial flow type with cast aluminium impellers with blades of aerofoil design The fan unit shall be complete with air filters and casing shall be of galvanized sheet steel construction. The wall mounted exhaust fan shall be of axial flow type with cast aluminium impellers with blades of aerofoil design. The fan shall be directly driven through three phase induction motor. Wall mounted exhaust fans for toilets shall be propeller type and driven by single phase motor.
Mechanical Items
Pre Filter The pre-filter section shall be washable HDPE filter panels suitably arranged in holding GSS frames having a minimum efficiency of 90% down to 10 micron size and velocity across the filters shall not be more than 2.5m/s.The pressure drop across the filter shall be restricted to 5 mm of wg in clean condition and 7.5 mm of wg at dirty conditions 3.3.0 Louvers with bird screen The louvers shall consist of parallel metallic blades. For louvers, the minimum projected width of blades in horizontal plane shall be 150mm with the blades inclined at minimum 35 degrees. Design face velocity for louvers is 2.5 m/s. Bird screen of 10 sq.mm and minimum 16 G wire mesh is provided on the outer face of Louvers. 3.4.0 Supply Air Filters The pre-filter shall be washable type filter panels suitably arranged in holding frames having a minimum efficiency of 90% down to 10 micron size.
4.0.0 4.1.0
FIRE SAFETY Ventilation system The following fire safety measures are provided. a. b. c. d. Quartzoid type fire dampers are provided at suitable locations on the ventilation ducts to prevent spread of fire : Quartzoid type fire dampers are provided at the inlet of exhaust fans, Suitable interlocks are to be provided for tripping of supply air fans, exhaust fans in the event of fire. Individual areas shall be isolated from fire by fire dampers located in the ducts (beside walls/ ceilings).
4.2.0
Air Conditioned Areas The split ACs fans shall be interlocked with fire detection systems, so as to be tripped in case of fire.
4.3.0
Fire Dampers & Fire stops / Barriers All fire dampers (Quartzoid link operated types) shall be rated and qualified for one and half hour fire rating as per UL-555. Fire dampers shall be made from inherently corrosion resistant material or otherwise protected to inhibit corrosion. Fire dampers are to close automatically after sensing fire in an area/ fire zone. Fire stops/ Fire Barriers shall be provided by Contractor in the annular space around all the fire-damper installation in walls/floors. The Contractor shall supply
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Mechanical Items
and erect the fire-barriers along with all accessories complete in all respect, of fire rating suit to building fire rating, so that in case of fire in a location it does not spread to other areas. All materials pertaining to fire barrier/ stop shall be of high quality, gas and smoke tight besides being efficient fire seal and shall also be compatible with GI duct penetration/ steel plate etc. Cement type fire protection compound with high strength and adhesion shall be used for firestop/ barrier. Fire protection compound shall be non-toxic, non-shrinking, weather proof and water resistant type. The same shall be suitable for application, mixed with water, in vertical as well as horizontal openings. It shall also permit installation by pump, trowel or hand packing without any formwork in vertical plane. Application temperature of water mixed fire protection compound shall be preferably at room ambient.
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Mechanical Items
ANNEX - 6.1 SPECIFIED DESIGN DATA AIR CONDITIONING & VENTILATION SYSTEM 1.0 Split type air conditioners Description Areas Served Capacity Quantity Type Indoor unit Cooling coil Fan type Filters Filter media Efficiency Outdoor unit Condenser coil Compressor Fan type 2.0 Axial flow fans Description Axial Flow Fans Areas Served Capacity Quantity Type Areas Served Capacity Quantity Type Areas Served Capacity Quantity Type General
Unit Control Room TR 3 2 Nos. (1W + 1S) Air cooled type Internally Centrifugal grooved
Data
copper
tubing
with
aluminium fins
Non Woven synthetic type, washable 90% down to 20 microns Copper coil with aluminium fins Semi/Hermetically sealed Scroll Propeller
Unit
Data
Pump house 13000 CMH 3 Nos. (3W) (Bidder Shall confirm) Wall mounted tube axial exhaust fans Switch Gear & Control Room 3000 CMH 3 Nos. (3W) (Bidder Shall confirm) Wall mounted tube axial supply fans along with filters Toilet at SG & Control Room 1000 CMH 1 Nos. (1W) Wall mounted propeller exhaust fan
Mechanical Items
Description Casing Material Casing Thickness Impeller Shaft Inlet Cone / Outlet cone Hub Support frame and structure Neoprene rubber pads Bird screen Rain Protection cowl Mounting flange on casing Critical Speed
Unit
Data MS Sheet with spray galvanization Thickness 3.0 mm for fan dia upto 750 mm, Thickness 5.0 mm for fan dia above 750 mm Cast Aluminium, made in a single piece EN8 Galvanized Mild steel Al Alloy M.S of adequate thickness (Galvanized) IS2062. As Required Min 16 SWG Galvanized wire mesh Galvanized after fabrication from MS At inlet and outlet The first critical speed of rotating assembly be at least 25% above the operating speed
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Mechanical Items
JHABUA POWER LIMITED 1 X 600 MW + 1X 660 MW JPL SEONI Project Specification for River Water Intake System
SECTION 4 DETAILED TECHNICAL SPECIFICATION ELECTRICAL
Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume-II Detailed Technical Specification
Section-4
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Technical Specification - Electrical
TABLE OF CONTENTS CLAUSE NO. DESCRIPTION PAGE NO.
SECTION 4.1 GENERAL .................................................................................................................. 3 SECTION 4.2 HT SWITCHGEAR...................................................................................................... 9 SECTION 4.3 - TRANSFORMERS ..................................................................................................... 16 SECTION 4.4 LT SWITCHGEAR ..................................................................................................... 21 SECTION 4.5 MOTORS ................................................................................................................... 30 SECTION 4.6 MOTOR ACTUATORS .............................................................................................. 35 SECTION 4.7 220V DC SYSTEM .................................................................................................... 38 SECTION 4.8 UPS SYSTEM ........................................................................................................... 42 SECTION 4.9 POWER AND CONTROL CABLES ........................................................................... 45 SECTION 4.10 CABLING, EARTHING & LIGHTNING PROTECTION SYSTEM ............................. 48 SECTION 4.11 LIGHTING SYSTEM ................................................................................................. 53 SECTION 4.12 ELECTRICALS FOR EOT CRANE ........................................................................... 58 SECTION 4.13 HT CAPACITOR BANK ............................................................................................ 62 SECTION 4.14 11KV TRANSMISSION LINES ................................................................................. 64 SECTION 4.15 ERECTION, TESTING & COMMISSIONING OF ELECTRICAL SYSTEM............... 78
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SECTION 4.1 GENERAL 1.0.0 INTRODUCTION This specification covers the design, manufacture, assembly, testing at manufacturer's works, packing, transportation to site including unloading, storage at site, erection, testing & commissioning of electrical equipment including the following complete with all accessories for efficient and trouble-free operation of River water intake system. a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s) t) u) v) w) x) y) 11kV Switchgear. 2 Nos. Service Transformers (11/0.433 kV) LT Switchgear. 11kV Isolator 11 kV capacitor banks Soft starter for 11 kV motors (if required) Local push button stations. HT & LT Motors Electrical Actuators. 220 V DC Battery, Charger & DCDB along with 1x100% Lead Acid Plante Battery for PLC & HMI equipment 240 V AC UPS & UPS DB. 11 kV power cables with all accessories shall be laid along the pipeline running over a length of 5.5kms, comprising of 3km forest area & 2.5 Km approach bridge. 11 kV double circuit transmission line with all accessories for a balance reach of 6.5Kms. Power and Control Cables. Illumination system complete with Lighting panels, Lighting fixtures, lighting poles, receptacles, conduits, wires, switch boxes etc. Cabling system complete with cable trays, supports, conduits, glands, lugs etc. Installation of all the interconnecting cables (HT, LT & Control cables) between the equipments supplied by the Bidder. Fire sealing system for cable penetrations. Earthing system including buried earth mat and above ground earthing. Lightning protection system. Rubber mats, First aid box, Danger plate, etc. Erection components, Tools, Tackles, hardware, etc. Erection & Commissioning spares O&M spares. Any other electrical equipment and accessories required to complete the River water intake System.
2.0.0 2.1.0
GENERAL REQUIREMENTS Power Supply To feed Raw Water Supply System auxiliaries, 2 nos. 11 kV feeders will be provided from Main Plant Switchgear. The 2 nos. of 11kV cables from the main plant to plant boundary will be by owner .From Power plant boundary 11KV power cables (by bidder) shall be laid along the pipeline running over a length of 5.5kms, comprising of 3km forest area & 2.5 Km approach bridge along with the accessories and11KV double circuit transmission line for the reach of 6.5 Kms.11kv Isolators and 11 kV breakers shall be provided at receiving end at river water pump house. 2 nos. Service Transformers (11/0.433kV), each rated to feed 100% power
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of complete river water system, shall be provided to step down the voltage level to 0.433 kV. The 11 kV Switchgear shall comprise 2 incomers, one bus coupler and required no. of outgoing motors feeders, service transformer feeder etc,. Motors rated less than 200 KW shall be connected to 415V system and motors rated >1500 kW shall be connected to 11 kV system. 415 V motors rated > 125 KW shall be controlled by breakers. Motors rated <125 KW will be controlled by contactors. All motors shall have direct on line starter. Soft starters can be considered if required. 125kW and above capacity motors shall to be fed by ACBs at 415V level. Less than 125kW capacity motors shall be fed by MCCBs and contactors. 11 kV Motors shall be controlled by Breakers. Capacitor bank shall be provided to improve power factor to 0.95. Power supply arrangement is shown in enclosed drawing titled Electrical key single line diagram (Drg. No. 00-3109142-E-107). 2.1.1 For essential loads such as Control Supply to Switchgears / Panels, Emergency DC lighting etc, 220 V DC supply is envisaged backed by DC Batteries. The 220V DC Power Supply System consists of redundant 220V Sealed Maintenance Free (SMF) lead acid batteries & redundant 220V float cum boost chargers which will be connected to 220V DCDB. To provide uninterrupted power supply to RWPH PLC and other Control Panels, 240 V AC redundant UPS system is envisaged. UPS system shall be of parallel redundant with static bypass consisting of 2x100% inverters, Static bypass and Maintenance bypass switches. UPS shall derive supply 1 x 100% lead acid plante battery Codes & Standards The electrical system and equipment shall conform to the relevant Indian Standards (IS)/International standards and code of practices and as well as Indian Electricity rules and guidelines issued by CBIP as per the latest revision / update. All equipment supplied and all work done including system design and detailed engineering shall also comply with the statutory requirements of the Government of India, Regulations laid by the office of the Chief Electrical Inspector of the State and Indian Electricity Rules. Power supply voltage Motors rated upto to 0.75kW Motors rated from 0.75kW to 200kW Motors rated from 200kW to 1500kW Motors rated above 1500kW Lighting Panel lighting & Space Heater DC Motors UPS Supply DC Control Supply 415V Breaker Control Supply Control & Relay panels Supply Variations:11kV, 3.3kV & 415 / 240V voltage Frequency Variation Combined Variation of Voltage & Frequency DC System Voltage dip during starting of HT Motor Voltage dip during starting of LT Motor : : : : : : : : : : : 240V. 50Hz 415V, 50Hz 3.3 kV, 50Hz 11 kV, 50Hz 240V, 50Hz 240V, 50Hz 220V DC 240V, 50 Hz 220V DC 220V DC 110V AC
2.1.2
2.2.0 2.2.1
2.2.2
2.3.0
: : : : : :
10% 5% 10% +10% to -15% 20% at motor terminals 15% at motor terminals
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2.4.0
Insulation level For 11 kV System One minute Power Frequency withstand voltage : 1.2/50 Micro sec, impulse withstand voltage : 28 kV (rms) 75 kV (peak)
2.5.0
Short circuit withstand rating 11 kV Switchgear 3.3 kV Switchgear 415V MCC of up to 1000 kVA 415V MCC of over 1000 kVA 220 V DC System : : : : : 50 kA for 1 second 50 kA for 1 second 50 kA for 1 second 50 kA for 1 second 20 kA for 1 second
2.6.0
Neutral Grounding System Neutral of the LV winding (415V) of Service Transformer shall be solidly grounded. 220V DC systems shall be ungrounded.
2.7.0 2.7.1
Design Margin Unless otherwise specified in the corresponding Mechanical Specification, maximum continuous rating of motors shall be at least 10% above the maximum load demand of the driven equipment under entire operating range including voltage & frequency variations. For Transformer sizing applicable no-load correction factor shall be considered. Also each bus section of switchgear / MCC shall normally be loaded to 50% maximum to take the load of the other bus section under its outage. Design margin for other equipment are envisaged. Power transformers/ service Transformers: 10% Margin over normal Power Demand. Busbars & incomers of Switchgear : 10% Margin over rated current. Batteries : 10% design margin and ageing factor of atleast 25%. Battery Chargers : 10% Margin over normal power demand. UPS : 10% Margin over normal Power Demand.
2.7.2
2.7.3
The above said margin shall be over and above the other design factors considered. 2.7.4 Design ambient temperature of all electrical equipment shall be considered as 50 degree C and relative humidity of 95% maximum. Equipment Enclosure Unless otherwise specified, Equipment enclosures in non-hazardous locations shall have following degree of protection: Motors Indoor 11 kV & 3.3 kV Switchgear Indoor LT Switchgear Outdoor Switchgear Local starters Local Push button stations Control & Relay Panels Battery Charger UPS : IP 55 : IP 4X : IP 52 : IP 55 : IP 55 : IP 55 : IP 42 : IP 31 : IP 31
2.8.0
All Switchboards and panels shall be located indoor.

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume-II Detailed Technical Specification Section-4 Page : 5 of 86
2.9.0
Paint Shade Final shade of outside surface of Switchboards, Electrical Control panels and other Electrical Equipment shall be RAL 7032. However this will be firmed up during detailed engineering.
2.10.0 Spare feeders 2.10.1 For 11 kV Switchgear and MCC, 10% spare feeders with a minimum of one of each type and rating shall be provided. 2.10.2 For ACDB, UPS DB & DCDB, 10% spare feeders with a minimum of one of each type and rating shall be provided. 2.10.3 10% spare terminals shall be provided in terminal blocks for control circuits. 2.11.0 Controls of Plant Electrical: 2.11.1 All Incomer, Tie breaker and outgoing feeders including motor feeders shall be controlled from RWPH PLC. 2.11.2 During normal running conditions, should any of the incomer trip due to under voltage, the bus coupler breaker shall be automatically closed after ensuring bus no voltage. This changeover shall, however, be inhibited in the event of incomer tripping on fault. 2.11.3 Auto changeover scheme shall be envisaged at 11 kV Switchgear and at 415 V MCC. 2.11.4 For motors, Local Emergency Stop Pushbuttons shall be provided. Start push button shall be considered if required as per drive control philosophy. 2.11.5 Local / Remote selector switch shall be provided in MCC / switchgear. Local selection is envisaged for trial start of motor from LPB/MCC. Remote selection shall enable starting from RWPH PLC. 2.11.6 Electrical motor operated actuators shall have integral starters. 2.11.7 Motor feeders rated 30 kW and above shall have ammeter. 2.11.8 For all motor feeders, interposing relays shall be provided in respective Switchgear/MCC module to receive start/stop command from RWPH PLC. 2.12.0 Layout Aspects: 2.12.1 Separate Switchgear room shall be provided to accommodate 11 kV and 415 V Switchgear and LV dry type transformer. Power Transformers shall be installed outdoor adjacent to Switchgear room. 2.12.2 Minimum clearance of 1000 mm shall be provided on rear of panel for single front boards. For double front boards, clearance from wall/column shall be 2000 mm. For installations with two rows of boards facing each other, minimum clearance of 2000 mm shall be maintained between fronts of boards. Clearance between adjacent panels in a row shall be < 200 mm or > 800 mm. However actual clearance shall be firmed up during detailed engineering stage. 2.12.3 Switchgear rooms and cable spreader rooms shall have two doors. For cable spreader rooms, doors shall be fire rated. 2.12.4 A minimum clearance of 1000 mm shall be provided between transformer and wall. For compartment housing transformers containing > 2300 litre oil (aggregate capacity) shall be provided with soak pit (Capacity to take whole of oil of transformer). The soak pit shall be atleast 5 M away from the transformer compartment. 2.12.5 Transformers shall be located in a fenced enclosure.
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2.12.6 Fire wall shall be not less than 355 mm thick brick or 230 mm thick RCC extended atleast 600 mm above the highest point of the transformer. 2.12.7 Battery charger & UPS shall be located in air-conditioned room.. 3.0.0 3.1.0 3.2.0 VENDOR LIST The equipment supplied shall be of proven design, incorporating the latest generation technology, best engineering practice and of reputed make. The manufacturer whose equipment are offered should have designed, manufactured, tested and supplied the same for the specified system voltage and which are in satisfactory operation for at least Five (5) years as on date of bid opening. Makes of all electrical equipment and accessories are subject to prior approval by the Owner. Similar equipment and components shall be of same make. Equipment of same type and rating shall be interchangeable. For various other items, bidder shall furnish a list of makes proposed by him. All the makes shall be subject to Owners approval. SPARES LIST The spares list for the Electrical System is furnished in Section-10 of this Technical Specification.
3.3.0
4.0.0
5.0.0
QUALITY ASSURANCE, TESTING & INSPECTION The contractor shall adopt suitable quality assurance Program to ensure that the equipment and services under the scope of contract whether manufactured or performed within the contractors works or at his sub-contractors premises or at the Owners site or at any other place of work are in accordance with the specification. Such Program shall be outlined by the contractor and shall be finally accepted by the Owner / authorized representative after discussion. The QA Program shall be generally in line with ISO-9001. All materials, components and equipments covered under this specification shall be procured, manufactured, erected, commissioned, and tested at all stages, as per a comprehensive Quality Assurance Program. It is the contractors responsibility to draw up and implement such Program duly approved by the Owner . Manufacturing Quality Plan (MQP) will detail out for all the components and equipments, various test/inspection, to be carried out as per the requirements of this specification and standard mentioned therein and quality practices and procedures followed by Contractors/sub-contractors Quality Control Organization, the relevant reference documents and standards, acceptance norms etc. during all stages of manufacturing including raw material procurement, in-process manufacturing, assembly, and final testing/performance testing. The Quality Plans shall be submitted to Owner in soft form for review and Comment. Hard copies of Final Quality Plans shall be submitted for stamping and approval in addition to soft copies. Field Quality Plans (FQP) will detail out for all the equipments, the quality practices and procedures etc. to be followed by the contractors Site Quality Control Organization, during various stages of site activities starting from receipt of materials/equipment at site. The contractor shall carry out an inspection and testing of component and equipment during manufacture at his work and at his sub-suppliers work and at site to ensure to ensure the compliance with the drawing, quality, conformance to functional and performance requirements of the parts and equipments. Contractor shall carry out all tests/inspection required to establish that the items/equipments conform to the requirements of the specification and relevant codes/standards specified in the specification , in addition to carrying out tests as per the approved Quality Plans. Quality audit/
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surveillance/approval of the test results, inspection and acceptance of material will not, however, prejudice the right of the Owner to reject the equipment if it does not comply with the Specification when erected or does not give complete satisfaction in service and the above shall in no way limit the liabilities and responsibilities of the Contractor in ensuring complete conformance of the materials/equipments supplied to relevant specification, standard, data sheet, drawing etc. For all spares and replacement items, the quality requirements as agreed for the supply of main equipments shall be applicable. Repair/rectification procedures to be adopted to make the job acceptable shall be subject to the approval of the Owner/ authorized Inspection Agency. 6.0.0 6.1.0 DRAWINGS, DATA AND MANUAL To be submitted with the Bid: a) b) c) 6.2.0 Technical Data sheet General arrangement drawing Catalogues
To be submitted after the award of contract: As detailed in respective sub sections
6.3.0 6.4.0
Drawing/Documents Distribution Schedule will be firmed-up during finalization of Contract.. For all technical tables and diagrams, calculation results, drawings, test data and scales adopted in the design the Standard International unit system (SI) as per International Standardization Organization (ISO) shall be uniformly employed. All engineering documents and drawings shall be of international A series sizes that is of A0, A1, A2, A3 & A4
6.5.0
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SECTION 4.2 HT SWITCHGEAR 1.0.0 INTRODUCTION This specification covers the requirements of 11kV Switchgear for the River water intake System. 2.0.0 CODES AND STANDARDS The equipment to be furnished under this specification shall be in accordance with the applicable section of the latest version of the following Indian Standards and relevant IEC standard, except where modified and /or supplemented by this specification. IS 375 IS 13118 IS 12729 IS 2705 IS 3156 3.0.0 3.1.0 Marking and arrangement of switchgear bus Specification for high voltage alternating current circuit breakers Switchgear & Control gear for voltages exceeding 1000V General requirements Current Transformers Voltage Transformers
GENERAL REQUIREMENTS The 11kV switchgear shall comprise the following complete with vacuum circuit breakers, Current transformers and Protective relays. The 11kV switchgear shall comprise two incomers and a buscoupler and required number of outgoing feeders. Normally, each incomer shall feed respective bus section with buscoupler in open condition. In case of any constraint, one incomer shall be opened and other incomer shall be made to supply both the bus sections through buscoupler. Changeover shall take place either by Manual /Auto Changeover Scheme. No.of feeders of 11 kV Switchgear shall be as follows: Inomer-1 Inomer-2 Bus coupler Bus PT Motor feeders with capacitor bank 2 nos. LT service transformer feeders Spare motor feeder Line PT Busbars, breaker and other components shall be designed for continuous operation at rated current considering temperature inside the cubicle. The inside cubicle temperature shall be considered as design ambient temperature for maximum continuous operation rating of the equipment. For breaker control, 220 V DC supply shall be considered. Each breaker module shall be provided with multifunction numerical relay for protection. 11 kV Switchgear shall be provided with separate earthing trucks for cable earthing and bus earthing.
3.2.0
3.2.0
3.3.0 3.4.0 3.5.0
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4.0.0 4.1.0 4.1.1
DESIGN AND CONSTRUCTION Switchgear Construction The switchgear shall be indoor, single front, single tier, metal-clad, floor mounted, fully draw-out with VCB breaker. Design and construction shall be such as to allow extension at either end. Switchgear cubicle shall be so sized as to permit closing of the front access door when the breaker is pulled out to Test position. The working zone shall be restricted within 750 mm to 1800 mm as from floor level. Circuit breakers, instrument transformers, bus-bars, cable compartment, auxiliary control devices etc., shall be housed in separate compartments within the cubicle. The design shall be such that failure of one equipment shall not affect the adjacent units. The circuit breaker and bus voltage transformers shall be mounted on withdrawable trucks .In case breaker truck rolls out on telescopic rails suitable trolley shall be provided. The breakers shall be designed for a short circuit rating of 50kA for 1 sec. All relays, meters, switches and lamps shall be flush mounted on the respective cubicle door or on a control cabinet built on the front of the cubicle. The trucks shall have distinct Service, Test and Isolated positions. The switchgear assembly shall be designed to achieve IP 4X degree of protection, with the truck in any position Service, Test and Isolated and all doors and covers closed. Relaying and Metering compartment shall have degree of protection of IP52. Enclosure shall be constructed with rolled steel sections/ sheets of not less than 2mm. The switchgear shall be cooled by natural airflow. Forced cooling shall not be accepted. The Breaker and the auxiliary compartments provided on the front side shall have strong hinged doors. Breaker compartment doors shall have locking facility. Bus and Bus Taps The main buses and connections shall be of high conductivity Copper or aluminium / aluminium alloy, sized for specified current ratings with maximum temperature limited to 90C and 250C for short circuit current rating. The busbars shall be designed for specified short circuit rating for 1 sec. All bus connections shall be silver plated. Adequate contact pressure shall be ensured by means of two bolts connection with plain and spring washers and lock nuts. Bimetallic connectors shall be furnished for connections between dissimilar metals. Busbar insulators shall be epoxy cast resin type designed to withstand stresses due to maximum short circuit current. Busbars and connection shall be fully insulated for working voltage with adequate phase/ground clearances. Insulating sleeves for busbars and cast-resin shrouds for joints shall be provided. Cross section of the main horizontal busbar shall be uniform throughout the switchboard and continuous in one transport unit. All buses and connection shall be supported and braced to withstand stresses due to maximum short circuit current and also to take care of any thermal expansion. Busbars shall be colour coded for easy identification and so located that the sequence R-Y-B shall be from left to right, top to bottom or front to rear, when viewed from front of the switchgear assembly. The busbar chamber shall be provided with inter panel barrier with epoxy case seal-off bushings which the buses shall pass through so as to prevent fire from one panel to another.
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4.1.2
4.1.3
4.1.4 4.1.5
4.1.6
4.1.7
4.2.0 4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.3.0 4.3.1
Circuit Breaker Circuit breaker shall be triple pole, single throw Vacuum Circuit breaker. It shall be restrike free, trip free type. Breakers shall be suitable for switching transformers at any load. Rated operating duty shall be O-3min-CO-3min-CO. Circuit breakers shall be draw-out type, having SERVICE, TEST and DISCONNECTED positions with mechanical positive indication for each position. Operating mechanism shall be stored energy type. Circuit breakers of identical rating shall be physically and electrically interchangeable. Each breaker feeder shall be provided with the following: An antipumping relay. Motor charged spring operating mechanism. Manual spring charging Mechanical indication of spring charge Mechanical position indicator (to show whether the breaker / contactor is ON or OFF in the service, test and disconnected positions) Closing coil (100% continuous rated) Shunt trip (100% continuous rated) Manual trip push button Operation counter, Locking facility to prevent breaker/contactor from being closed when it is open. Pressure relief device Lockable Safety shutters for power contacts Interpole insulators
4.3.2
4.3.3 4.3.4
4.3.5
For motor wound mechanism, spring charging shall take place automatically after each breaker closing operation. One open-close-open operation of the circuit breaker shall be possible after failure of power supply to the motor. Robust fail-safe mechanical and electrical interlocks shall be provided to prevent the following situations: Move the breaker unit from the service or disconnected position while the unit is closed. Move the breaker from the disconnected position to the service position while the earthing switch is closed. Close the earthing switch when the breaker unit is in service position or between the service and disconnected position. The operation of the circuit breaker while the truck is not properly installed in the service, test or disconnected position.
4.3.6
4.3.7
The closing coil and spring charging motor shall operate satisfactorily at all values of control supply voltage between 80 and 110 percent of the rated voltage. The shunt trip coil shall operate satisfactorily at all values of control supply voltage between 70 and 110 percent of the rated voltage. For breakers spring charging motor shall be provided with overcurrent protection. Motor windings shall be provided with class B insulation or better. Circuit breaker shall not produce any harmful over-voltage during switching off induction motors. Surge protective devices to limit over voltage shall be included in the scope of supply for all motor feeders.
4.3.8 4.3.9
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4.4.0 4.4.1
Current Transformer The CTs shall be mounted on the switchgear stationary parts. The CTs shall be of cast resin, bar primary type and of Class B or better insulation. CT secondary current shall be 1A. Accuracy class of the Current Transformer shall be: Class PS for differential relaying Class PS for REF protection ( For Transformers rated 2MVA and above ) Class 5P20 for other relaying Class 0.5 and ISF < 5 for metering
4.4.2
4.4.3
For metering separate core shall be provided. Core balance CT and associated relay combination shall be such as to ensure a pick up sensitivity of 10 A primary ground fault current for all the outgoing feeders. Facilities for easy shorting and grounding the terminals shall be provided at the terminal block. All terminal blocks shall be of stud type with marking strip. Voltage Transformer Voltage Transformer shall be cast-resin, draw-out type and shall have an accuracy class of 0.5. Voltage Transformer mounted on breaker carriage is not acceptable. The following over voltage factor shall be considered for PT. 120% for continuous duty. 190% for 30 sec ( for resistance grounded system)
4.4.4
4.5.0 4.5.1
4.5.2
High voltage windings of voltage transformer shall be protected by current limiting fuses. The voltage transformer and fuses shall be completely disconnected and visibly grounded in fully draw-out position. Low voltage MCBs, sized to prevent overload, shall be installed in all ungrounded secondary leads. MCBs shall be suitably provided with auxiliary contacts. MCBs auxiliary contacts connected suitably through relay shall be provided on the secondary side of all voltage transformers to monitor failure or trip of MCBs. The relay shall initiate alarm and block the tripping etc. which shall operate in case of VT MCB trip or failure. Relays Numerical multifunction relays shall be provided for protection of switchgear incomers, tie feeders and all outgoing feeders. Numerical relay shall have trip circuit supervision. All protective relays shall be of draw-out type, suitable for flush mounting and fitted with dust tight covers. All relays shall have built-in testing facilities. Small auxiliary relays may be of non-draw-out type and mounted within the cubicle. Relays shall have lock-out facility with manual reset. Each feeder shall be complete with necessary auxiliary relays, timers, etc., to meet the circuit requirement. Under voltage relays shall be provided in the bus PT circuit. Relays shall be rated for operation on 110V V.T. secondary voltage and 1 A C.T. secondary current. The switchgear shall be provided with D.C. fail relay and D.C. fail indication lamp for each D.C. control supply incomer. DC isolation switch for each feeder shall be provided with backup HRC fuse. Breaker auxiliary contacts used for interlocking purposes shall be multiplied using electrically latched relay.
4.5.3
4.5.4
4.6.0 4.6.1
4.6.2
4.6.3 4.6.4
4.6.5
4.6.6
11 kV Incomer and Tie feeders shall have the minimum following protection relays. - Numerical protection relay having IDMT Back up over current protection (51) on all the three phases and Definite time delayed Back up earth fault protection residually connected (50N). - Latched Lock out relay (86). - Trip circuit supervision relay 11 kV Motor feeders shall have the minimum following protections. Numerical motor protection relay Instantaneous earth fault protection through CBCT (50 N). Latched Lock out relay (86). Under voltage protection Trip circuit supervision relay
4.6.7
4.6.8
11 kV Bus PT shall have the following protections. - Under voltage relay - MCB trip or failure relay - No voltage relay 11 kV capacitor feeders shall have the following minimum protection relays. - Numerical protection relay having Short circuit protection (50) on all the three phases, IDMT Over current protection (51) on all the three phases, Instantaneous earth fault protection (50 N). - Instantaneous earth fault protection through CBCT (50 N). - Over Voltage protection - Latched Lock out relay (86). - Trip circuit supervision relay
4.6.9
4.7.0 4.7.1
Control Switches Circuit breaker control switches shall be 3-position spring return to `neutral' from both close and trip positions. They shall have `Pistol Grip' handle. Ammeter selector switches shall have make before break feature on its contacts. The selector switch shall generally have four positions, three for reading three phase currents and the fourth as off position. The voltmeter selector switch shall measure phase to phase voltages. The contacts shall be of silver plated, air break type. The continuous current and breaking capacity of the contacts shall be adequate for the duty involved. Indicating lamps Indicating lamps shall be of the panel mounting, LED type. The lamps shall have escutcheon plates marked with its function, wherever necessary. Lamps shall have translucent lampcovers of the following colors, as warranted by the application. Bulbs and lamp covers shall be easily replaceable from the front of the cubicles. Low Voltage Glow Prevention (LVGP) feature shall be provided for indicating lamps. The colour of indication lamps shall be as follows: GREEN RED AMBER BLUE WHITE : : : : : Breaker Open Breaker Closed Auto trip & all Alarm conditions Spring Charged For all healthy conditions (eg .Trip coil healthy & Control supply healthy).
4.7.2
4.7.3
4.8.0 4.8.1
4.8.2
For each breaker feeder, Panel indication lamps shall be provided as follows: Breaker Open
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Breaker Closed Auto trip Motor Spring Charged Trip coil healthy Control supply healthy Breaker in service position Breaker in Test position Lockout relay healthy Any other indication, as required For incomer & Bus, indicating lamps for R, Y, B phase shall be provided. 4.9.0 4.9.1 Meters Digital multifunction meters with communication port with true rms measurement facility with minimum 1% accuracy level shall be provided. For incomers, following meters shall be provided: Multifunction meter for current, voltage, kW, kVAR, kWH and power factor measurement. For outgoing transformer feeders following meters shall be provided: Multifunction meter for current, KW & kVA measurement. For outgoing motor feeders following meters shall be provided: Multifunction meter for current, KW & PF measurement. For Bus VT, digital meters with voltage & frequency measurements shall be provided:
4.9.2
4.9.3
4.9.4
4.9.5
4.10.0 Secondary wiring 4.10.1 The Switchgear shall be fully wired at the factory to ensure proper functioning of control, protection, transfer and inter locking schemes. Fuse and links shall be provided to permit individual circuit isolation from bus wires without disturbing other circuits. All spare contacts of relays, switches and other devices shall be wired up to terminal blocks. 4.10.2 Wiring shall be done with flexible, 650V grade, PVC insulated switchboard wires with stranded copper conductors of 2.5mm for current circuits and 1.5 mm for voltage circuits. Each wire shall be identified, at both ends, with permanent markers bearing wire numbers as per Contractors wiring Diagrams. 4.10.3 Wire termination shall be made with crimping type connectors with insulating sleeves. Wires shall not be spliced between terminals. All external cable terminations shall be accessible while the breaker is in service position 4.11.0 Terminal Blocks Terminal blocks shall be 660V grade box-clamp type with marking strips. CT shorting links, Drop link type terminals shall be provided for C.T secondary leads. Not more than two wires shall be connected to any terminal. Spare terminals equal in number to 20% active terminals shall be furnished. Terminal blocks shall be located to allow easy access. Wiring shall be so arranged that individual wires of an external cable can be connected to consecutive terminals. 4.12.0 Cable Termination Switchgear shall be designed for cable entry from the bottom. Sufficient space shall be provided for ease of termination and connection. All provision and accessories shall be furnished for termination and connection of cables, including removable gland plates, cables supports, crimp type tinned copper lugs, brass compression glands with tapered washer and terminal blocks.
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4.13.0 Name plates Name plates of approved design shall be furnished at each cubicle and at each instruments & device mounted on or inside the cubicle. The material shall be lamicoid or approved equal, 3 mm thick with white letter on black back ground. The material shall be held by self-tapping screws. Nameplate size shall be minimum 20 X 75 mm for instrument. device and 40 X 150 mm for panels. Caution notice on suitable metal plate shall be affixed at the back of each vertical panel. 4.14.0 Space heaters and plug sockets Each cubicle shall be provided with thermostat controlled space heaters and cubicle lamp with door switch suitable for operation from 240 V ,single phase A.C. supply and 5A, 3 pin plug socket. The space heater shall be located at the bottom of each switchgear compartment. Cubicle heater, Motor heater, Plug/socket circuits shall have individual MCB units. In addition, motor feeder cubicle shall be wired-up for feeding the motor space heater through suitable rated breaker auxiliary NC Contact and/or contactor. 5.0.0 PAINTING Painting shall be carried out by approved process. After preparation of the under surface the equipment shall be painted with epoxy based paint by powder coating. The final thickness of paint film on steel shall not be less than 85 microns. Final shade shall be RAL 7032. 6.0.0 TESTING AND INSPECTION Switchgear and all its components should have been type tested and proven type. Type test certificates shall be furnished for Owners review. Switchgear and its components shall be subjected to routine tests as per applicable Indian Standard. In addition, any special test required shall also be performed. Test reports shall be submitted for approval. 7.0.0 DRAWINGS, DATA AND MANUAL To be submitted after the award of contract: Completely filled in technical Schedules Dimensional General Arrangement drawing Single line diagram & Schematic wiring diagrams Relay setting calculation. Quality Plan Test certificates O&M manual
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SECTION 4.3 - TRANSFORMERS 1.0.0 INTRODUCTION This specification covers the requirements of 11/0.433 kV oil type service transformers and solid grounding system for the River water intake System. 2.0.0 CODES AND STANDARDS The equipment to be furnished under this specification shall be in accordance with the applicable section of the latest version of the following Indian Standards, except where modified and /or supplemented by this specification. IS 335 IS 2026 IS 3639 IS 4257 IS 10028 IS 11171 3.0.0 3.1.0 New insulating oils. Power transformers. Fittings and accessories for Power transformers. Dimensions of porcelain transformer bushings for use in normal and lightly polluted atmosphere. Code of practice for selection, installation and maintenance of transformers Specification for Dry Type Power Transformers
DESIGN REQUIREMENTS The power transformers shall be suitable for outdoor installation in a hot, humid and tropical climate. The power transformers shall be oil-immersed type capable of operating continuously at its rated output without exceeding the temperature limits specified. The service transformers shall be Dry type Transformers suitable for indoor installation.
3.2.0
The transformers shall be suitable for connection to the system having short circuit level and short circuit duration as specified. The transformers shall be capable of withstanding without injury, the thermal & magnetic stresses caused by faults on any of the winding /through faults. The transformers shall be capable of delivering the rated output at any particular tap without exceeding the specified temperature limits under the following operating conditions. Voltage variation of 10% of rated voltage of that particular tap. Frequency variation of 5% of rated frequency. Combined voltage and frequency variation of 10% (absolute sum).
3.3.0
3.4.0
The transformers shall be free from annoying hum and vibration when it is in operation, even at 110% rated voltage. The noise level at rated voltage and frequency shall be as per NEMA-TR1 standard. The transformers shall be suitable for overfluxing (due to combined effect of voltage & frequency) up to 10% on any tapping without injurious heating at full load condition. The maximum flux density in any part of core and yoke under such condition shall not exceed 1.9 Tesla. Salient parameters of the service transformers are as follows: Nominal system voltage (HV / LV) Vector group Type of cooling Class of insulation Temp rise in winding 415 V System fault level 415 V Neutral 11/0.433 kV Dyn1 ONAN Resin cast, Class H Class F limits 50kA for 1 sec Solidly grounded
3.5.0 3.6.0
3.8.0
4.0.0 4.1.0
CONSTRUCTIONAL FEATURES OF SERVICE TRANSFORMER Tank The transformer tank shall be of welded construction and fabricated from low carbon steel of adequate thickness. All seams or joints shall be continuously welded. The tank shall be designed and tested for a vacuum and pressure as per the guidelines indicated in CBIP manual. The tank cover shall be bolted on the tank with weather proof, hot oil resistant, resilient neoprene gasket in between for complete oil tightness. Inspection openings of sufficient size shall be provided in the tank cover to give access to leads, bottom terminals of bushings, taps and testing earth connections.
4.2.0 4.2.1
Core & Windings The core shall be made from low loss, grain oriented, cold-rolled, and silicon steel laminations. The coil shall be manufactured from electrolytic copper of suitable grade and shall be properly insulated and stacked. The core assembly shall be connected to the transformer tank for effective core earthing. The insulation structure for the core to bolts and core to clamp plates shall withstand a voltage of 2 kV AC for one (1) minute. The core shall be provided with lugs suitable for lifting the complete core and coil assembly. Transformer Oil shall be new conforming to the latest revision of IS 335. Conservator Tank Oil preservation shall be done by means of conservator tank. Conservator shall be aircell type. The conservator shall be fitted with a magnetic oil level gauge with alarm contacts. A Silicagel breather shall be provided in the airside vent line at about 1400 mm above ground level.
4.2.2
4.3.0 4.4.0
4.5.0
Pressure relief device Spring loaded type pressure relief device shall be provided and shall have potential free trip contacts. Suitable means shall be provided to direct the major flow of oil downwards away from the transformer when pressure relief device operates.
4.6.0 4.6.1
Temperature Indicators For top oil measurement, 150 mm dia dial type oil temperature indicator (OTI) with adjustable potential free alarm and trip contacts, maximum reading pointer and resetting device shall be provided. Temperature sensing element shall be connected to OTI by means of capillary tubing. Accuracy class of OTI shall be +/- 2C or better. For measuring hot spot temperature in the winding, 150 mm dia dial type winding temperature indicator (WTI) with adjustable potential free alarm and trip contacts, maximum reading pointer and resetting device shall be provided. Temperature sensing element shall be complete with image coil, bushing CT etc. Accuracy class of WTI shall be 2C or better. Buchholz Relay A double float buchholz relay with isolating valves, test cock and gas sampling valve shall be provided. The device shall have potential free alarm and trip contacts.
4.6.2
4.7.0
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4.8.0 4.8.1
Bushings All bushings shall be homogenous, non-porous porcelain type, uniformly glazed and free from blisters, burns and other defects complete with suitable terminal connectors of adequate capacity. Bushings located inside cable boxes flanges can be epoxy-molded types. Bushing CTs shall be provided as per system requirement. Secondary leads of CTs shall be wired upto-marshalling box. The arrangement shall be such that the CT can be removed from the transformer without removing the tank cover. Current transformers shall be cast resin type with Class E or better insulation. Terminal Arrangement For cable termination, terminals of transformer shall be brought out through side wall mounted bushings to a detachable cable box with disconnect link . The cable box shall be suitable for cable termination kits and shall be self supporting, weather proof, air filled type complete with all hardware such as gland plates, etc. Cable box shall have IP 55 degree of protection.
4.8.2
4.9.0 4.9.1
4.9.2
4.10.0 Marshalling Box 4.10.1 Marshalling box shall be sheet steel enclosed with IP 55 degree of protection alarm & trip contacts of all the fittings & accessories and secondary leads of CTs shall be wired up to marshalling box. Cable gland plate shall be of removable type. 4.10.2 The marshalling box shall have isolating switch & MCB for incoming power supply. Cubicle illumination lamp with door switch and space heater with thermostat and ON/OFF switch shall be provided. 4.10.3 The marshalling box shall have 10% additional set of control terminals. 4.11.0 Grounding 4.11.1 Two grounding pads, located on the opposite sides of the tank, shall be provided for connection of station ground mat for each transformer. Grounding pads shall have clean buffed surface with tapped holes. M10 GI bolts, nuts and spring washers. 4.11.2 Two ground terminals each shall be provided on marshalling box & cable box. 4.11.3 For neutral connection, cable box shall be provided for connecting to Neutral grounding resistor. 4.12.0 Cooling Tank mounted radiator banks shall be provided with required valves. Radiators shall be of pressed sheet CRCA steel.
4.13.0 Off Circuit tap Changer Off Circuit tap changers shall be provided on HV winding with +2.5 % to -7.5% range of taps insteps of 2.5%. The tap changing shall be effected by an external 3 phase gang operated tap change switch. The operating handle shall be padlocked at any position. The mechanism shall be provided with a mechanical tap position indicator, mechanical stop to prevent over cranking of mechanism etc. A warning plate indicating For denergised operation only shall be fitted.
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4.14.0 Valves Valves shall be of gunmetal type for drain, filter, sampling and air release application. For shut off application valves can be of cast iron type. They shall be of fullway type with screwed ends. Every valve shall be provided with position indicators. Bottom valves shall have means for pad locking in open/close positions. All valves shall be provided with flanges having machined faces. Oil tight blank flanges shall be provided for the following. - Valves opening to atmosphere. - For each connection for use when any radiator is detached. 4.15.0 Wiring and Terminal Blocks 4.11.1 All control cabinets, marshalling boxes, etc shall be fully wired at the factory to ensure proper functioning of the control, protection and interlock schemes. All spare contacts of switches, relays and other devices shall be wired upto the terminal block. 4.11.1 Wiring shall be done with flexible 650V grade HR PVC cables with stranded copper conductor of minimum size 2.5 sq.mm. Wiring shall be identified at both ends with ferrules bearing wire numbers as per approved drawings. Wire termination shall be made with crimping type connectors with insulating sleeves. Wires shall not be spliced between terminals. 4.11.1 Terminal blocks shall be of 650 V grade suitable for terminating required cable size. Terminals for CT secondary shall have provision for shorting. Not more than two wires shall be connected to any terminal. 10% spare terminals shall be provided. 4.15.4 All devices and terminal blocks within the panel shall have identification numbers as per schematic diagram. 4.16.0 Neutral Grounding Resistor Neutral shall be grounded through resistor wherever specified / required. The neutral grounding resistor shall be mounted in respective cubicles near the transformers and connected by cables. The cubicles shall be factory assembled metal clad, hot dip galvanized, suitable for outdoor installation with IP 33 degree of protection. The resistor elements shall be of stainless steel or steel alloy, rust proof, corrosion and acid resistant type limiting hot spot temperature to 250 C. The resistors shall be designed to carry earth fault current of 300 A for 10 s. 4.17.0 Nameplate Each transformer shall be provided with a nameplate of weather-resistance material fitted in a visible position showing all the information and additional information as per IS 2026-I. 4.18.0 Fittings & Accessories Each transformer shall be supplied with the following as a minimum: 1 no. Oil conservator with set of valves 1 no. Silica gel breather with oil seal & charge. 1 no. Double float Buchholz relay with isolating valves, test cock & sampling valve. 1 no. Magnetic oil level gauge. 1 no. Pressure relief device. 1 no. Thermometer pocket with mercury in glass thermometer 1 no. Winding temperature indicator 1 no. Oil temperature indicator 1 no. Drain valve. 2 nos. Sample valve (top and bottom). 2 nos. Filter valves (top and bottom)
Set of Radiator banks with isolating valve & drain valves. 1 no. Air release devices. 4 nos.hauling lugs 4 nos. Jacking Pads 4 nos. Rollers /flanged wheels 4 nos.Cover lifting eyes 2 nos. Grounding pads for transformer tank, cover and radiator banks, cable box and marshalling box. Two nos. Stainless steel Rating and diagram plate (Hindi & English). 1 no. Stainless steel Valve diagram plate 1 no. Marshalling box 1 no. off circuit tap changer 3 nos. HV Bushings with terminal connectors in Cable box 3 nos. LV Bushings with terminal connectors in Cable box 1 no. LV Neutral Bushing with terminal connectors in Cable box 1 set LV Neutral Bushing CTs 2nos.Inspection covers. 1 Lot Interconnecting cables.
6.0.0
TESTING AND INSPECTION Transformer and all its fittings should have been type tested and proven type. Type test certificates shall be furnished for Owners review. Transformer and all its fittings shall be subjected to routine tests as per applicable Indian Standard. In addition, any special test required shall also be performed. Test reports shall be submitted for approval.
7.0.0
PAINTING Cleaning and painting shall be as per clause 1.6 of section-A of CBIP manual. After preparation of the under surface the equipment shall be painted with epoxy based paint. Oil resistant paint shall be applied as required. The final thickness of paint film on steel shall not be less than 100 microns and shall not be greater than 150 microns. Final shade shall be RAL 7032.
8.0.0 8.1.0
DRAWINGS, DATA AND MANUAL To be submitted after the award of contract: Completely filled in technical Schedules Dimensional General arrangement drawing for the transformer indicating disposition of various fittings & accessories Cable box & Marshalling box Schematic & wiring diagram for Marshalling box Properties of transformer oil List of valves indicating material & size. Quality Plan Test certificates Operation & Maintenance Manual Details of Erection, Testing and Commissioning at Site.
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SECTION 4.4 LT SWITCHGEAR
1.0.0
INTRODUCTION This specification covers the requirements of 415 V Motor Control Centre, Distribution Boards, Starters, Local Push button stations etc. for the River water intake System.
2.0.0
CODES AND STANDARDS The equipment to be furnished under this specification shall be in accordance with the applicable section of the latest version of the following Indian Standards and relevant IEC standard, except where modified and /or supplemented by this specification. IS 3427 IS 8623 IS 10118 IS 12021 IS 13703 IS 13947 Metal-enclosed switchgear and control gear. Specification for low voltage switchgear and control gear assemblies. Code of Practice for Selection, Installation, and Maintenance of switchgear & controlgear Specification for Control transformers for switchgear and controlgear for voltages not exceeding 1000V AC. Low voltage fuses. Low voltage switchgear and control gear.
3.0.0 3.1.0
GENERAL REQUIREMENTS The switchgear and its components shall be designed for design ambient temperature of 50C. Switchgear shall be designed for natural air cooling. No forced cooling is acceptable. Motor Control Centre (MCC) shall have two incomers and one bus coupler. Auto/Manual Changeover scheme shall be provided for MCC with interlocking of MCC I/C breaker with upstream breaker. For MCC, Incomer, buscoupler & Outgoing breakers shall be controlled from RWPH PLC and as well as Local.
3.2.0
3.3.0
3.4.0 3.5.0
415V normal system shall be solidly grounded. 220V DC system shall be ungrounded.. Busbar, breaker and other components shall be designed for continuous operation at rated current considering temperature inside the cubicle.. For MCC, Close & Open control of the Incomer & Tie breakers and outgoing breakers, motors shall be from RWPH PLC. Close & Open control of all the motors shall be provided in RWPH PLC. Local operation of circuit breakers shall be possible only in "Test" position. Remote indications / alarms shall be provided in the RWPH PLC. The control / interlock schemes for various types of feeders shall be commensurate with their application. MCC shall be of draw out type for all the modules including breaker modules/ Starter module. All /MCC shall be of double front type. 110V control supply shall be derived from redundant 415/110V control supply transformers. 240V AC space heater supply provision shall be provided for motors rated above 30 kW.
3.6.0
3.7.0
3.8.0
3.9.0
3.10.0 For breaker operated feeders control supply voltage shall be 220V DC.
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3.11.0 The continuous current rating of the bus bars, incomers, bus couplers of the MCC shall be the maximum load on the bus due to all the running auxiliaries during any operating condition plus 10% margin rounded off to the next higher standard rating. 3.12.0 At least 10% of feeder modules covering the range of motors used subject to minimum of one module in each bus section shall be provided as spare. Spare modules shall be completely wired up. 3.13.0 All motors shall have direct on line starter.125kW and above capacity motors shall be fed from ACBs. Less than 125kW capacity motors shall be fed by MCCBs and contactors. 3.14.0 Operating height of the handles/switches shall be limited to a maximum of 1800 mm and a minimum of 300 mm. 3.15.0 For MCC changeover shall be provided. If there is an under voltage (dipped to 30-40% voltage) on any one of the buses, sensed through under voltage relays, the respective incomer breaker shall trip automatically and the bus coupler shall close, if the voltage is available on the other bus section, thereby establishing voltage at 415V motor terminals before motor reaches standstill condition. The auto changeover shall be blocked if any of the following condition exists: Any of the involved breaker is in the test or withdrawn position. Source voltage is not available. Source breaker is tripped due to bus fault. 3.16.0 MCCB, Contactor and overload relay shall meet type-2 co-ordination as per applicable standard. 4.0.0 4.1.0 4.1.1 DESIGN AND CONSTRUCTION MCC 415 V MCC shall be of metal enclosed, indoor, floor-mounted, free-standing type. switchboard frames and load bearing members shall be fabricated using CRCA sheet steel of thickness not less than 2.0 mm. Doors and covers shall also be of CRCA sheet steel of thickness not less than 1.6 mm. Thickness of gland plates shall not be less than 3.0 mm for sheet steel & 4.0mm for non-magnetic material. All switchboards shall be of dust-proof and vermin-proof construction and shall be provided with a degree of protection of IP: 52 as per IS: 13947, Part-1. All switchboards shall be of uniform height not exceeding 2450 mm. Switchboards shall be easily extendable on both sides by the addition of vertical sections after removing the end covers. Module size of switchboards shall not be less than 200mm. Cable entry shall be from bottom. Switchboards shall be divided into distinct vertical sections (panels), each comprising of the following compartments: Main busbar compartment: Switchgear / feeder compartment Cable alley Auxiliary busbar compartment Control compartment for relays for ACB feeder 4.1.5 The feeder compartment shall be sheet steel enclosed on all sides with the withdrawable units in position or removed. The front of the compartment shall be provided with the hinged single leaf door with captive screws for positive closure.
4.1.2
4.1.3
4.1.4
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4.1.6
All circuit-breaker panels shall be of single-front type. All single-front switchboards shall be provided with single-leaf, hinged or bolted covers at the rear. The bolts shall be of captive type. The covers shall be provided with DANGER labels.. All 415 V circuit-breaker modules and MCC modules shall be of fully drawout type having distinct `Service and `Test positions. The equipment pertaining to a drawout type module shall be mounted on a fully withdrawable chassis, which can be drawn out without having to unscrew any wire or cable connection. Suitable arrangement with cradle / rollers and guides shall be provided for smooth movement of the chassis. Air Circuit Breakers Air Circuit breakers shall be (three pole for motor feeders and TPN for other feeders), air break, horizontal drawout type, and shall have fault making and breaking capacities as specified. There shall be SERVICE, TEST and ISOLATED positions for the breakers. In Test position the circuit breaker shall be capable of being tested for operation without energizing the power circuits i.e. the power contacts shall be disconnected, while the control circuits shall remain undisturbed. Locking facilities shall be provided so as to prevent movement of the circuit breaker from the SERVICE, TEST or ISOLATED position. It shall be possible to close the door in Test position. Each breaker feeder shall be provided with the following as a minimum: Electrical antipumping feature Motor charged spring operating mechanism. Manual spring charging Mechanical indication of spring charge Mechanical position indicator Closing coil Shunt trip coil Manual trip push button Operation counter Phase barriers Shutter assembly Door interlock kit Static releases for over current & short circuit and earth fault protection
4.1.7
4.2.0 4.2.1
4.2.2
4.2.3
The closing coil and spring charging motor shall operate satisfactorily at all values of control supply voltage between 80 and 110 percent of the rated voltage. The closing coil & shunt trip coil shall be rated for 100% continuous duty. One Open-Close-Open operation of the circuit breaker shall be possible after failure of power supply to motor. For breakers spring charging motor shall be provided with over current protection. Motor windings shall be provided with class B insulation or better. The shunt trip coil shall operate satisfactorily, all the values of control supply voltage between 70 and 110 percent of the rated voltage. Circuit breaker of the same type and ampere rating shall be wired alike and shall be mechanically interchangeable. All Air Circuit Breakers shall be provided with the following interlocks : Movement of a circuit breaker between SERVICE and TEST position shall not be possible unless it is in open position. Closing of a circuit breaker shall not be possible unless it is in SERVICE position, TEST position or in ISOLATED position. Once the closing springs are discharged, after one closing operation of circuit breaker, it shall automatically initiate recharging of the spring.
4.2.4
4.2.5
4.2.6
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4.2.7
Telescopic trolley or suitable arrangement shall be provided for maintenance of circuit-breaker module in a cubicle. The trolley shall be such that the topmost breaker module can be withdrawn on the trolley and can be lowered for maintenance purpose. ACBs shall have CT operated relays for over current and earth fault protection. Circuit Breakers (ACB) Circuit breakers shall be (three pole for motor feeders and TPN for other feeders), horizontal drawout type, and shall have fault making and breaking capacities as specified Each breaker feeder shall be provided with the following as a minimum : Closing coil Shunt trip coil Manual trip push button Phase barriers Door interlock kit
4.2.8 4.3.0 4.3.1
4.3.2
4.3.3
The closing coil and spring charging motor shall operate satisfactorily at all values of control supply voltage between 80 and 110 percent of the rated voltage. The closing coil & shunt trip coil shall be rated for 100% continuous duty. One Open-Close-Open operation of the circuit breaker shall be possible after failure of power supply to motor. For breakers spring charging motor shall be provided with over current protection. Motor windings shall be provided with class B insulation or better. The shunt trip coil shall operate satisfactorily, all the values of control supply voltage between 70 and 110 percent of the rated voltage. Circuit breaker of the same type and ampere rating shall be wired alike and shall be mechanically interchangeable. CBs shall have CT operated relays for over current, Short Circuit and earth fault protection. Control and Selector Switches Control and selector switches shall be of rotary type, with escutcheon plates clearly marked to show the function and positions. Circuit breaker control switches shall have three positions and shall be spring return to NEUTRAL from CLOSE and TRIP positions and shall have pistol grip handles. Circuit breaker selector switches shall have three stay put positions marked `Test, `Local and `Remote, respectively. They shall have black spade handles. Selector switches for starter modules shall have Test, Local, Remote positions as specified. Contactors Motor starter contactors shall be of air break, electromagnetic type rated for uninterrupted duty. Contactors shall be double-break, non-gravity type and their main contacts shall be silver faced. Direct-on-line contactors shall be of utilisation category AC3. Reversing starters shall comprise of Forward and Reverse contactors mechanically and electrically interlocked with each other. These contactors shall be of utilisation category AC4. The contactor shall operate satisfactorily between 85% to 110% of the rated voltage. The contactor shall not drop out at 70% of the rated voltage but shall definitely drop out at 20% of the rated voltage. Instrument Transformers
4.3.4
4.3.5
4.3.6 4.4.0 4.4.1
4.4.2
4.5.0 4.5.1
4.5.2
4.6.0
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4.6.1
The CTs shall be mounted on the switchgear stationary parts. For metering separate core shall be provided. The CTs shall be of cast resin, bar primary type and of Class E or better insulation. CT secondary current shall be 1A. Accuracy class of the Current Transformer shall be :a. Class 5P20 for other relaying b. Class 1.0 and ISF < 5 for metering CTs for current rating less than 50A shall be Wound primary type and above 50A shall be Bar primary type. Voltage Transformer shall be cast-resin, draw-out type and shall have an accuracy class of 1.0. The bus VTs shall be housed in a separate compartment. All VTs shall have readily accessible fuse and MCBs on primary and secondary sides respectively. Indicating Instruments Digital multifunction meter with communication port shall be provided.
4.6.2
4.6.3
4.6.4
4.7.0
4.8.0 4.8.1
Push Buttons Push-buttons shall be of spring return, push-to-actuate type. Where specified push buttons shall be stay put type. Their contacts shall be rated to make, continuously carry and break 6 A at 110 V AC and 1 A (inductive) at 110 V DC. Push buttons shall have 2NO+2NC contacts. All push-buttons shall have two normally open and two normally closed contact, unless specified otherwise. The contact faces shall be of silver alloy. All push-buttons shall be provided with integral escutcheon plates marked with its function. All emergency push-buttons shall be stay put/latching type. To delatch, master key provision shall be provided..
4.8.2
4.8.3
The colour of the button shall be as follows: Green for motor START, breaker CLOSE, valve / damper OPEN /CLOSE commands. Red for motor TRIP, breaker OPEN. Black for all annunciator functions, overloads reset and miscellaneous commands. Indicating Lamps Indicating lamps shall be of the panel mounting, LED type .The lamps shall have escutcheon plates marked with its function, wherever necessary. All indicating lamps shall be rated for continuous operation at 85% to 110% of their rated voltage. Low Voltage Glow Prevention (LVGP) feature shall be provided for indication lamps. Lamps shall have translucent lampcovers of the following colours, as warranted by the application: Red for motor ON, breaker CLOSE. Green for motor OFF, breaker OPEN. Blue for Service White for Test, Spring Charged, Spring Discharged, Lockout Relay Healthy Amber for auto trip
4.9.0
4.10.0 Control supply and space heater supply 4.10.1 The breaker operated MCC shall receive two nos. 220V DC feeder for the control supply and distribute to each panel. Auto changeover arrangement shall be envisaged between two supplies. Each panel shall receive control supply through bus wires and shall be tapped off through switch & fuse provided in the respective panel. It shall be possible to isolate any panel without disturbing the power supply to other panels. Each sub circuit shall have separate fuse.
4.10.2 An under voltage relay to monitor control supply shall be provided. A contact of the relay shall be wired to the terminal for external use. `Control Supply Failed indication shall be provided. 4.10.3 MCC shall derive 110V AC control supply through redundant control supply transformer. The control transformers shall be of insulation class `B or better. The sizing of control transformers shall be carried out by the bidder considering the actual load of power contactors, auxiliary contactors, indicating lamps and other equipment including remote auxiliary relays and lamps in the circuit. 4.10.4 For space heater circuits of motor rated more than 30kW and also for panel space heater, 240V AC supply shall be provided by tapping from the incomer before the main isolating switch/breaker. . Necessary switch and MCB to isolate and distribute the supply to each panel shall be provided. 4.10.5 For motor feeders, circuit for motor space heater shall be wired through NC contact of breaker/contactor and MCB . 4.10.6 Each panel of MCC shall be equipped with the following as required: Thermostatically controlled space heater(s). Illumination lamp with door switch 5A 3pin socket with MCB protection. 4.11.0 Wiring 4.11.1 All switchboards shall be supplied completely wired internally upto the terminals, ready to receive external cables. All internal wiring shall be carried out with 650 V grade, HR PVC/ XLPE insulated single core, copper conductor of minimum 2.5 sq.mm for CT circuits and 1.5 sq.mm for other circuits. 4.11.2 All internal wiring terminations shall be made with solderless crimping type tinned copper lugs. Insulation sleeves shall be provided over the exposed parts of lugs. Engraved core identification plastic ferrules marked to correspond with panel wiring diagrams shall be fitted at both ends of each wire. Number 6 and 9 shall not be used for wire identification. 4.11.3 Control terminal blocks shall be of 650 Volts grade, rated for 10 Amps and in one piece molding. It shall be complete with insulating barriers, clip-on type terminals and identification strips. Marking on terminal strip shall correspond to the terminal numbering on wiring diagrams. Terminal blocks for CT & VT secondary leads shall be provided with test links & isolating facilities. CT secondary leads shall be provided with short circuiting & earthing facilities. 4.11.4 In all the panels at least 10% spare terminals for external connections shall be provided and these spare terminals shall be uniformly distributed on all terminal blocks. 4.12.0 Power cable termination Cable termination compartment and arrangement for power cables shall be suitable for heavy duty, 1.1 kV grade, stranded aluminium conductor, PVC / XLPE insulated, armoured and FRLS PVC sheathed cables. All power cable terminals shall be of stud type and the power cable lugs shall be of tinned copper solderless crimping ring type conforming to IS:8309. All lugs shall be insulated / sleeved. 4.13.0 Nameplates and labels 4.13.1 Boards shall be provided with prominent, engraved identification plates. The module identification plate shall clearly give the feeder number and feeder designation. For single
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front switchboards, similar panel and board identification labels shall be provided at the rear also. 4.13.2 All name plates shall be of non-rusting metal or 3-ply Lamicoid, with white engraved lettering on black background. Suitable stenciled paint mark shall be provided in side the panel/module for identification of all equipment, in addition to the plastic sticker labels, if provided. These labels shall be positioned so as to be clearly visible and shall have the device number, as mentioned in the module wiring drawings. 4.13.3 Caution name plate Caution Live Terminals shall be provided at all points where the terminals are likely to remain live and isolation is possible only at remote end. 4.14.0 Busbars and Insulators 4.14.1 MCC shall be provided with three phase and neutral busbars. DC distribution boards shall have two busbars. All busbars and jumper connections shall be of high conductivity copper / aluminium/ aluminium alloy of adequate size. The cross-section of the busbars shall be uniform throughout the length of switchboard .. 4.14.2 All busbars shall be adequately supported by non-hygroscopic, non-combustible, trackresistant and high strength sheet moulded compound or equivalent type polyester fibre glass moulded insulators. All busbar joints shall be provided with high tensile steel bolts, belleville/ spring washers and nuts. All copper to aluminium joints shall be provided with suitable bimetallic washers. All busbars shall have HRPVC sleeves and colour coded. 4.14.3 Contact surfaces at all joints shall be silver plated or properly cleaned and anti-oxide grease applied to ensure an efficient and trouble free connection. Suitable bimetallic connectors shall be used for dissimilar metal connections 4.14.4 The continuous rating of the main busbars shall be same as that of the incomer breaker, and busbar shall carry this continuous current without exceeding the temperature of 90 C. For silver plated joints, temperature shall not exceed 105C. All horizontal and vertical busbar joints shall be covered by insulating shrouds. 4.15.0 Earthing 4.15.1 A copper/ Aluminium earthing bus of adequate size shall be provided at the bottom and shall extend through out the length of switchgear. It shall be bolted to the framework of each panel and each breaker earthing contact bar. The earth bus shall be sized to withstand specified short circuit current. 4.15.2 The truck and breaker frame shall get earthed while the truck is being inserted in the panel and positive earthing of the truck and breaker frame shall be maintained in all positions i.e., Service, Test and Isolated as well as through out the intermediate travel. 4.15.3 All non-current carrying metal work of the switchboard shall be effectively bonded to the earth bus. All hinged doors shall be earthed through flexible earthing braid. VT and CT secondary neutral point earthing shall be at one place only on the terminal block. All metallic cases of relays, instruments and other panel mounted equipment shall be effectively bonded to the earth bus by independent stranded copper wires of size not less than 2.5 sq.mm. 4.16.0 Local Push Button Stations The local push buttons stations shall be with FRP enclosure, suitable for outdoor mounting on wall or steel structures. The local push button stations shall be dust and vermin proof and shall have a degree of protection of IP - 55 as per IS : 13947 Part-1. Local push button stations shall comprise Start/Stop push buttons as per drive control philosophy. Emergency stop Push-buttons shall be stay put/ Latching type, requiring master key for de-latching. 4.17.0 Modules Description
4.17.1 The following shall be provided for each breaker feeders Electrical anti pumping feature Hand reset High speed lockout relay (86) Trip circuit supervision relay (74) Aux relay for breaker contact multiplication Aux relays as required for contact multiplication Indicating lamps for ON, OFF, Auto trip, Spring charged, Trip circuit healthy, DC supply fail etc. Breaker control switch Local / Remote/Test selector switch Test Terminal blocks 4.17.2 ACB incoming feeders for MCC from transformers shall be provided with the following as a minimum. TPN Circuit Breaker Current transformers for metering & protection Digital Multi function meter for Current, voltage, kW, kVA, PF measurement with communication port. Fuse/MCBs for control circuits Voltage transformers & digital voltmeter. Under voltage relay with timer Static releases for over current & short circuit and earth fault protection 4.17.3 ACB Bus coupler for PCC from transformers shall be provided with the following as a minimum. TPN Air Circuit Breaker Current transformer for protection & metering Fuse/MCBs for control circuits Static releases for over current & short circuit and earth fault protection Digital meter for Current 4.17.4 Unidirectional motor feeders rated up to 30 kW shall be provided with the following as a minimum. Triple pole MCCB Triple pole contactor. Auxiliary contactors LOCAL/REMOTE selector switch Bimetallic thermal overload relay with single phasing preventor. Push buttons. Indicating lamps with coloured lenses. MCB for control circuit Interposing relays Current transformer with digital ammeter for 30 kW rating only 4.17.5 Unidirectional motor feeders rated above 30kW and less than 125kW shall be provided with the following as a minimum. Triple pole MCCB Triple pole contactor. Auxiliary contactors LOCAL/REMOTE selector switch Bimetallic thermal overload relay with single phasing preventor. Push buttons. Indicating lamps with coloured lenses. MCB for 240V AC space heater circuit MCB for control circuit Current transformer with digital ammeter Interposing relays
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4.17.6 Unidirectional motor feeders rated 125 kW and above shall be provided with the following as a minimum. Triple pole Air Circuit Breaker Current Transformer for metering & Protection Numerical Motor protection relay Fuse/MCBs for control circuit Indicating lamps with coloured lenses. MCB for 240V AC space heater circuit MCB for control circuit Current transformer with digital ammeter Interposing relay 5.0.0 PAINTING Painting shall be carried out by approved process. After preparation of the under surface the switchgear shall be powder coated with epoxy based paint. The final thickness of paint film on steel shall not be less than 85 microns. Sufficient quantity of touch-up paint shall be furnished for application at site. Final shade shall be of RAL 7032. 6.0.0 TESTING AND INSPECTION Switchgear and all its components should have been type tested and proven type. Type test certificates shall be furnished for Owners review. Switchgear and its components shall be subjected to routine tests as per applicable Indian Standard. In addition, any special test required shall also be performed. Test reports shall be submitted for approval. 7.0.0 DRAWINGS, DATA AND MANUAL To be submitted after the award of contract: Completely filled in technical Schedules Dimensional General arrangement drawing Single line diagram Schematic & wiring diagram Busbar sizing calculation Catalogues/drawings for breakers, contactor, O/L relay, MCBs, Instrument Transformers, relays, meters etc. Quality Plan Test certificates Operation & Maintenance manual
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SECTION 4.5 MOTORS 1.0.0 INTRODUCTION This specification covers the requirements of HV Motors rated for 11 kV AC supply & Low Tension Motors rated for 415 / 240 AC supply for the River water intake System. 2.0.0 CODES AND STANDARDS The equipment to be furnished under this specification shall be in accordance with the applicable section of the latest version of the following Indian Standards, except where modified and /or supplemented by this specification. IS 325 IS 900 IS 996 IS 4029 IS 4691 IS 12065 IS 12075 IS 2148 3.0.0 3.1.0 3.1.1 Three phase induction motors. Code of practice for Installation and maintenance of induction motors. Single-phase small AC and universal electrical motors. Guide for testing three phase induction motors Degree of protection provided by enclosure for rotating electrical machinery. Permissible limits of noise level for rotating electrical machines Mechanical vibration of rotating electrical machines Flame proof enclosure of electrical apparatus.
DESIGN AND CONSTRUCTION Power Supply All AC Motors shall be squirrel cage induction type DC Motors shall be shunt wound type. All the motors shall be rated for continuous duty. Power supply for AC motors shall be as follows: Upto 0.75 kW From 0.75 kW to < 200 kW From 200 kW upto 1500kW Above 1500 kW : : : : 240 V, 1 Phase, 50 Hz. 415 V, 3 Phase, 50 Hz solidly grounded system 3.3 kV, 3 Phase, 50 Hz resistance grounded system 11kV, 3 Phase, 50 Hz resistance grounded system
Motors fed through AC VVVF drives shall be of inverter duty type. 3.1.2 3.1.3 All HT & LT motors shall have direct on-line starting.. AC Motors shall be capable of delivering the rated output with supply voltage variation of 10% and frequency variation of 5% and absolute sum of 10%.. HT Motors (200kW rating and above) shall be controlled from HT switchgear through Vacuum type breakers. Motor of rating from 125kW and less than 200kW shall be controlled through ACBs. Motors of rating below 125kW shall be controlled through MCCB and contactors. However, the duty of the drive/application, i.e. high impact loading, etc. to be considered as criteria for selecting ACB operated motors even for motor rating < 125kW Motors shall be capable of starting and accelerating the load with the direct on line starting without exceeding acceptable winding temperatures when supply voltage is 85% of the rated voltage for LV motors and 80% for HT motors. The motors shall be capable of operation at full load at a supply voltage of 80% of the rated voltage for 5 minutes commencing from hot condition. Motors shall withstand the voltage and torque stresses developed due to the vector difference between the motor residual voltage and the incoming supply voltage equal to 150% of the rated voltage, during fast change over of buses. The duration of this condition is envisaged for a period of one (1) second.
3.1.4
3.1.5
3.1.6
3.1.7
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3.2.0
Temperature rise Motors shall be designed for design ambient temperature of 50C. Temperature of the stator winding shall not exceed 120C while delivering maximum continuous rating.
3.3.0
Design Margin Unless otherwise specified in the corresponding Mechanical Specification, maximum continuous rating of Motors shall be atleast 16% above the maximum load demand of the driven equipment under entire operating range including voltage & frequency variations. Efficiency of motors shall conform to EFF2 values.
3.4.0
Torque Requirements The motor characteristics shall match the requirements of the driven equipment so that adequate starting, accelerating; pull up, breakdown and full load torque are available for the intended service. The accelerating torque at any speed with the lowest starting voltage shall be at least 10% of rated full load torque of the motor. The pull out torque at rated voltage shall not be less than 205% of full load torque.
3.5.0 3.5.1
Starting Requirements: Motors shall be suitable for the following starts under the specified conditions of load, torque and inertia in the motor initially at its normal operating temperature. No. of consecutive startups with initial temperature of the motor at ambient level (cold):3 No. of consecutive startups with initial temperature of motor at full load operating level (Hot):2 Locked rotor current of the AC motors shall be limited to 600% of the full load current of the motors. Locked Rotor Withstand Time The locked rotor withstand time for HT motors under hot conditions at 110% rated voltage shall be more than the starting time at minimum permissible voltage specified above by atleast three seconds or 15% of the accelerating time whichever is greater. Provision of speed switch shall be avoided to the extent possible. In case the speed switch is required, it shall be indicated by the bidder in his offer. When a speed switch is mounted on the motor shaft, the same shall remain closed for speeds lower than 20% and open for speeds above 20% of the rated speed. The speed switch shall be capable of withstanding 120% over speed in either direction of rotation. The locked rotor withstand time for LV motors under hot condition at 110% rated voltage shall be more than motor starting time by at least 2.5 seconds for motors with 20 seconds starting time and by 5 seconds for motor with more than 20 seconds starting time and more than the starting time by atleast 10% of the starting time for motors with starting time more than 45 seconds. Starting time shall be at the minimum permissible voltage specified. If the above conditions cannot be met in unavoidable cases, special provisions such as motor shaft speed switch, etc. shall be provided subject to the approval of the Owner/Consultant. Enclosure Motors shall have IP 55 degree of protection. detachable metal canopy. All motors for outdoor duty shall have
3.5.2
3.6.0 3.6.1
3.6.2
3.6.3
3.7.0
3.8.0
Cooling: Type of cooling for LT motors shall be TEFC and for HT motors TETV/TEFC/CACA.
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3.9.0 3.9.1
Winding All insulated winding shall be of copper. All HT & LT motors shall have class F insulation but limited to Class B temperature rise. Windings shall be impregnated to make them nonhygroscopic and oil resistant. The windings, fittings and hardware shall be corrosion resistant. The windings shall be tropicalized and suitably varnished, baked and treated for operating satisfactorily in humid and corrosive atmosphere. For motors rated above 30 kW, space heaters rated for 240V AC, 50 Hz supply shall be provided.
3.9.2
3.9.3
3.10.0 Bearings 3.10.1 Motor shall be provided with antifriction bearings, unless sleeve bearings are required by the motor application. Vertical shaft motors shall be provided with thrust and guide bearings. Thrust bearing of tilting pad type is preferred. However, if anti-friction bearings can take vertical thrust, thrust and guide bearings are not required. Bearings shall be provided with seals to prevent leakage of lubricant or entrance of foreign matters like dirt, water etc. into the bearing area. 3.10.2 Sleeve bearings shall be split type, ring oiled with permanently aligned, close running shaft sleeves. Grease lubricated bearings shall be prelubricated and shall have provisions for inservice positive lubrication with grease nipple and relief holes and shall be suitable for 8000 working hours without change of grease. 3.10.3 Lubricant shall not deteriorate under all service conditions. The lubricants shall be limited to normally available types. For motors rated 30kW & above relubrication facility shall be provided. 3.11.0 Accessories for HT Motor: 3.11.1 Embedded Temperature Detectors (ETDS) For HT motors, 12 nos. duplex RTDs for the stator winding each having D.C. resistance of 100 ohms at 0C, embedded in the stator winding at locations where highest temperatures may be expected, shall be provided. The material of the RTDs shall be platinum.. The temperature detectors shall be of 3 wire, duplex type. For bearing temperature measurement, RTDs shall be provided for each of the motor bearing & shall be wired upto the terminal box. 3.11.2 Bearing Thermometers: Each bearing shall be provided with a dial type thermometer. Each thermometer shall consist of temperatures gauges. The thermometers shall be located at a convenient height for easy reading and handling. One bearing shall be insulated to prevent shaft currents. 3.12.0 Terminal Boxes Separate terminal boxes of IP 55 degree of protection shall be provided for stator leads, space heaters and temperature detectors. For single core cables, gland plate shall be non-magnetic material. Terminal box shall be capable of being turned 360 in steps of 90, unless otherwise approved. The terminal boxes shall be split type with removable cover with access to connections. Terminal box design shall include special provision to avoid entry of fine Ash dust even after repeated maintenance activities. Cable boxes of all 11 kV motors shall be phase segregated type provided with quick disconnecting type terminal connectors. Separate terminal boxes to be provided for space
heater, RTDs for winding bearings temperature, vibration monitors etc. Double compression type brass cable glands and crimping type copper lugs shall be provided for termination For breaker operated Motors, terminal box shall have fault withstand capacity equal to at least rated short circuit level of the system voltage ( 40 kA for 11 kV System) for 1 sec. Terminals for LV motors shall be stud type, substantially constructed and thoroughly insulated from the frame. The terminals shall be clearly identified by phase markings, with corresponding direction of rotation marked on the non-driving end of the motor. For HT motors, the terminals of three phases shall be segregated by barriers of metal or fibre glass. Terminal boxes shall be suitable for receiving armoured aluminium / copper cables. Motor terminal box shall be furnished with suitable crimping type copper lugs and double compression type brass cable glands. For HT motors, cable box design shall be suitable for termination kits. 3.13.0 Earthing Terminals The frame of each motor shall be provided with two separate and distinct grounding pads complete with tapped hole, GI bolts and washer. The cable terminal box shall have a separate grounding terminal. The earthing terminal shall be suitable for receiving above ground earthing conductors. 3.14.0 Noise & Vibration Motors shall be selected with low noise levels in accordance with IS 12065. The peak amplitude of the vibration shall also be within the specified limits of IS: 12075. Maximum noise level measured at a distance of 1.5 metre from the outer surface of the motor shall not exceed 85 db(A). All HT motors shall be provided with vibration pads for mounting vibration detectors. 3.15.0 Name Plates Motor shall have stainless steel nameplate(s) showing diagram of connections, all particulars as per IS: 325 and following additional information : - Year of Manufacture - Type of bearing and recommended lubricants. - Additional tag (Stainless steel) at two places on the Motor body for equipment identification. Details of which shall be provided during detailed engineering stage 4.0.0 PAINTING Painting shall be carried out by approved process. After preparation of the under surface the equipment shall be painted with epoxy based paint. The final thickness of paint film on steel shall not be less than 100 microns and shall not be greater than 150 microns. Final shade shall be of RAL 7032. 5.0.0 TESTING AND INSPECTION Motors should have been type tested and proven type. All the motors shall be subjected to routine tests as per applicable Indian Standard. In addition, any special test required for the driven equipment shall be performed. Type test reports shall be furnished for approval.
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6.0.0
DRAWINGS, DATA AND MANUAL To be submitted after the award of contract: Completely filled in technical Schedules Dimensional General Arrangement drawing Characteristic curves Terminal box details Quality Plan Type test certificates Installation manual O&M manual
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SECTION 4.6 MOTOR ACTUATORS
1.0.0
INTRODUCTION This specification covers the requirements of motor operated electrical actuators for of the River water intake System.
2.0.0
CODES AND STANDARDS The equipment to be furnished under this specification shall be in accordance with the applicable section of the latest version of the relevant Indian Standards, and IEC publications, except where modified and /or supplemented by this specification.
3.0.0 3.1.0 3.2.0
DESIGN AND CONSTRUCTION General Actuators shall be integral type. Starter module required for the actuators are provided in actuator itself (Integral to actuators). Actuators shall be of totally enclosed weather proof and dust proof construction with IP 65 enclosure and shall be suitable for outdoor applications without the necessity for a canopy. Actuator shall be tested and proven type. Actuators shall be suitable for operation in damp, dusty polluted atmospheres of 90% relative humidity and 50C ambient temperatures. The unit shall be suitable for operation on a 415V, 10% 3 phase 50 Hz 5% AC supply. The Actuator shall be complete with motor, reduction gears, change gears, terminal compartment, Switch compartment with limit switches & Torque switches, local position indicator, position transmitter for remote position indicator, Thermistor, space heaters, cable glands, mechanical position indicator, Hand wheel for manual operation, Valve attachment etc. The actuator shall be suitable for mounting directly on the valve. The actuator shall be capable of giving the required torque, rpm and thrust without the help of any spur gear arrangement. The actuator shall be suitable for mounting in any position without lubrication leakage or other operational difficulty. Each actuator shall have a hand wheel fitted on it for emergency operation. The hand wheel shall be designed such that is de-clutched automatically when the power supply to the motor is restored. The material of the hand wheel shall be either malleable iron or steel. The hand wheel shall have adequate clearance from housing for each gripping and operation. Actuators offered shall be with self-locking worm. Two number adjustable torque switches, one for each direction of travel having 2 NO & 2 NC potential free contacts shall be provided. Torque switch dial should graduated directly in Nm for easy setting to desired value within the range specified. Separate dials should be provided for OPEN & CLOSE torque switches. Two auxiliary limit switches, one for each direction of travel having 2 NO & 2 NC potential free contacts shall also be provided. The limit switches shall be of independently adjustable type.
3.2.1
3.2.2
3.2.3 3.2.4
3.2.5
3.2.6
3.2.7
3.2.8
3.2.9
3.2.10 Limit switches and actuating mechanism shall be rust proof suitable for damp atmospheres and shall not cause any trouble during commissioning and operation. Limit switches compartment shall be weather proof and spacious enough for easy setting. 3.2.11 Limit switches shall be operated by gear driven cams, which are mechanically linked to the driving devices. The counter gear used for counting & tripping the limit switches shall be of metallic construction like brass, etc. No plastic gearing shall be allowed.
3.2.12 The Torque & Limit switches shall be suitable for the 220 Volts AC, 5 Amps and 220 Volts DC, 1 Amp. The switches shall individually be enclosed to a minimum of IP 66 protection class and shall have only stainless steel flaps for better protection against environmental condition. 3.2.13 Each actuator shall have a space heater in the limit switch compartment. 3.2.14 The actuator shall have built in local position indicator for 0-100% travel and position transmitter of non contract LVDT, 2 wire 220V DC type with 4-20 mA DC output for remote indicator. 3.2.15 The wiring from the limit switches, torque switches, position transmitter, space heater etc. shall be brought out in a separate terminal box of adequate size, so as to easily terminate the control cables. 3.2.16 Upon completion, each actuator shall be subject to standard routine test as per relevant standard. In addition, any special test required to prove the performance of the actuator shall also be carried out. 3.2.0 3.2.1 Motors Duty cycle of motors shall suit the system requirement. For open-close service, motors shall be rated for short time duty S2-15 minutes. For regulating/modulating service, motors shall be rated for intermittent duty S4-25%. Motors shall be suitable for direct on line starting. Motors shall comply with the latest revisions of IS: 325. Motor rating shall be atleast ten(10) percent above the kW requirement of driven equipment under entire operating range including voltage and frequency variation. Motor rating shall be such that it is not overloaded at any operating point of driven equipment from zero to full load. Maximum torque shall not be less than 200% of full load torque. All motors shall be designed to withstand hundred twenty (120) percent of rated speed without any mechanical damage for two (2) minutes. Motor shall capable of starting and accelerating to full speed at full load (including loaded equipment at eighty five (85) percent nominal voltage at motor terminals). Class of insulation shall be Class F. However temperature rise shall be restricted to limits corresponding to Class B insulation. Motor shall be of totally enclosed surface cooled (TESC) type with IP 65 protection class. Motor shall have thermister for overload protection. Motor shall have glossy, light grey finish to RAL 7032 The terminal boxes shall be complete with cable glands and termination accessories as required. Adequate clearance shall be provided for cable connections. Two (2) grounding terminals one (1) on either side at the bottom suitable for connecting GI flat / wire grounding conductor shall be provided Integral Starters with Electronic Controls Integral starter unit shall be provided with electronic control logic. Entire unit along with basic actuator shall conform to IP 65 enclosure standards. Required control supply voltage shall be derived from 3 phase 415V power supply. A three position selector switch (marked as LOCAL-OFF-REMOTE) and push buttons OPENSTOP-CLOSE (for local operation) with indication lamps for running OPEN and running CLOSE shall be provided.
3.2.2 3.2.3
3.2.4
3.2.5
3.2.6
3.2.7 3.2.8
3.2.9
3.3.0 3.3.1
3.3.2
3.3.3 3.3.4 3.3.5
Electro-mechanically interlocked contactors shall be offered as starters. Tripping by close torque or close limit switch shall be provided. Remote command signal (OPEN-STOP-CLOSE) from RWIS PLC shall be isolated from control electronics through opto-isolator. Individual status/fault annunciation LEDs shall be provided locally (Integral to actuator) to annunciate for easy local monitoring. Thermal overload relay shall be provided to trip actuator in case of overload. DRAWINGS & DOCUMENTS Information On Award Of Contract Completely filled in technical schedules GA drawing. Catalogues Wiring diagram Terminal block details Electrical data Functional description
3.3.6
3.3.7 4.0.0
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SECTION 4.7 220V DC SYSTEM 1.0.0 INTRODUCTION This specification covers the requirements of 220 V DC Batteries and Chargers for the River water intake System. 2.0.0 CODES AND STANDARDS The equipment to be furnished under this specification shall be in accordance with the applicable section of the latest version of the following Indian Standards and IEC standard, except where modified and /or supplemented by this specification. IS 266 IS 3895 IS 4540 IEEE-484 IEEE-485 3.0.0 3.1.0 3.2.0 DESIGN The batteries shall be sealed maintenance valve regulated lead acid types. The function of the 220V DC Power Supply System is to provide the normal source of power to the 220V DC loads, such as Control Supply to Switchgears / Panels and emergency lighting. The 220V DC Power Supply System shall also be capable of constantly supplying emergency loads for a period of 1 hour when AC supply to Charger fails. The duty cycle imposed on the battery shall include the following. Continuous loads (Emergency DC lighting, indicating lights, continuously energized coils, Control Panels, Relays) Momentary loads (switchgear operation (Trip coil/Closing coil), Solenoid valves operation (Closing/Opening), which exist for a period of less than 1 min period) Specification for Sulphuric acid Mono crystalline Semi conductor rectifier cells and stacks Mono crystalline Semi-conductor rectifier assemblies and equipment Recommended Design for Installation design and installation of large lead storage batteries for generating stations and substations. Sizing large lead storage batteries for generating stations and substations.
3.3.0 3.4.0
3.5.0
The 220 VDC Power Supply System shall be operated as an ungrounded system; that is, the negative terminal or ground reference terminal is not connected to the station ground grid . A DC ground monitoring system on the DC systems shall be provided and any DC ground fault shall be alarmed. Batteries shall be sized in accordance with IEEE-485. The battery shall be sized with a 10% design margin and an ageing factor of 1.25 220V DC Power Supply System consists of 2X100%, 220V battery, 2X100% 220V float cum battery chargers and DC Distribution Boards. End Cell Voltage of Lead Acid battery is 1.85 V / Cell . During Normal operating condition, batteries shall be supplied from two (2) 100 percent battery chargers. The chargers are supplied power from MCCs. The battery chargers shall supply the 220V DC loads and, at the same time, shall continuously float charge fully charged batteries. Both the chargers shall have dedicated incoming AC supply from MCC.
3.6.0 3.7.0 3.8.0 3.9.0
3.10.0 During Emergency operation the battery shall supply the DC load when there is a loss of all auxiliary AC power supplies and/or a loss of power from the battery chargers. Battery shall normally be permanently connected to the load in parallel with a charger and shall supply the load during emergency condition when AC supply is lost. 3.11.0 The Charger shall be float cum boost type Chargers shall be suitable for float charging both
the batteries and supply load simultaneously. Chargers shall boost change fully discharged batteries in 12 hours. Design margin of minimum 10% shall be considered in charger sizing for either mode of operation. 3.12.0 Charger protections such as DC-O/V & U/V, AC U/V, E/F, S/C protection etc shall be considered. 4.0.0 4.1.0 CONSTRUCTION OF BATTERY Containers shall be made of Polyproplene. Containers shall be clear, robust, heat resistance, shock absorbing, leak proof, non-absorbent, acid/alkaline resistant, non-bulging type and free from flaws such as wrinkles, cracks, blisters, pin holes etc. Batteries shall have thick Positive plates & negative Plates with low Corrosion, low self discharge rates & maintenance free characteristics. Battery terminals shall be specially designed for sustained high current discharges. All connectors, hardwares like nuts and bolts shall also be designed accordingly. The separators shall maintain the electrical insulation between the plates and shall allow the electrolyte to flow freely. The positive and negative terminals shall be clearly marked. The following items shall be provided for the battery a) b) c) d) 4.7.0 Long/Short connectors Inter row connectors Fasteners Cell number plates
4.2.0
4.3.0
4.4.0
4.5.0 4.6.0
Battery Racks shall be free standing type. Numbering tags for each cell shall be attached on to the racks. The bottom tier of the stand shall not be less than 150 mm above the floor. Wherever racks are transported in dismantled conditions, suitable match markings shall be provided to facilitate easy assembly. CONSTRUCTION OF BATTERY CHARGER During float charging, each charger shall feed the respective DC Distribution board and as well as float charge its own batteries and shall maintain a DC voltage that shall pass the minimum current through the cells to keep them charged without overcharging. In case of mains failure to charger or charger failure, battery shall supply the full load. While boost charging of respective battery, DCDB shall be isolated from the Charger and shall be fed from other Charger. Each Battery charger should meet the Trickle requirement of both banks (under emergency) and boost requirement of each bank During boost charging, the battery charger shall operate on constant current mode (when automatic regulator is in service). It shall be possible to adjust the boost charging current continuously over a range of 50 to 100 % of the rated output current for boost charging mode. During boost charging the Boost charger shall recharge the completely discharged battery to full capacity in 10 hours. When on automatic control mode during float charging, the charger output voltage shall remain within + / - 1% of the set value for AC input voltage variation of 10%, frequency variation of 5% , a combined voltage and frequency (absolute sum) variation of 10 % and a continuous DC load variation from zero to full load. Uniform and stepless adjustments of voltage setting (in both manual and automatic modes) shall be provided on the front of the
5.0.0 5.1.0
5.2.0
5.3.0
5.4.0
charger panel covering the entire float charging output range specified. Battery chargers shall have a selector switch for selecting the battery charging mode i.e. whether float or boost charging. 5.5.0 All battery chargers shall be provided with facilities such as automatic voltage regulator (AVR) for both automatic and manual control of output voltage and current. The chargers shall be of self regulating, natural air cooled, static type provided with suitable double wound transformer, full wave thyristor type rectifiers, filter circuits, DC & AC Switchgear. Chargers shall be metal enclosed, fixed type, suitable for indoor mounting on floor. Panel frame shall be fabricated using cold rolled sheet steel of thickness not less than 2.0 mm. The frames shall be enclosed by cold rolled sheet steel of thickness not less than 2.0 mm. Suitable synthetic rubber gaskets shall be provided to achieve a degree of protection of IP-31. Rectifier transformer shall be continuously rated, dry type, class F insulation, epoxy resin impregnated, A.N. cooling and with adequate no of taps. The rating of rectifier transformers shall correspond to the rating of the associated rectifier assembly. All the charger panels shall be provided with an illuminating CFL lamp, a 5 Amp socket and space heaters with thermostat. Toggle switches and MCBs shall be provided separately for each of the above fittings. Space heaters ON indication to be provided. Two separate grounding pads shall be provided. Locking facilities shall be for locking float / boost selector switch in the float position only.
5.6.0
5.7.0
5.8.0
5.9.0
5.10.0 Digital type Window annunciator shall be provided for alarm annunciation with acknowledge, test and rest push buttons and a buzzer for the following conditions. SCR fuse fail Battery / DC system under voltage DC system over voltage DC over load Output fuse blown AC supply fail AC under voltage Battery earth fault Filter fuse failure Battery on Float / Boost Charger fail/Battery on discharge Any other annunciation, as required
5.11.0 Protection features, indications, meters and alarms shall be provided for each charger. Protection features shall include the following as minimum. 6.0.0 Overload Protection Phase failure protection Voltage unbalance protection Fuse failure protections for SCR and filter circuit
PAINTING Painting shall be carried out by approved process. After preparation of the under surface the switchgear shall be powder coated with epoxy based paint. The final thickness of paint film on steel shall not be less than 85 microns. Final shade shall be RAL 7032.
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7.0.0
TESTING AND INSPECTION Battery & Charger and all its components should have been type tested and proven type. Type test certificates shall be furnished for Owners review. Battery & Charger shall be subjected to routine tests as per applicable Indian Standard. In addition, any special test required shall also be performed. Test reports shall be submitted for approval.
8.0.0 8.1.0
DRAWINGS, DATA AND MANUAL Drawings/Documents to be Submitted After Award of Contract: Technical schedules duly filled in Dimensional General arrangement drawing for Chargers Schematic & wiring diagram for Chargers Sizing Calculation for Charger Dimensional General arrangement drawing for each Battery, Fuse box & Discharge Resistor. Sizing Calculation for battery Drawings for battery rack & fixing arrangement Quality Plan Test certificates O&M Manual
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SECTION 4.8 UPS SYSTEM 1.0.0 INTRODUCTION This specification covers the requirements of Uninterruptible Power Supply system (UPS) for the River water intake System. 2.0.0 CODES AND STANDARDS The equipment and accessories covered under this specification shall be designed, manufactured and tested in accordance with the latest revision of the applicable Standards.. 3.0.0 3.1.0 DESIGN AND CONSTRUCTION To provide Uninterrupted power supply to River water intake system PLC, back up panel and other control panels, 240 V AC UPS system is envisaged. UPS system shall be of parallel redundant with static bypass consisting of 2x100% chargers, 2X100% inverters, 1x100% battery, Isolating transformer and Servo controlled voltage stabilizer, Static bypass and Maintenance bypass, UPS battery shall be rated for 60 minutes back-up. Normally, each inverter shall share 50% UPS load. On failure of any inverter, other inverter shall feed 100% load. On failure of both the inverters, a Normal AC source shall feed UPS load automatically through a static transfer switch. Additionally maintenance bypass switch shall be provided. Power supply shall be restored manually back to inverter from the voltage stabilizer. Output from Inverter shall be single phase sine wave, 50 Hz. The output from UPS shall be connected to UPS DBs. Redundant feeders shall be provided for all critical loads. UPS shall be located in Air conditioned room. UPS Battery shall be of Sealed Maintenance free Lead Acid Plante battery. In the event of mains supply failure, the floating battery bank shall be connected to the DC input of each inverter and maintain continuity of AC Power output without interruption, through inverters During normal operation both the inverters shall share the load equally. On failure of an inverter due to any one of the following faults: Excess inverter output voltage Very low inverter output voltage
3.2.0
3.3.0 3.4.0 3.5.0 3.6.0 3.7.0
3.8.0
On failure of inverter, the entire load shall be automatically transferred to the other inverter. Parallel operation (load sharing) shall start automatically when the fault condition clears. If the transfer was due to the inverter failure the retransfer (parallel operation) shall be manually initiated. 3.9.0 The entire load shall be automatically transferred to the alternate AC source through static switch within a maximum of five (5) milli-seconds under the following conditions : Battery discharged completely Initiation of manual control switch Failures of both inverters Inverter output voltage is more than 5 % of the rated value The load current exceeds specified over load rating and time.
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3.10.0 Retransfer of load shall be accomplished automatically by synchronizing the inverter to the alternate source and allowing the inverter to ramp into the load and then disconnecting the alternate source. Manual transfer facility through static transfer switches shall be provided in either direction. 3.11.0 The UPS shall be protected from over voltage, under voltage, overload and short circuits. The UPS shall have facility for remote indication of the essential alarms and indications. 3.12.0 The overall efficiency of UPS system shall be more than 90%. 3.13.0 Battery capacity shall be based on inverter efficiency. Supplier shall furnish sizing calculations for the battery. 3.14.0 The batteries shall be supplied with the following accessories. a. b. c. d. e. f. g. plated terminals posts Battery racks Porcelain insulators, rubber pads etc. Set of intercell, intertier and interbank connectors as required. Centre - Zero DC voltmeter for cell voltage measurements Spanner set Ammeter
3.15.0 The UPS system components comprising of inverters shall be suitably housed in sheet steel panels and shall be complete with all interconnections. The panels shall be fabricated with 2 mm thick cold rolled sheet steel and structural steel. Degree of protection for cubicles shall be IP 31. 3.16.0 Each UPS panel shall be provided with the following:a. Internal illumination lamp with door switch b. Thermostat controlled space heater. c. One (1) no 3 pin, 5A, receptacle with plug. The above shall be rated for 240 V + 10%, 50Hz + 5% 1 phase AC, supply and shall have individual MCB units. 3.17.0 All control wiring shall preferably be enclosed in plastic channels or neatly bunched together. Each wire shall be identified at both ends by self sticking wire marker tapes or PVC ferrules. Ferruling of wires shall be as per relevant IS. 3.18.0 UPS shall be provided with the required meters, controls, indications and alarms for proper operations and maintenance. The display shall be of LCD type. 4.0.0 PAINTING Painting shall be carried out by approved process. After preparation of the under surface the equipment shall be painted with epoxy based paint by powder coating. The final thickness of paint film on steel shall not be less than 85 microns. Final shade shall be 631 (light grey) of IS 5. 5.0.0 TESTING AND INSPECTION UPS & Battery should have been type tested and proven type. Type test certificates shall be furnished for Owners review. UPS shall be subjected to routine tests as per applicable Indian Standard. In addition, any special test required shall also be performed. Test reports shall be submitted for approval.
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6.0.0 6.1.0
DRAWINGS, DATA AND MANUAL Drawings/Documents to be Submitted After Award of Contract: Technical schedules duly filled in Dimensional General arrangement drawing for UPS Schematic & wiring diagram for UPS Sizing Calculation for UPS and battery Quality Plan Test certificates O&M Manual
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SECTION 4.9 POWER AND CONTROL CABLES 1.0.0 INTRODUCTION This specification covers the requirements Power & Control cables for the River water intake System. 2.0.0 CODES AND STANDARDS The equipment to be furnished under this specification shall be in accordance with the applicable section of the latest version of the following Indian Standards, except where modified and /or supplemented by this specification. IS 1554 IS 7098 -I IS 7098 -II IS 10810 3.0.0 3.1.0 DESIGN Power cables shall be sized to satisfy the following Criteria: 3.2.0 Short circuit withstand capacity for applicable fault current and duration. Full load current carrying capacity under installation conditions considering Site ambient temperature & site installation (Grouping) conditions based on Manufacturers recommendation. Permissible voltage drop limits under steady state/transient state as applicable. PVC insulated (heavy duty) electric cables for working voltages up to and including 1100 volts. Cross linked polyethylene insulated PVC sheathed cables for working voltages up to and including 1100 volts. Cross linked polyethylene insulated PVC sheathed cables for working voltages from 11 kV up to and including 33 kV. Methods of tests for cables.
Power cables shall withstand the fault current of the circuit for the duration not less than the max. time taken by the primary protective system to isolate the fault. Cables shall be sized for specified short circuit rating for the following duration. Incoming cables to 11kV Switchboards : 1 sec. Outgoing cables from 11kV Switchboards : 0.16 sec. Incoming cables to 415 V MCC (Breaker operated) : 1 sec. Cables from 415 V MCC to breaker operated Motors : 0.16 sec
3.3.0
To maintain voltage at motor terminals /equipment end with in desirable limit, it is proposed to limit the voltage drop in the cables with in the following limits: Steady state Voltage drop (Continuous running condition) Transient state voltage drop (During Motor Starting) : 2-3% : 15 %
3.4.0
All cables shall be suitable for laying on racks, in ducts, trenches with chances of flooding by water and shall also be suitable for directly buried installation. All the cables shall be flame retardant low smoke (FRLS) type designed to withstand mechanical, electrical and thermal stresses developed under steady state and transient operating conditions. The minimum size of LV power cable shall be of 2.5 Sq.mm for Copper. Power cables shall have copper conductor for sizes up to 4 sq.mm. For higher sizes, aluminium conductor shall be provided. The minimum size of control cable shall be of 1.5 Sq.mm copper. For CT/VT circuits, minimum 2.5 sq.mm copper cable shall be provided. Conductor of Copper cables shall have plain annealed copper. All the conductors shall be multi-stranded.
3.5.0
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3.6.0
Power cables shall be XLPE insulated.. Control cables shall be PVC insulated. PVC insulation shall be suitable for continuous conductor temperature of 70C and short circuit conductor temperature of 160 deg.C. XLPE insulation shall be suitable for continuous conductor temperature of 90 C and short circuit conductor temperature of 250C. The cable cores shall be laid up with fillers between the cores wherever necessary. All the cables shall have distinct extruded PVC inner sheath. For single core armoured cables, armouring shall be of aluminium wire. For multicore armoured cables, armouring shall be of galvanised steel strip/wire as per applicable IS. Outer sheath shall be of PVC black in colour having following FRLS properties. Oxygen index of not less than 29. Acid gas emission of max. 20% Smoke density of not more than 60%
3.7.0
3.8.0
3.9.0
3.10.0 The cables shall meet flammability test as per IEEE 383. 3.11.0 All the cables shall be protected against rodent and termite attack. Necessary chemicals shall be added in to the PVC compound of the outer sheath. 4.0.0 4.1.0 CONSTRUCTION 11 kV cables Cables shall be XLPE insulated, screened, PVC inner sheathed (extruded), armoured, FRLS PVC outer sheathed, compacted aluminium conductor conforming to IS : 7098 Part-II. 11 kV cables shall be suitable for unearthed system. The conductor screen and insulation screen shall both be of extruded semi-conducting compound and shall be applied along with the XLPE insulation in a single operation of triple extrusion process. The metallic screen of each core shall consist of copper tape with minimum overlap of 20% copper screen which shall be capable of carrying the system earth fault current of 300A for 2 seconds. Outer sheath shall be FRLS PVC. 4.2.0 LV Power cables LV Power cables shall be of 1.1 kV grade, XLPE insulated, PVC inner sheathed (extruded), armoured, FRLS PVC outer sheathed, compacted aluminium conductor conforming to IS: 7098 Part-I. 4.3.0 Control cables Control cables shall be of 1.1 kV grade, multicore, PVC insulated, PVC inner sheathed, armoured, FRLS PVC outer sheathed stranded copper conductor conforming to IS:1554 Part-I. Up to 5 cores it shall be colour coded and above 5 cores shall be numbered. 4.4.0 Cable identification system In addition to manufacturers identification on cables as per IS, following marking shall also be embossed over outer sheath. Cable size and voltage grade. Word `FRLS at every 5 metre. Sequential marking of length of the cable in meters at every one metre. The embossing shall be progressive, automatic, in line and marking shall be legible and indelible. 4.5.0 Cable drums Cables shall be supplied in wooden or steel drums of heavy construction. The surface of the drum and the outer most cable layer shall be covered with waterproof layer. Both the ends of
the cables shall be properly sealed with heat shrinkable PVC/rubber caps, secured by Ù nails so as to eliminate ingress of water during transportation, storage and erection. Wood preservative anti-termite treatment shall be applied to the entire drum. Wooden drums shall comply with IS 10418. 5.0.0 5.1.0 TESTING AND INSPECTION Cables offered shall be of type tested and proven type. Type test certificates for test conducted earlier on similar rating shall be furnished. Routine tests, Acceptance tests and all special tests for FRLS properties shall be carried out for all the cables as per applicable standards. The sample shall be drawn at the rate of one per type and size for every lot offered for inspection. Special Tests The following tests as applicable to FRLS sheathed cables shall be conducted as type tests on each size of each lot. a. Oxygen index test b. Temperature index test c. Acid gas generation during fire d. Smoke generation test under fire e. Swedish chimney test for class F3 as per SS : 4220 14 : 75 f. Under fire conditions for bunched cables as per IEEE std. 383 / 74 6.0.0 6.1.0 DRAWINGS, DATA AND MANUAL To be submitted after the award of contract Completely filled in technical Schedules Cross section drawing showing construction details. Various rating factors Quality Plan Test certificates
5.2.0
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SECTION 4.10 CABLING, EARTHING & LIGHTNING PROTECTION SYSTEM 1.0.0 INTRODUCTION This specification covers the requirements of cable trays, support structures, cable laying, termination, earthing and lightning protection system for the River water intake System. 2.0.0 CODES AND STANDARDS The equipment to be furnished under this specification shall be in accordance with the applicable section of the latest version of the following Indian Standards, except where modified and /or supplemented by this specification. IS 1255 IS 732 IS 2309 IS 3043 3.0.0 3.1.0 3.2.0 3.3.0 Code of practice for installation and maintenance of power cables up to and including 33 kV rating. Electrical wiring installation (system voltage not exceeding 650 V). Code of practice for the protection of building and allied structures against lightning. Code of practice for earthing.
GENERAL REQUIREMENTS While finalizing Cable routing layouts, consideration shall be given to the requirements of Safety, Reliability and Convenience of cable laying and termination. Where duplicate drives/auxiliaries are provided for reliability, cable routing shall be segregated to the extent practically possible. In cable trenches, distance between bottom most tier and bottom of trench shall be 150 mm and clearance from top most tray to top of trench cover shall be 400 mm. Distance between two tiers shall be minimum 250 mm. PCC flooring of built-up trenches shall be sloped in longitudinal and also in transverse direction for effective drainage system. Other than cable vault & cable trenches, Cable trays shall be laid in vertical formation to avoid dust accumulation in RWIS areas. Cables tray route shall be separate for both the streams of RWIS and shall be designed & spaced such that cables are not affected due to conveyor belt fires. In cable spreader room a clear access passage of atleast 800 mm wide shall be provided along the cable ways. Wherever passage is through cable routes, a clear height of not less than 2.0 M shall be provided. Cables should not be laid directly in the trench floor. Cables trenches should be provided with strong & effective covers with water & fire proof sealing arrangement at trench entry & exit points. Cables of different voltages shall be laid in separate racks. Minimum distance of 250 mm shall be maintained along the routes between various types of cables. In case of horizontal formation, the highest voltage cables shall be laid in the top most position in the tray stack followed by other grades as follows in the descending order. HT Power cables (Top Tier) 1.1kV Power cables ( Below HT Tier) Electrical Control Cables ( Below LT Tier) Instrumentation/Signal cables ( Bottom most tier)
3.4.0 3.5.0 3.6.0 3.7.0
3.8.0
3.9.0
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3.10.0 On cable trays all the multicore power cables can be laid in touching formation. Single core cables shall be laid in trefoil formation with the spacing equal to twice the diameter of the cable. 3.11.0 Control cables shall be laid in not more than two layers. 3.12.0 Cables shall be terminated using double compression cable glands suitable for the voltage grade of cables. Cable glands shall be heavy duty brass. For flame proof equipment cable glands shall be of flame proof type. Cable lugs for power and control cables shall be tinned copper solderless crimping type conforming to IS 8309. 11 kV cable termination shall preferably be of heat shrinkable type kits. 3.13.0 Power & Control cables shall be laid on ladder type trays. instrumentation & Signal cables shall be laid on Perforated type trays. Cable trays shall be of galvanized steel. Cable trays shall be supported at an interval of 1500 mm approximately. Vertical runs shall be supported at an interval of 1000 mm approximately. Cable tray support system shall be of site fabricated, welded and painted steel supports. 3.14.0 Cable tray support system shall consist of ISMC channel as vertical support & ISA horizontal arm. Horizontal arm is welded to the vertical support MS channel. as
3.15.0 Fire barriers/ Fire stops shall be provided for all fire rated wall and floor penetrations and for all direct cable entries into electrical Switchgear / Panels from Cable Vault. 3.16.0 Fire barriers/ Fire stops shall provide a fire endurance rating of at least 2 hours. The fire sealing material shall be non-hygroscopic, mechanically steady, non-toxic and physically & chemically stable under fire conditions. Fire barriers/ Fire stops shall be either of the following methods: a) b) 4.0.0 4.1.0 4.1.1 Panel sealing method comprising Encasing Panels, Cavity fill material & Sealant Mortar Sealing method comprising Mixing Mortar curing with water.
DESIGN AND CONSTRUCTION Cable trays, Fittings & Accessories Cable trays shall be ladder/perforated type as specified prefabricated made out of hot/cold rolled mild steel sheets, complete with matching fittings (like elbows, bends, reducers, tees, crosses, etc.), accessories (like side coupler plates, Tray cover etc.) and hardware (like bolts, nuts, washers, G.I. strap, hook etc.) as required. All the items (including hardware) shall be hot dip galvanized. Thickness of galvanising shall be not less than 610grams/sq.M. The size of the trays shall be selected on the basis of maximum 40% fill criteria. Cable trays shall be standard width of 150mm, 300mm , 450 mm & 600mm and standard lengths of 2.5 M or more. Minimum thickness of mild steel sheets used for fabrication of cable trays and fittings shall be 2mm. Rung spacing shall be 250 mm maximum. The thickness of side coupler plates shall be minimum 2.5 mm and of tray covers shall be minimum 1.6mm. Cable Trough shall be required for branching out few cables from main cable route. These shall be fabricated of mild steel sheets of minimum thickness 2mm and shall be hot dipped galvanised. Troughs shall be of standard width of 50mm & 75mm and 25mm height. Conduits/Pipes, Fittings & Accessories Conduits/pipes offered shall be complete with fittings and accessories (like tees, elbows, bends, check nuts, bushings, reducers, enlargers, coupling caps, nipples etc.). The size of the conduit/pipe shall be selected on the basis of maximum 40% fill criteria. Hume pipes shall be of reinforced concrete conforming to class NP3 for road crossings as per IS:458. GI pipes shall be of medium duty as per IS:1239.
4.1.2
4.2.0 4.2.1
4.2.2
4.2.3
Rigid steel conduits conforming to IS:9537 Part-I & II shall be suitable for heavy mechanical stresses, threaded on both sides and threaded length shall be protected by zinc rich paint. Conduits shall be smooth from inside and outside. Fittings and accessories shall also be hot dip galvanised. Flexible conduits where required, near equipment terminations, shall be made with bright, cold rolled, annealed and electro-galvanized mild steel strips. Flexible conduits shall be supplied with suitable end coupler nipple and check nut. In corrosive areas, epoxy coated conduits shall be provided. Clamps Trefoil clamps for single core cables shall be pressure die cast aluminium or fibre glass or nylon and shall include necessary fixing accessories like G.I. nuts, botls, washers etc. Trefoil clamps shall have adequate mechanical withstand capability in case of a fault and shall be tested and proven type. For clamping the multicore cables selflocking, de-interlocking type nylon used. CABLING INSTALLATION The work shall be carried out in the best workman like manner in conformity with relevant specifications / code of practices of the Bureau of Indian Standards. In addition, work shall also confirm to the requirements of latest editions / amendments of the following: Indian Electricity Act and rules framed thereunder. Fire Insurance Regulations Regulations laid by the office of the Chief Electrical Inspector to Government. Any other regulations laid down by the local authorities. clamps shall be
4.2.4
4.3.0 4.3.1
4.3.2
4.4.0 4.4.1
4.4.2
Support system shall be so designed that it is able to withstand weight of the cable trays, Weight of the cables (75 Kg/metre run of each cable tray), Concentrated load of 75 Kg between every support span without any permanent deflection. Factors of safety of atleast 1.5 shall be considered. Cable tray mounting structure shall be welded/bolted to the plate inserts or to steel structure and the type of welding shall be of fillet type of at least 6mm size. All cable way sections shall have identification, designations as per cable way layout drawings and painted/stenciled at each end of cable way and where there is a branch connection to another cable way. Minimum height of letter shall be not less than 75mm. For long lengths of trays, the identification shall be painted at every 10 meter. Risers shall additionally be painted/stenciled with identification numbers at every floor. Tray covers shall be provided for over head cable trays on top most tier. The cable risers or vertical raceways shall also be covered by cable tray covers upto 1.5 metres from respective floor for mechanical protection. The sheet cover shall be of removable type. EARTHING SYSTEM Buried earth grid conductors shall be provided in entire River water intake system. Earthing mat design shall be carried out as per IS-3043. Earth mat shall be designed such that ground grid resistance shall not exceed 1.0 ohm. For earth mat design the following shall be considered:. Maximum ground fault current Ground fault current duration for conductor sizing : As per system requirement : 1 sec
4.4.3
4.4.4
4.4.5
5.0.0 5.0.0
Shock duration for Mesh sizing Type of buried earthing conductor Type of above ground earthing conductor 5.1.0
: 0.5 sec : Mild steel rod : galvanized steel flat
Earth continuity conductor shall run throughout the plant as part of personnel safety & E/F return current path 50 x 6 mm galvanised M.S. flats are run as main earth conductor along building columns / walls and securely fixed to the same by welding / clamping at intervals not exceeding 1000mm. Electronic earthing shall be provided for RWPH PLC system and shall be completely isolated from the Plant earthing system. For multicore cables, cable screen/armour shall be earthed at both the ends. For Single core cables, cable screen/armour shall be earthed at one end at preferably at Switchgear end only. Metallic frame of all electrical equipment shall be earthed by two separate and distinct connections to earthing system, each of 100% capacity. Steel RCC columns, metallic stairs, hand rails etc. of the building housing electrical equipment shall be connected to the nearby earthing grid conductor by one earthing . For cable trays, a separate ground conductor shall run along the entire length of cable tray and shall be suitably clamped on each cable tray at periodic intervals. Each continuous laid out lengths of cable tray shall be earthed at minimum two places by G.S. flats . The ground conductor connections shall be welded except at the equipment end, where the connections are bolted. On completion of installation, continuity of earth conductors and efficiency of all bonds and joints shall be checked. Earth resistance at earth terminations shall be measured in presence of Owner's representatives. Thickness of galvanising shall be atleast 610gm/sq.m for all galvanised steel conductors. LIGHTNING PROTECTION SYSTEM Lightning protection system shall be provided for all the buildings and structures covered under the Scope as per the provisions contained in the latest issues of Indian Electricity Rules and IS 2309. Lightning protection system shall comprise air terminations down conductors, test links, earth terminations & earth electrodes. Material for lightning protection conductor shall be as follows: 50 x 6 mm Galvanised steel strip for Horizontal Air termination & Down Conductors 40 mm dia 3 m long Mild Steel rod with earth pit for Earth termination Air termination network consist of horizontal conductors. Down conductors should follow the most direct path possible between the air terminal network and the earth termination network. The down conductors should be arranged as evenly as practicable around the outside walls of the structure. Each down conductor shall be provided with a test link for testing. An earth electrode with treated earth pit shall be connected to each down conductor.
5.2.0
5.3.0
5.4.0
5.5.0
5.6.0
5.7.0
5.8.0
5.9.0 6.0.0 6.1.0
6.2.0
6.3.0 6.4.0
6.5.0
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7.0.0
TESTING AND INSPECTION Equipment offered shall be of type tested and proven type. Type test certificates for test conducted earlier on similar rating shall be furnished. Routine tests shall be carried out for all the equipment as per applicable standards.
8.0.0
DRAWINGS, DATA AND MANUAL To be submitted after the award of contract: Completely filled in technical Schedules. General arrangement drawings & mounting details for various items Equipment layout drawing Cable tray layout drawing Earthing layout drawing Lightning protection layout drawing Quality Plan Test certificates Catalogues
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SECTION 4.11 LIGHTING SYSTEM 1.0.0 INTRODUCTION This specification covers the requirements of Illumination system for River water intake System. 2.0.0 CODES AND STANDARDS The equipment to be furnished under this specification shall be in accordance with the applicable section of the latest version of the following Indian Standards, except where modified and /or supplemented by this specification. IS 418 Tungsten filament general service electric lamps IS 1777 Industrial luminaire with metal reflectors. IS 1947 Flood Lights IS 10322 Luminaires for street lighting. IS 1944 Code of practice for design of Street lighting IS 2206 Flame proof electric lighting fittings IS 2215 Starters for fluorescent lamps. IS 2418 Tubular fluorescent lamps for general lighting services IS 4013 Dust-light electric lighting fittings IS 8224 Electric Lighting fittings for Div. 2 areas. IS 9583 Emergency lighting units. IS 9900 High-pressure mercury vapour lamps. IS 9974 High Pressure sodium vapour lamps. IS 2713 Specification for Tubular Steel Poles for Overhead Power Lines 3.0.0 3.1.0 DESIGN AND CONSTRUCTION The plant lighting system includes 100% Normal AC lighting Emergency DC lighting in selected areas of the RWIPH area during emergency conditions.
3.2.0 3.3.0
Normal AC Lighting shall be energised from 3-phase, 4-wire, 415 V lighting panels fed from MCC. Emergency DC lighting shall be provided in specific areas such as control room, switchgear rooms, areas near local panels, staircases and other strategic areas during AC supply failure. DC emergency lighting shall normally be off, and upon loss of normal AC supply, DC lights shall be turned on in auto mode. Illumination levels proposed at various places are listed below: Limiting values of glare index to be ensured as per area / location. Further design should ensure uniform lighting with no dark-spots and proper selection of fitting height etc. Location o o o o o o o o River water intake outdoor area Control rooms Switchgear rooms Battery rooms Pump house area Transformer area(Outdoor) Street lighting-main roads Office Rooms Illumination level (lux) 50 lux 400 lux 200 lux 150 lux 200 lux. 30 to 50 lux. 20 lux 300 lux
3.4.0
3.5.0
Fixtures considered shall be energy efficient type with low loss ballast & low harmonics with higher lumen / watt.
3.6.0
Recommended luminaries at various places are listed below : Area Switch gear /MCC rooms UPS, Battery charger room Battery Room Stair cases, Passages, Toilets, Office Control rooms Emergency DC Lighting Other Outdoor Area Roads Type of Luminaries Fluorescent industrial fixture Fluorescent industrial fixture Fluorescent corrosion proof fixture Fluorescent rail type fixture Mirror optics, decorative Fluorescent fixture Mirror optics, non glare type Fluorescent fixture Incandescent Lamps MH fixtures on steel tubular poles Metal Halide street light fixtures on Steel tubular poles
3.7.0 3.8.0
All fluorescent fixtures shall have Triphosphrous fluorescent lamps. All other lamps shall be screw type. AC lighting fixtures and accessories shall be suitable for operation on 240 V,AC, 50 Hz supply with supply voltage variation of 10%, frequency variation of 5% and combined voltage and frequency variation of absolute sum of 10%. DC lighting fixtures and accessories shall be suitable for operation on 220 V DC with variation between 190 V & 240 V. MH/Fluorescent lighting fixtures shall be provided with Power factor correction capacitor to achieve high power factor.
3.9.0
3.10.0 Lighting level design shall include a Maintenance factor as follows to account for lamp lumen depreciation, luminaries surface dirt and room surface dirt, etc. Air conditioned areas Non-Air conditioned areas Dust prone outdoor Areas : 0.8 : 0.7 : 0.6
3.11.0 At least one 5/15 ampere, 240 volt AC universal socket outlet with switch shall be provided in offices, cabins, etc. Receptacles with decorative cover plates shall be used in office / Control rooms. 3.12.0 Suitable number of 63 ampere, 3 phase, 415V AC welding receptacles shall be provided throughout the entire plant. Welding receptacles shall be placed near all major equipment. 3.13.0 20A, 240V, Single phase convenience receptacle with switch shall be provided in industrial area. The convenience outlets shall be spaced to provide access to any point in the interior industrial areas with a 15 meter extension cord. 3.14.0 Receptacles shall be served from an earth leakage circuit breaker (ELCB). 3.15.0 Welding sockets shall be fed from MCC. Number of receptacles per circuit shall be not more than 2. Each welding receptacle unit shall have dedicated MCB installed adjacent to the receptacle with IP55 type enclosure. 3.16.0 The light fixtures shall be circuited so that adjacent fixtures are connected to alternate phases of a 3-phase circuit. Auto-timed switching may be considered with manual bypass mode for indoor lighting system 3.17.0 The lighting for enclosed areas within the buildings shall be manually switched on and off at local light switches near personnel entrance doors. Wall mounted switches shall be provided at the entrance to battery room and equipment/office rooms. 3.18.0 Electric power to light fixtures located outdoors shall be switched with photoelectric controllers and timers. outdoor lighting shall have auto/manual mode of operation. Provision shall be made to bypass the photoelectric controller and timer.
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3.19.0 Switches shall be sized maximum of 80 percent of the light switch ampere rating with enclosures suitable for the location in which they are installed. 3.20.0 Load on each lighting circuit and single phase receptacle circuit shall be limited to 1500 W. 3.21.0 For areas illuminated by more than one circuit, the adjacent circuit shall be fed from different phase. Load balance on all the 3 phases to be envisaged for lighting as well as 1-ph power distribution circuit. 3.22.0 For Road lighting, alternative lighting fixtures shall be fed from different phases. 3.23.0 Each Street lighting pole/Flood lighting pole shall be provided with MCB protection. 3.24.0 Wiring for indoor lighting installation shall be carried with PVC insulated wire with following sizes laid in conduit. Lighting Panel to lighting Fixtures Switch box to lighting Fixtures Lighting Panel to Sockets : 2.5 sq.mm copper : 2.5 sq.mm copper : 4 sq.mm copper
3.25.0 Wiring for lighting circuits of Normal AC system and DC system shall run in separate conduits. Proper demarcation of various feeding lighting. Wiring for Lighting fixtures and receptacle units shall be fed from different circuits and shall run in separate conduits. Two different phase circuits shall not be laid in the same conduit. 3.26.0 All conduits shall be surface mounted in general. In Office rooms & Control rooms conduit shall be concealed type. Conduit fill criteria shall be 40%.Conduits should have the minimum number of bends in their run with pull boxes at suitable locations. Conduits shall be sloped & drained to avoid water accumulation & draining into the equipment at its end. 3.27.0 Conduits shall be galvanized steel except in corrosive areas, where it shall be epoxy painted. 3.28.0 For indoor lighting metallic troughs can be used for wiring in place of steel conduits. 3.29.0 Lighting/Receptacle Panels 3.34.1 For Lighting circuits, Lighting panel shall be provided. For receptacle circuits, separate receptacle panels shall be provided. The lighting/Receptacle panels located in hazardous areas shall be of flame proof. 3.34.2 Lighting panels shall be provided with one 63 Amp TPN MCB for incomer and required number of 20 Amp SP outgoing feeders with MCBs with neutral links for each circuit distributed over three phases. Maximum lighting load on any one circuit shall be restricted to 1500 watts. 3.34.3 DC Lighting panels shall be provided with one 63 Amp DP MCB for incomer and required number of 20 Amp DP MCB outgoing feeders. 3.34.4 Receptacle panels shall be provided with one 63 Amp TPN MCB with ELCB for incomer and required number of 20 Amp SPN outgoing feeders with MCBs with neutral links for each circuit distributed over three phases. Maximum lighting load on any one circuit shall be restricted to 2000 watts. 3.30.0 Receptacles 3.35.1 3 phase Industrial type welding receptacles shall be rated for 415V, 63 Amps with interlocked switches, scrapping earth connection, male and female units and cover. Protection class shall be IP-65.
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3.35.2 1 phase Industrial type receptacles shall be rated for 240V, 20A Amps with interlocked switches, scrapping earth connection, male and female units and cover. Protection class shall be IP-65. 3.35.3 1 phase receptacles with switches shall be provided at each DC portable lamp fittings. 3.35.4 Flush type single phase receptacles shall also be provided in control rooms and false ceiling areas. 3.35.5 All receptacles shall be provided with matching plug-tops. 3.35.6 All hardwares shall be of Stainless steel type only including the mesh of well glass luminaries, nut, bolts, washers, etc. 4.0.0 4.1.0 INSTALLATION Mounting height of centre line of the various lighting equipment from FFL/Working platforms or finished grade level shall be as noted below unless otherwise specified in corresponding lighting layout drawings. Lighting panels/control gear boxes Switch boxes Receptacle boxes (Indoor) Receptacle boxes (Outdoor) JB on poles/Masts 4.2.0 1500 mm 1500 mm 500 mm 1000 mm 750 mm
Lighting fixtures to be mounted on ceiling/platforms having considerable vibrations which can cause damage to the fixtures shall be suitably supported with rubber pads to limit vibrations in the fixtures. Where conduit wiring is adopted, an earth continuity conductor of 12 SWG galvanised steel wire shall be provided for earthing the lighting fixtures, switch boxes, etc. The earthing conductors shall be run along the entire length of the conduits and shall be securely connected and terminated at the junction boxes/control gear boxes/lighting panels. The earth connection shall be properly secured with bolts, nuts and washers. For the outdoor lighting installations, an earth continuity conductor of atleast 25 x 3 mm galvanised steel flat shall be used for earthing the lighting masts/poles. While designing the lighting circuit the cables shall be sized such that the farthest loop from the supply receives no less than 95% of its nominal voltage, in addition it must be assumed that all the light fittings are energised while this design calculation is made. Fluorescent lights should be chosen & located carefully where they illuminate rotating shafts, so as to avoid stroboscopic effect. Fittings made from Aluminium and its alloys should be avoided because the oxide that invariably forms after a time is considered as a potential source of sparks caused by mechanical impact . All fittings shall be installed at a safe height for maintenance & effective illumination. All lighting controls shall be from a non-hazardous area, using double pole, switches, the supply neutral should be switchable along with the phase.
4.3.0
4.4.0
5.0.0
TESTING AND INSPECTION Equipment of Illumination system should have been type tested and proven type. Type test certificates shall be furnished for Owners review. Equipment shall be subjected to routine tests as per applicable Indian Standard. Test reports shall be submitted for approval.
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6.0.0 6.1.0
DRAWINGS, DATA AND MANUAL Drawings/Documents to be Submitted After Award of Contract: Technical schedules duly filled in Dimensional General arrangement drawing for Lighting fixtures, LDB, Lighting panel, receptacles, poles, switch boxes, lighting masts etc. Schematic & wiring diagram Lighting design Calculation Lighting layouts Conduit layout Quality Plan Test certificates O&M Manual
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SECTION 4.12 ELECTRICALS FOR EOT CRANE 1.0.0 INTRODUCTION This specification covers requirement of the Electrical Equipment including the following complete with all accessories for the EOT Crane. 2.0.0 Motors 415 V protective panel & Control Panel Pendent push button station Emergency stop pushbuttons Main disconnect switch & Safety switch Power & Control cables Festoon cables Conduits, Cable glands, lugs & clamps etc. Earthing system
CODES AND STANDARDS The equipment to be furnished under this specification shall be in accordance with the applicable section of the latest version of the following Indian Standards, except where modified and /or supplemented by this specification. IS 3177 IS 325 IS 3427 IS 8623 IS 10118 IS 3043 Code of practice for Design, Manufacture, Erection and testing of Cranes and Hoists. Three phase induction motors. Metal-enclosed switchgear and control gear. Specification for low voltage switchgear and control gear assemblies. Code of Practice for Selection, Installation, and Maintenance of switchgear & control gear Code of practice for earthing
3.0.0 3.1.0 3.1.1
GENERAL REQUIREMENTS Motor Motors shall be of intermittent duty, three phase induction motors designed for crane duty requirement of frequent starting, reversing and plugging. These motors shall have minimum S4 duty class with a cyclic duration factor of 40%. All the motors shall be sized with 10% margin over and above the design requirement. Motors shall be capable of delivering the rated output with supply voltage variation of 10% and frequency variation of 5% and absolute sum of 10%. Squirrel cage Motors shall be suitable for VVVF starting. The crane motors shall be of TEFC type having class F insulation with temperature rise limited to class B operation. The enclosure of the motors shall conform to IP 54 degree of protection. All insulated winding shall be of copper. Windings shall be impregnated to make them nonhygroscopic and oil resistant. Control Panel Control panel shall house main switch, fuses, contactors, overload relays, VVVF control etc for all motions. Panel shall be of fixed type, Single front construction. It shall be of metal enclosed, free-standing type. Switchboard frames and load bearing members shall be fabricated using CRCA sheet steel of thickness not less than 2.0 mm. Doors and covers shall also be of CRCA
3.1.2
3.1.3 3.1.4
3.1.5
3.2.0 3.2.1
sheet steel of thickness not less than 1.6 mm. Thickness of gland plates shall not be less than 3.0 mm. Panel shall be of dust-proof and vermin-proof construction having a degree of protection of IP: 52. Ant vibration pad shall be provided for mounting the panels. All incoming and outgoing cables shall be terminated on suitable terminal blocks. 3.2.2 The MCCBs shall be operable from outside the module door. MCCB shall be provided with padlocking facility in both ÒN and ÒFF positions.. Motor starter contactors shall be of air break, electromagnetic type rated for uninterrupted duty. Contactors shall be double-break, non-gravity type and their main contacts shall be silver faced. Reversing starters shall comprise of Forward and Reverse contactors mechanically and electrically interlocked with each other and shall have utilization category AC4. All indicating meters shall be digital type. Push-buttons shall be of spring return, push-to-actuate type. All emergency push-buttons shall have mushroom knobs. The colour of the button shall be Green for motor START, Red for motor TRIP, Black for overload reset. Indicating lamps shall be of the panel mounting, LED type .The lamps shall have escutcheon plates marked with its function. Lamps shall have translucent lamp-covers having colours of Red for motor ON, Green for motor OFF, Amber for trip. 110V control supply shall be derived from control supply transformers located in control panel. Control panel shall be equipped with the following as required: 3.2.9 Illumination lamp with door switch 5A 3pin socket with MCB protection.
3.2.3
3.2.4 3.2.5
3.2.6
3.2.7 3.2.8
All internal wiring shall be carried out with 650 V grade, HR PVC/ XLPE insulated single core, copper conductor (minimum 2.5 sq.mm for power circuit and 1.5 sq.mm for control circuit). All internal wiring terminations shall be made with solderless crimping type tinned copper lugs.
3.2.10 Control terminal blocks shall be of 650 Volts grade, rated for 10 Amps and in one piece molding. It shall be complete with insulating barriers, clip-on type terminals and identification strips. Marking on terminal strip shall correspond to the terminal numbering on wiring diagrams. In Control panel at least 10% spare terminals for external connections shall be provided. 3.2.11 All controls shall be Variable Voltage and Variable Frequency (VVVF) control. VVVF system shall be rated for continuous duty as per IEC 146 (clause II). VVVF system for A.C drives shall mainly comprise of the following. A.C power circuit with converter transformer filters etc. Converter bridge Inverter Control & regulation equipment including protection, indication & annunciation 3.3.0 3.3.1 Main Disconnect Switch/ Safety Switch 415V, 3 phase, load-break, Main disconnect switch shall be provided at one end of Main gantry to feed power to the crane. This switch shall be housed in IP 54 enclosure complete with compression brass glands and copper lugs. Further, the operating handle of the switch shall be mechanically interlocked with the enclosure cover and cover shall not be possible to open unless the switch is in OFF position. Sheet steel thickness shall be not less than 2 mm. Main and Cross Conductors The Main conductor for crane shall consist of flexible trailing cable system mounted on retracting supports. Power supply shall be connected from Main disconnect switch to control panel through
3.4.0 3.4.1
PVC flexible copper conductor cable by means of festoon type cabling arrangement running on four wheeled cable trolleys with anti friction ball bearing running on Separate track. The bridge conductors for trolley and hoist drives shall also consist of flexible trailing cable system mounted on retracting supports. The power supply shall be through PVC flexible copper conductor cable by means of festoon type cabling arrangement running on four wheeled cable trolleys with antifriction ball bearing running on a separate track. 3.4.2 The festooned cables shall be of Flame retardant rubber insulated copper conductor. Separate cables shall be provided for power and control circuits. Minimum size of power cable shall be not less than 2.5 Sq.mm copper and control cable 1.5 sq.mm copper Illumination 240 V, 20 A, 3 pin industrial socket outlets shall be provided in the following locations: Receptacles shall be housed in FRP enclosure. Degree of protection shall be IP: 55. 3.5.2 One (1) no. on the Crab Two (2) nos. on the bridge along the walkway.
3.5.0 3.5.1
40 W industrial type fluorescent fixtures shall be provided for lighting bridge platform to maintain lux level of 100. 4 x 250 W HPSV high bay fixtures shall be provided below bridge for illumination of working area. One (1) no. portable 40 W hand lamp shall be furnished with adequate length of flexible cable for inspection of crane components. Power & Control Cables All required power and control cables shall be provided for the crane which shall include the following as a minimum: Trailing cables. Cables from Control panel to all the equipment mounted on the Crane
3.5.3
3.6.0 3.6.1
3.6.2
To maintain voltage at motor terminals /equipment end with in desirable limit, it is proposed to limit the voltage drop in the cables with in the following limits: Steady state Voltage drop (Continuous running condition Transient state voltage drop (During Motor Starting) :3% : 10 %
3.6.3
All the fixed cables shall be flame retardant low smoke (FRLS) type armoured cables. Power cables of up to 4 Sq.mm shall be copper conductor only. Higher sizes shall be aluminium conductor. Conductor of control cables shall have plain annealed copper. All the conductors shall be multi-stranded. Control cables shall be of minimum 1.5 sq.mm copper conductor. Power cables shall be of minimum 2.5 Sq.mm copper conductor. LV Power cables shall be of 1.1 kV grade, XLPE insulated, PVC inner sheathed (extruded), FRLS PVC outer sheathed, compacted aluminium/copper conductor conforming to IS: 7098 Part-I. Control cables shall be of 1.1 kV grade, multicore, PVC insulated, PVC inner sheathed, FRLS PVC outer sheathed stranded copper conductor conforming to IS:1554 Part-I. Trailing cables shall be of 1.1 kV grade, rubber insulated, sheathed, copper conductor. Grounding The crane rails, structures, motor frames, metal enclosures of all electrical equipment conduits and tray system shall be effectively grounded in accordance with IE Rules and Regulations.
3.6.4
3.6.5
3.6.6 3.7.0 3.7.1
3.7.2
Two (2) common earth conductors shall be provided along the bridge to which all earthing leads shall be connected. These common earth conductors shall be connected to the ground conductor of the runway conductors. The crane grounding system shall be connected to Plant Earthgrid. Metallic frame of all electrical equipment shall be earthed by two separate and distinct connections to earthing system, each of 100% capacity. On completion of installation, continuity of earth conductors and efficiency of all bonds and joints shall be checked. . PAINTING Painting shall be carried out by approved process. After preparation of the under surface the equipment shall be painted with epoxy based paint. The final thickness of paint film on steel shall not be less than 85 microns. Final shade shall be 692 (smoke grey) of IS 5.
3.7.3
3.7.4
5.0.0
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SECTION 4.13 HT CAPACITOR BANK 1.0.0 INTRODUCTION This specification covers the requirements of HT capacitors required for connecting across motors to improve the power factor up to 0.95. 2.0.0 CODES & STANDARDS The equipment to be furnished under this specification shall be in accordance with the applicable section of the latest version of the following Indian Standards, except where modified and /or supplemented by this specification. Standard IS 13925 IS 5553 IS 2544 Description Shunt capacitors for ac power systems having a rated voltage above 1000 V Series reactor Porcelain post insulators
3.0.0 3.1.0
DESIGN CONSIDERATIONS Capacitor across each motor shall be selected to improve the power factor up to 0.95. However care shall be taken that kVAR of capacitor shall not exceed magnetizing kVAR of the motor even if corrected power factor is less than 0.95. The capacitor cubicle will be one number for each motor. The rated voltage of the 3-phase capacitor banks shall be 11 KV (phase-to phase) and the individual capacitor units shall be rated for 11/3 KV. The units shall be connected in star formation with floating neutral. The maximum permissible overloads with regard to voltage, current and reactive output shall not exceed the limits specified in IS : 13925. The power loss in capacitors shall not exceed 0.2 watt/KVAR (subject to a tolerance of +10%). Suitable discharge device shall be connected across the capacitor unit in accordance with the provision of IS:13925. The discharge device shall reduce the residual voltage from the crest value of the rated voltage to 50V or less within 10 minutes after the capacitor is disconnected from the source of supply. The capacitor units shall be provided with external HRC fuses. A set of six spare fuse links shall be supplied along with each capacitor bank. The capacitors shall be of non-PCB type, using polypropylene film as the dielectric. Suitable Inrush Suppression Series Reactors shall be provided on each capacitor Bank steps to limit the inrush current due to switching within a safe limits. The capacitor switch shall be vacuum type suitable for indoor installation and shall have sealed weather proof type construction. The capacitor switch shall be provided with a mechanical indicator to show the contact position in the open/closed position. Provision shall also be made for manual closing and opening.
3.2.0 3.3.0
3.4.0
3.5.0
3.6.0
3.7.0
3.8.0
3.9.0
3.10.0 The metallic enclosure of the capacitor switch shall be provided with two earthing terminals.
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3.11.0 The bushings provided on the switch shall be of higher quality porcelain and shall have clamp type of terminals to directly receive aluminium conductors in both horizontal and vertical directions. The terminal arrangement shall be such as to avoid bimetallic corrosion. 3.12.0 The control parameter for switching operation shall be the line current. A current transformer shall be supplied to monitor the line current in for the purpose of control. The unit shall have adjustable current at which the capacitor bank shall be switched on or switched off. Suitable voltage transformer of 11 kV rated shall be supplied. Current transformer & voltage transformer can be supplied integral to switch. 3.13.0 The operating mechanism shall be either solenoid or motor charged spring. Suitable HRC fuses along with the mounting insulators etc. to provide proper protection. 3.14.0 The Automatic control unit shall be provided to automatically switch ON or switch OFF the capacitor banks through the operation of Capacitor Switch. The control unit shall provide a closing command to the vacuum switches of capacitor banks during lagging power factor based on setting. In the event of leading power factor, the control unit shall give a tripping command to the vacuum switch to disconnect the capacitor bank. Overriding provision shall also be made for electrical switching ON or OFF of the capacitor switch by the operator from ACU panel. 3.15.0 Capacitor bank shall be switched on based on power factor of the system. Power factor shall be sensed by an electronic control unit (relay) which shall receive current and voltage inputs from current and voltage transformers. ACU unit shall also have current relays and voltage relays for protection of each capacitor bank. 3.16.0 Automatic control unit shall be located indoor. 3.17.0 The automatic control unit shall instantly switch OFF the capacitor switch in the contingencies occurring in any of the phases. Normal automatic functioning of the Capacitor Bank shall resume when conditions improve. 3.18.0 Besides in-built protection against line surges and transient over voltages, suitable fuses shall be provided for protection against over current. The ACU shall remain fully functional during and after line surges and transient over voltage.
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SECTION 4.1411KV TRANSMISSION LINES 1.0 INTRODUCTION This Specification covers the requirements of 11KV line materials, support poles, crossarms, steel materials, insulators, line fittings, all aluminium alloy conductor (AAAC) of Overhead transmission lines for Raw Water Supply system. CODES AND STANDARDS The equipment to be furnished under this specification shall be in accordance with the applicable section of the latest version of the following Indian Standards and relevant IEC standard, except where modified and /or supplemented by this specification. IS: 1678 Specification for pre-stressed concrete poles for overhead power, traction and telecommunication lines Method of test for concrete poles for overhead power and telecommunications lines. Code of Practice for selection, handling and erection of concrete poles for overhead power and telecommunication lines Gr A Characteristics of the line post insulators Insulators for overhead lines with a nominal voltage above 1000V. IS- 731 IS 2486 (Part I, II, III) IEC 273 IS 2544 IEC 575 IS-1445 IS- 5300 IS 6005 IS-2633 IEC 1109 IS-2486 ISO/R/630/1967 ISO 2092 1/2 IS :2062 IS-5082 IS-2121 IEC 1284 Insulator and Conductor fittings performance BS 3288 Porcelain insulators for overhead power lines Specification for insulator fittings for overhead power lines with a nominal voltage greater than 1000V. Characteristics of indoor and outdoor insulators. Porcelain post insulators Thermal-mechanical performance test and mechanical performance test on string insulator units. Porcelain insulators for LV overhead power lines Stay insulators Phosphating of iron and steel Tests on galvanized steel Composite Insulators Metal fittings of insulators Steel for general structural purposes Wrought aluminium and and aluminium alloys Overhead power line fittings
2.0
IS: 2905 IS: 7321
IS 2062 IEC 720 IEC 383
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IS 398 IEC 1089
Aluminium conductors Insulated power cables 1 33 KV
IEC 502 ASTM D1000 IEC 454 BS EN 10218-1 : 1994 Shot blasting ISO 8501-1 IS 398 IS 9997 IEC 104 IS 1778 3.0 3.1 DESIGN AND CONSTRUCTION PSC Poles PSC Poles shall be of solid rectangular type with an overall length of 8.0 M (200 Kg) suitable for use in 11KV overhead power lines . The poles shall be designed for the following requirements: a) The poles shall be planted directly in the ground with a planting depth as per IS: 1678. Wherever, planting depth is required to be increased beyond the specified limits or alternative arrangements are required to be made, on account of ground conditions e.g. water logging etc., the same shall be in the scope of the bidder at no extra cost to owner. The bidder shall furnish necessary design calculations/details of alternative arrangements in this regard. b) The working load on the poles should correspond to those that are likely to come on the pole during their service life. c) The factor of safety for all 8.0 M poles, the factor of safety shall not be less than 2.5. d) The average permanent load shall be 40% of the working load. e) The F.O.S against first load shall be 1.0. f) At average permanent load, permissible tensile stress in concrete shall be 30Kg/cm2. The maximum compressive stress in concrete at the time of transfer of pre-stress should not exceed 0.8 times the cube strength. Aluminium Alloy Stranded Conductors Aluminium Alloy redraw rods for electrical purposes Aluminium Magnesium Silicon alloy wire for overhead line conductors Reels and drums of bare conductor. Test methods of pressure sensitive, adhesive coated taps for electrical and electronic applications Mechanical tests on steel wire
Material The cement used in the manufacture of pre-stressed concrete poles shall be ordinary or rapid hardening Portland cement conforming to IS:269-1976 or IS: 8041 E-1978 Aggregates used for the manufacture of pre-stressed concrete poles shall confirm to IS: 383. The nominal maximum size of aggregates shall in no case exceed 12mm..Admixture should not contain Calcium Chloride or other Chlorides and salts. The admixture shall conform to IS 9103.
Pre-stressing steel The pre-stressing steel wires including those used as untensioned wires should conform to IS: 1785 (Part-I), IS 1785 (Part-II) or IS:6003 All pres-stressing steel shall be free from splits, harmful scratches, surface flaws, rough, aged and imperfect edges and other defects likely to impair its use in pre-stressed concrete. Concrete Mix, Welding and Lapping Of Steel, Compacting, Curing The concrete mix shall be designed to the requirements laid down for controlled concrete in IS: 1343-1980and IS: 456-1978, The high tensile steel wire shall be continuous over the entire length of the tendon. Welding shall not be allowed in any case. However, jointing or coupling may be permitted provided the strength of the joint or coupling is not less than the strength of each individual wire. Concrete shall be compacted by spinning, vibrating, shocking or other suitable mechanical means. Hand compaction shall not be permitted; The concrete shall be covered with layer of sacking, canvass, hessian or similar absorbent material and kept constantly we up to the time when the strength of concrete is at least equal to the minimum strength of concrete at transfer of prestress. Thereafter, the pole may be removed from the mould and watered at intervals to prevent surface cracking of the unit, the interval should depend on the atmospheric humidity and temperature. Lifting eye-hooks or holes Separate eye-hooks or holes shall be provided for handling the transport, one each at a distance of 0.15 times the overall length, from either end of the pole. 3.2 STEEL MATERIALS V Crossarms The crossarm shall normally be constructed of steel and it will be the Bidders responsibility to ensure that the conductor spacing at the crossarms is adequate to prevent phase clash while supporting the loads generated, as per line design, by conductor weight, by wind, and by conductor tension for maximum windspan and worst design conditions, for all pole duties and for all permitted line deviations. Crossarms shall be fixed to the pole in a manner which prevents rotations in any plane even if the bolts are not fully tightened. Bolts and nuts All bolts and nuts shall comply with ISO 272, 885,888,4759/1 and the washer shall conform with ISO/R/887. All hardware shall be galvanized as per the Surface Treatment. Tie Rods Tie rods shall be supplied with four full nuts. The material of the rods shall be steel to ISO 272, 885, 888, 4759/1 and shall meet the requirements for mechanical properties detailed in ISO 272, 885,888, 4759/1. Associated nuts shall comply with ISO 272, 885, 888, 4759/1.
3.3
11 KV INSULATORS The porcelain used in the manufacture of shells and shall be sound, free from defects, thoroughly vitrified and smoothly glazed. The finished porcelain shall be glazed in brown
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colour. The glaze shall cover all exposed parts of the insulator and shall have a good luster, smooth surface and good performance under the extreme weather conditions of a tropical climate. It shall not be cracked or chipped by ageing under the specified service conditions. The glaze shall have the same coefficient of expansion as of the porcelain body throughout the working temperature range. Cement used in the construction of the insulators shall not cause fracture by expansion or loosening by contraction and proper care shall be taken to locate the individual parts correctly during cementing. 3.3.1 Pin Insulators 11kV disc insulator conforming to IS:731/1971 3.3.2 Disc Insulator Insulators shall be of the cap and pin type and the insulating material shall be brown glazed aluminous porcelain.11kV disc insulator conforming to IS:731/1971 The design shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration. Precautions shall be taken to avoid chemical reaction between cement and metal fittings, either by choice of suitable materials, or by the manufacturing method. The pin ball shall move freely in the cap socket but without danger of accidental uncoupling during erection or in position. The design of the disc should be such that stresses due to expansion or contraction in any part of the insulator shall not lead to deterioration. The locking devices shall be so formed that when set there shall be no risk of the locking device being displaced accidentally under any conditions. Corrosion Protection and Finish Ferrous parts, unless of stainless steel, shall be hot dip galvanized in accordance with BS 729 or IS :2629. Dimensions The dimensions of ball and socket insulators shall be in accordance with the standard dimensions stated in IS: 2486- (Part-II) / IEC - 120. The dimensions shall be checked by appropriate gauge after galvanizing. Associated Hardware
The hardware for insulator strings with disc insulators together with ball and socket fittings shall be of standard design, so that units are interchangeable with each other and suitable for use with disc insulator of any make conforming to relevant Indian or International Standard. Split pins shall be used with bolts and nuts.
3.3.3
Stay Insulators (11 KV) The insulators shall be used with 7/8 SWG (7/4.00 mm ) steel stay wire, having an overall diameter of 12.2 mm and tensile strength of 70 kgf/sq. mm.
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3.4
11 KV Line Fittings Insulator Fittings and Hardware Insulator fittings and hardware for use in line terminations or anchor points shall be capable of withstanding a tension force at least equal to the breaking loads of the insulators.
3.4.1
Disc Insulator Fittings The insulators shall be cap and pin type with ball and socket couplings. The hardware for insulator strings, whether suspension or strain insulators, together with ball and socket fittings shall be of standard design. These hardwares shall be interchangeable and suitable for use with disc insulators of any make conforming to relevant Indian and International Standards. Fully dimensioned drawing of the complete insulator string hardware and their components parts should show clearly the following arrangements. Attachment of hanger or strain plate Suspension assembly. Dead end assembly Yoke plates. Hardware fittings of ball and socket type for interconnecting units to the yoke plate. Anchor links for connection of tension strings to crossarms with suitable fittings. Ball and socket designation
The designation should be in accordance with the standard dimensions stated in IS: 2486 (partII)/ IEC : 120. The dimensions shall be checked by appropriate gauge after galvanizing . Ball Ended Hooks Ball ended hooks, together with section straps, shall be used to attach the ball and socket chain of insulators to the angle, section and end pole crossarm. Ball ended hooks shall be manufactured to comply with ISO/R/630/1967 or IS 2026:1992 and shall be hot dip galvanized to conform with the section on Surface Treatment in this specification .
U Bolt Shackles U bolt shackles shall be made to comply with ISO/R/630/1967 or IS 2062 :1992 and shall be hot dip galvanized to conform with the section on Surface Treatment. Ball Ended Eye Links Ball ended eye links shall be made to comply with ISO/R/630/1967 or IS-2062:1992 and shall be hot dip galvanized to conform with the section on Surface Treatment. Socket Clevises Socket clevises may be used at 11 KV termination points to attach the compressed termination to the closest insulator in the chain.
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Ball Clevises Ball clevises may be used where lines require a duplicate chain of tension of suspension insulators. The ball clevises may be required to attach the first insulator in the chain to the first dual yoke plate. Socket Tongues Socket tongues may be used where lines require a duplicate chain of suspension insulators. The socket tongue may be required to attach the suspension clamp to the lower dual yoke plate by means of a ball ended eye link.
3.4.2
Pin Insulator Fittings Insulator Pin Pin insulator pins shall be made from grade 43A steel complying with ISO/R/630/1967 or IS 2062:1992 and shall be hot dip galvanized to conform with the section on Surface Treatment. The pins shall also comply with the requirements of IS 2486 (parts 1 & 2 ) The 11 KV pin insulator assembly complete is for use with the requisite crossarm and structure in an intermediate or light angle pole position. The galvanized steel pin when used with the 11 KV pin insulator the combination shall meet the following requirements: Conductor clearance to crossarm shall be a minimum of 220 mm. The minimum creepage distance shall be not less than 320 mm.
3.5
Terminations And Connectors All splice or termination connectors shall be capable of being used with AAAC conductors the sizes All straight through tension and non tension connectors shall be provided with a conductor stop at the center of the tube. The bore shall be tapered at each end for a distance of 5 mm. Tension splices shall be chamfered off leaving a minimum wall thickness at the ends of 2 mm. In the lug terminals, the palm faces shall be flat and the barrel length shall correspond to half the appropriate non tension connector. The connectors offered shall be suitable for application by compression. All terminations and splices shall be capable of being made with hand operated compression tool. Conductor connectors shall be able to accommodate typical variations in dimensions of conductors supplied by different manufacturers and shall be of a material which will not react chemically with the conductors to which they are attached. Tension or Dead End Terminations These terminations shall be manufactured from aluminium and be of the compression type, factory filled with a special grease compound to give optimum electrical and mechanical
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performance. They shall be used to terminate the main conductor under full tension at heavy angle, section and end pole position. Non Tension Terminations These fittings shall consist of palm type lug terminals and shall be used to terminate line jumpers and other non tension conductors on to equipment terminals, such as pole mounted transformers. Lugs shall be of two types: aluminium and bimetal. In the bimetal lugs the bimetal junction within the palm shall be of such design as to afford adequate protection against electrolytic corrosion. Tension Connectors Tension connectors shall be used for making conductor splices under full tension and shall consist of an aluminium sleeve, factory filled with a special grease compound to give optimum electrical and mechanical performance. These connectors shall be capable of being used to make splices in midspan and shall therefore be capable of supporting tension loads at least equal to the maximum conductor breaking load, Non Tension Connectors Non tension connectors comprise tap off connectors and straight through non tension connectors. The tap off connectors shall be used for branching off a main line and shall consist of a C shaped barrel which can be compressed on to the main conductor and in electrical contact with another closed barrel, holding the branch conductor forming a tee configuration. Both the closed and C shaped barrels shall be factory filled with a special grease compound to give optimum electrical and mechanical performance.
3.6
Line Binding Accessories Line binding accessories consisting of soft aluminium binding wire, aluminium binding stirrups, semiconducting tape and anticorrosive tape are required for the line. The aluminium binding wire & stirrups are used to bind bare aluminium conductor to the insulators in the construction of new lines and Reconductoring of line. Aluminium binding wire shall be delivered in 30 m coils, with a permitted tolerance of +5%. Random or non standard lengths shall not be permitted. Semiconducting tape shall be used under the bind with 11 KV PVC covered conductors. Anticorrosive tape shall be used as a barrier against ingress of moisture wherever copper and aluminium are spliced together, such as at the interface between aluminium conductors and the copper or brass terminals of equipment connected to the line. It may also be used to seal the ends of PVC covered conductor
3.7
Stay Assemblies The stay assembly and each of the components offered should be capable of supporting the loads generated, as per the line design, by wind acting on the pole and by conductor tension for maximum windspan and worst design conditions, for all pole duties and for all permitted line deviations and stay angles.
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Stay Wire They stay wire is required for use on stays from concrete and steel poles on the overhead distribution networks. Stay wires shall comply with the requirements of IS:2141 The wire shall be stranded galvanized steel wire, comprising seven wires, each having a nominal diameter of 4.0 mm. Each wire shall be circular in section and shall contain no weld, joint or splice whatever. It shall be free from any scale, inequalities, spills, splits or any other defects.
Pole Brackets The pole bracket shall be made of mild steel to grade 43A conforming to ISO/R/ 630/1967 or IS 2062:1992 Pole brackets shall be suitable for use on steel or concrete poles. The minimum strength of the bracket shall be equal to the design breaking load of the stay wire.
Stay Thimbles Stay thimbles shall be made of mild steel, crescent shaped, steel bar conforming to ISO/R/630/1967 or IS-2062:1992 The minimum strength of the thimble shall be equal to the design breaking load of the stay wire.
Stay Rods Stay rods shall be made of a steel bar of grade 43A, complying with ISO/R/630/1967 or IS 2062:1992 The stay rod shall be adjustable by means of a turnbuckle and shall be supplied complete with one lock nut and two thimbles. The tube portion of the turnbuckle shall be manufactured from heavy gauge steel tube. The stay rod shall come with a steel plate for bearing on the stay block. The minimum strength of the stay rod shall be equal to the design braking load of the stay wire. 3.8 All Aluminium Alloy Conductor (AAAC) The wires shall be of heat treated aluminium, magnesium silicon alloy containing approximately 0.5% magnesium and approximately 0.5% silicon and having the mechanical and electrical properties specified in the table and be smooth and free from all imperfections, such as, spills, splits and scratches. Neutral grease shall be applied between the layers of wires. The drop point temperature of the grease shall not be less than 1200 C. Mechanical and Electrical Characteristics of Aluminium Alloy Wires used in the Construction of Stranded Aluminium Alloy Conductors Minimum Diameter 2 mm 1.98 2.47 2.86 3.12 3.28 Max. Diameter 3 mm 2.02 2.53 2.92 3.18 3.34 Cross Sectional Area 4 mm2 3.142 4.909 6.560 7.793 8.605 Minimum Breaking Load Before After stranding stranding 6 7 KN KN 0.97 0.92 1.52 1.44 2.03 1.93 2.41 2.29 2.66 2.53
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Nominal Diameter 1 Mm 2.00 2.50 2.89 3.15 * 3.31
Mass 5 Kg/km 8.482 13.25 17.71 21.04 23.23
Maximum Resistance at 200 C 8 ohms/km 10.653 6.845 5.106 4.290 3.882
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3.40 3.45 3.55 3.66 3.71 3.81* 3.94 * 4.00 4.26 *
3.37 3.42 3.51 3.62 3.67 3.77 3.90 3.96 4.22
3.43 3.48 3.59 3.70 3.75 3.85 3.98 4.04 4.30
9.079 9.348 9.898 10.52 10.81 11.40 12.19 12.57 14.25
24.51 25.24 26.72 26.41 21.19 30.78 32.92 33.93 38.48
2.80 2.89 3.06 3.25 3.34 3.52 3.77 3.88 4.40
2.66 2.75 2.91 3.09 3.17 3.34 3.58 3.69 4.18
3.677 3.571 3.390 3.187 3.101 2.938 2.746 2.663 2.345
Maximum resistance values given in column 8 have been calculated from the maximum values of the resistivity as specified and the cross sectional area based on the minimum diameter. The minimum breaking load is calculated on nominal diameter at ultimate tensile strength of 0.309 KN / mm2 for wire before stranding and 95% of the ultimate tensile strength after stranding.
3.8.1
STANDARD SIZES The Aluminium alloy wires for standard constructions covered by this specification shall have the diameters as specified in the table and a tolerance of 1% shall be permitted on the nominal diameter.
3.8.2
Standard Conductors The sizes, resistance and masses (excluding the mass of grease) of stranded Aluminium alloy conductors shall be as given in table. Mechanical and Electrical Characteristics of Aluminium Alloy Stranded Conductors Sl. No. Actual Area Stranding and Wire Dia Approx. Overall Dia Approx. Mass Calculated Maximum Resistance at 200 C 6 ohms/km 1.5410 0.9900 0.6210 0.4250 0.3390 0.2735 0.2290 0.1969 0.1710 0.1471 0.1182 0.0984 0.0829 0.0734 0.0651 0.0598 0.0568 0.0534 0.0492 0.0446
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1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
2 Mm2 22 34 55* 80* 100* 125 148 173 200 232* 288 346 400 465 525 570 604 642 695 767
3 mm 7/2.00 7/2.50 7/3.15 7/3.81 7/4.26 19/2.89 19/3.15 19/3.40 19/3.66 19/3.94 37/3.15 37/3.45 37/3.71 37/4.00 61/3.31 61/3.45 61/3.55 61/3.66 61/3.81 61/4.00
4 mm 6.00 7.50 9.45 11.43 12.78 14.45 15.75 17.00 18.30 19.70 22.05 24.15 25.97 28.00 29.79 31.05 31.95 32.94 34.29 36.00
5 kg/km 60.16 94.00 149.20 218.26 272.86 342.51 406.91 474.02 549.40 636.67 794.05 952.56 1101.63 1280.50 1448.39 1573.71 1666.0 1771.36 1919.13 2115.54
Approx Calculated Breaking Load 7 KN 6.45 10.11 16.03 23.41 29.26 36.64 43.50 50.54 58.66 68.05 84.71 101.58 117.40 136.38 146.03 158.66 167.99 178.43 193.25 213.01
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There shall be no joint in any wire of a stranded conductor containing seven wires, except those made in the base rod or wire. In stranded conductors containing more than seven wires, joints in individual wires are permitted in any layer except the outermost layer (in addition to those made in the base rod or wire) but no two such joints shall be less than 15 m apart in the complete stranded conductor. Such joints shall be made by cold pressure butt welding. They are not required to fulfill the mechanical requirements for unjointed wires. 3.8.3 Stranding The wire used in the construction of a stranded conductor shall, before and after stranding, satisfy all the relevant requirements of this standard. In all constructions, the successive layers shall have opposite directions of lay, the outermost layer being right-handed. The wires in each layer shall be evenly and closely stranded. In Aluminium alloy stranded conductors having multiple layers of wires, the lay ratio of any layer shall not be greater than the lay ratio of the layer immediately beneath it. 3.8.4 PVC Covered Conductor Where the AAAC is required to be covered with Polyvinyl Chloride (PVC) then the requirements for the covering shall be in accordance with BS 6485: 1971 or other International Standard. The PVC covering shall comply with the requirements of IEC 502 for Type ST1 or ST2 compound and shall be green in color. The minimum thickness of the PVC covering at any point shall not be less than 1.6 mm. All PVC covered conductors shall be subjected to the spark test described in BS 6485: 1971 and there shall be no breakdown of the PVC covering during this test at an r.m.s voltage of 12 KV. The same test may be completed with a DC voltage of 18 KV 3.9 MARKING Marking for poles The pole shall be clearly and indelibly marked with the following particulars either during or after manufacture but before testing at a position so as to be easily read after erection in position. Month and year of manufacture Transverse strength of pole in Kg. Markers serial No. and mark.
Markings for insulators All insulators shall be clearly marked with the name or trademark of the manufacturer and the year of manufacture. These markings shall be legible and indelible. The markings may be printed or impressed, provided such impressions do not impair the performance of the insulator. Marking shall be applied before firing. Markings for fittings The manufacturers name or trademark shall be clearly stamped on every fitting. In addition, the following information shall be provided on connectors:
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Metric conductor size for which the connector is suitable; The die number suitable for compressing the connector; The points on the connector surface to be compressed; The sequence of die action i.e the order in which different parts of the connector shall be compressed;
3.10
EARTHING Earthing shall be provided by having length of 8 SWG GI wire embedded in concrete during manufacture and the ends of the wires left projecting from the pole to a length of 100mm at 250mm from top and 150mm below ground level. Earth wire shall not be allowed to come in contract with the pre-stressing wires.
4.0 4.1
TESTING AND INSPECTION PSC Poles Transverse Strength Test Sampling and Inspection a) Scale of sampling Lot : In any batch, all poles of the same class and dimensions shall be grouped together to constitute a lot. Sub-lot : If the number of poles in a lot exceed 500, the lot shall be divided into a suitable number of sub lots such that the number of poles in any sub-lot shall not exceed 500. Number of Tests All the poles shall be tested for overall length, cross-selection and uprightness. The tolerance shall be ()15 mm on overall length ()3 mm on cross sectional dimensions and 0.5 per cent on uprightness.
4.2
STEEL MATERIALS Steel materials and its components should have been type tested and proven type. Type test certificates shall be furnished for Purchasers review. Steel materials and its components shall be subjected to routine tests as per applicable Indian Standard. In addition, any special test required shall also be performed. Test reports shall be submitted for approval.
4.3 4.3.1
PIN, DISC AND STRAY INSULATORS Pin insulators and disc insulators Tests Type, acceptance and routine tests shall be carried out and results given along with certification as appropriate in the Technical Schedule and Test Certificates Schedule of this specification. The insulators shall comply with the following tests as per IS-731. Type tests The following type tests are required :
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Visible discharge test Impulse voltage withstand test Wet power frequency voltage withstand test Mechanical failing load test 24 hour mechanical strength test
Acceptance Tests The test samples having withstood the routine tests shall be subjected to the following tests according to the sampling procedure if IEC 383 clause 23; Verification of dimensions Electro-mechanical failing load test; Puncture test; Porosity test; Test for galvanization of ferrous parts
Routine Tests The following routine tests shall be conducted on each set and results are to be furnished for consideration: 4.3.2 Visual examination Tensile load test; Power frequency voltage test
Stray insulators Tests The insulators shall be subjected to the following type, acceptance and routine tests in accordance with IS 5300 : 1969. Type Tests The following type tests are required: Dry power frequency voltage withstand test Wet power frequency voltage withstand test Mechanical strength test
Acceptance tests The test samples having withstood the routine tests shall be subjected to the following tests according to the sampling procedure of IEC 383 clause 23; Verification of dimensions
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Mechanical or Electro Mechanical failing load test; Mechanical load shall be applied under conditions reproducing service conditions as closely as possible. Porosity test; Power frequency puncture test.
Routine Tests The following routine tests shall be conducted on each insulator: Visual examination 4.4 TERMINATIONS AND CONNECTORS Type tests The mechanical type test shall comply with BS 3288 part 1, whereas the electrical type test shall conform with IEC 1284/IS 2486 Tensile type tests on tension connectors. Tensile type tests on non tension connectors.
Electrical type tests These tests shall be in accordance with the full electrical requirements of the latest edition of IEC 1284/IS-2486 Acceptance Tests The test certificate must contain the following details : 4.5 Type of connector; Manufacturer; Textual and photographic description of test arrangements; Description of conductors used; Details of tools and dies used; Details of grease or compound used; Test results; Level and duration of load current; and Level and duration of short circuit current.
LINE BINDING ACCESSORIES. Aluminium binding wire Ultimate tensile strength Wrapping test semiconducting tape
The semiconducting tapes shall be tested in accordance with ASTM D 1000: Test methods for pressure sensitive, adhesive coated tapes used for electrical and electronic applications, or equivalent.
4.6
STAY ASSEMBLIES Stay wire
Sampling of stay wire shall be in accordance with IS 2141 The wires shall be subjected to the following tests before manufacture and in accordance with BS 443, BS 4545 and IS 2141 Ductility test Tolerance on wire diameter
The completed strand shall be tested as follows and in accordance with BS 443, BS 4545 and IS 2141, IS 4826 Tensile and elongation test Chemical analysis Galvanizing test
4.7
AAAC (ALL ALUMINIUM ALLOY CONDUCTORS) Type Tests The following tests shall be carried out once on samples of completed line conductor during each production run of up to 500 kms. of the conductor from each manufacturing facility. Ultimate Tensile Strength Test D.C Resistance Test Tensile Load Test Routine Tests Selection of Test Samples Breaking Load Test Elongation Test D.C Resistance Test Chemical Analysis of Aluminium Alloy Dimensional and Lay Length Check Visual and dimensional Checks on the Conductor Drums
5.0
SPARES LIST
The spares list of the Raw Water Supply system is furnished in Section-10 of this Technical Specification
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SECTION 4.15 ERECTION, TESTING & COMMISSIONING OF ELECTRICAL SYSTEM 1.0.0 INTRODUCTION This specification covers the requirements of Erection, Testing & Commissioning of Electrical equipment for River water intake System. 2.0.0 CODES AND STANDARDS The equipment to be furnished under this specification shall be in accordance with the applicable section of the latest version of the following Indian Standards, except where modified and /or supplemented by this specification. IS: 10028 IS: 10118 IS: 900 IS: 1646 IS: 1255 Installation and Maintenance of Transformers. Installation and Maintenance of Switchgear Installation and Maintenance of Induction Motors Fire safety of buildings (General) Electrical Installations Code of practice for installation and maintenance of power cables up to and including 33 kV rating. IS:732 Electrical wiring installation (system voltage not exceeding 650 V). IS:5216 Guide for safety procedures and practices in electrical works. IS: 3043 Code of practice for earthing.. Indian Electricity Act and Rules Fire Insurance Regulations Regulations laid down by the chief Electrical Inspector of the State. 3.0.0 3.1.0 GENERAL REQUIREMENTS The work shall be carried out in the best workman like manner in conformity with relevant specifications / codes and standards. In addition, work shall also confirm to the requirements of latest editions / amendments of the following: Indian Electricity Act and rules framed there under. Regulations laid by the office of the Chief Electrical Inspector to Government Any other regulations laid down by the local authorities. Manufacturer's drawings, instructions and recommendations shall be correctly followed in handling, erecting, testing and commissioning of all items/equipments and care shall be exercised in handling to avoid distortion to stationary structures, the marring to finish, or damaging of delicate instruments or other electrical parts. All electrical equipment shall be installed in a neat, professional manner so that it is level, plumb, squat and properly aligned and oriented. Tolerances shall be as established in the Manufacturers drawings. Clearances around Electrical panels, switchgears shall be as per relevant standards. The Contractor shall provide adequate and capable supervision for electrical installation work under this contract. The staff provided shall be adequate to provide detailed supervision at each stage of the work, in all areas so that any improvements modifications required to meet site conditions/layouts is effected in time. The Contractor shall ensure workmanship of good quality and shall assign qualified supervisors/Engineers and competent labor who are skilled having valid license, careful and experienced in carrying out similar works. The Contractor shall be fully and finally responsible for proper erection, safe and satisfactory operation of the equipment under his scope of work to the entire satisfaction of the Owner. Equipment and material, which are wrongly installed, shall be removed and re-installed to comply with the design requirement at the Contractors expense, to the satisfaction of the Owner.
3.2.0
3.3.0
3.4.0
3.5.0
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3.6.0
The installation shall be carried out in such a manner as to provide access to other equipment installed. The Bidder shall restore floor / wall chipping, road cuttings & other such works done including replacement of equipment removed back to its place and make good damages done to original. The Bidder shall effectively protect his work, equipment and materials under his custody from theft, damage or tampering. Finished work where required shall be suitably covered to keep it clean and free from defacement or injury. Bidder shall be held responsible for any loss or damage to equipment and material issued to him until the same is taken over by the Owner according to contract. All safety rules and codes as applicable to work shall be followed without exception. All safety appliance and protective devices including belts, hand gloves, aprons, helmets, shields, goggles, safety shoes etc. shall be provided by the Bidder for his personnel. The Bidder shall provide guards and prominently display caution notices if access to any equipment / area is considered unsafe and hazardous. In order to avoid hazards to personnel moving around the equipment such as switchgear etc. which is kept charged after installation, before commissioning, such equipment shall be suitably cordoned off to prevent anyone accidentally going near it
3.7.0
3.8.0
3.9.0
3.10.0 The bidder shall have a separate cleaning gang to clean all equipment under erection as well as the work area and the project site at regular intervals to the satisfaction of Owner. In case this is not done, the Owner will have the right to carry out the cleaning operation and any expenditure incurred in this regard will be to the bidder account. 3.11.0 The Bidder shall ensure that instruments and gauges to be used for testing and inspection have valid calibration and the accuracy can be traced to National Standards. 3.12.0 It shall be the Bidders responsibility to obtain approval from local statutory authorities including Electrical Inspector/CEA, wherever applicable, for carrying out any work or for installation carried out which comes under the purview of such authorities. 4.0.0 4.1.0 4.1.1 EQUIPMENT INSTALLATION Transformers The transformer shall be erected on a level foundation by bidder. The transformer tank contains the core and coil assembly should be first placed in position selected for assembly. The transformer shall then be jacked up and the roller fitted to the bottom frame. The oil to be used for filling and topping up must comply with IS: 335 (Latest revision) as supplied. The oil sample from the transformer tank before commissioning shall meet the following specifications. a. BDV 60 kV b. Water content 10 ppm 12 c. Resistivity 1 x 10 ohm cm d. Dielectric dissipation 0.05 factor (tan ) at 90C max. For transformer dispatched with gas filled, the filling of oil inside the tank is done under vacuum. When filling a transformer with oil, it is preferable that the oil be pumped into the bottom of the tank and that a filter press or other reliable oil drying and cleaning device should be interposed between the pumps and the tank. The bushings shall be checked for any damage at the oil end as well as the porcelains before fixing bushings shall be cleaned thoroughly. The bushings shall be lifted by using the lifting eyes and soft mainila ropes. The line lead of HV winding if coiled inside the transformer is drawn through the bushing using a string when the bushings is lowered into position. The cable ferrule is fixed in position at the top of the bushing brass tube. The lower end of the
4.1.2
4.1.3
4.1.4
bushing shall be inspected through the inspection cover for proper sealing. The line connection should be tight and should not strain the terminals. Sufficient flexibility in the connecting leads should also be provided to avoid mechanical stress on the bushing. 4.1.5 Conservator should be assembled with its pipe work, etc. making sure that all gasketed joints are oil-tight and the pipe work is clean and free from moisture. While topping up oil in the transformer, it should be ensured that oil is filled to a level indicated by the oil gauge on the conservator in commensurate with the filling oil temperature. The Buchholtz is checked for correct functioning of the reed switches. The angle of inclination is also to be checked. The gas release pipe is to be connected to the top petcock. In service, the top petcock should be open and gas release pipe should be full of oil. When the gas is to be collected through the gas release pipe, initially the oil will flow out and then the gas can be collected. The breather pipe work shall be properly cleaned. The oil level in the oil seal at the bottom should be filled to the correct level with transformer oil. It is to be ensured that the breathing hole at the bottom of the seal is not blocked by dirt, etc. The silica gel to be filled into the breather shall be blue colour. All CT secondary terminals should be short circuited or loaded before energising the transformer. Switchboards & Panels All the switchboards and panels. shall be installed in accordance with specified Code of Practice, drawings furnished and the Manufacturers instructions. The switchboards/panels shall be installed on finished surfaces or concrete or steel sills. These panels may be bolted on to the foundation pockets or welded to base frame members The Bidder shall be required to install and align any channel sills, which form part of the foundations. Proper aligning, joining of various vertical shipping sections, Busbar connections, inter panel wiring etc. shall be the responsibility of the Bidder. In joining shipping sections of the switchboards / panels together, adjacent housing or panel sections provided shall be bolted together after alignment has been completed. Power bus enclosures, ground and control splices of conventional nature shall be cleaned and bolted together, being drawn up with torque wrench of proper size or by other approved means. The Bidder shall take utmost care in handling instruments, relays and other delicate mechanisms. The blocking materials / mechanism employed for the safe transit of the instruments and relays shall be removed after ensuring that the panels/desks have been completely installed and no further movement of the same would be necessary. Motors The installation, commissioning of the motors shall be as per IS:900 and the Manufacturers instructions. 4.5.0 4.5.1 Battery and Chargers Each cell of the battery bank shall be inspected for breakage and condition of cover seals as soon as received at site. Each cell shall be filled with electrolyte in accordance with the Manufacturers instructions. Battery shall be set up on racks as soon as possible after receipt, utilising lifting devices supplied by the Manufacturer. The cells shall not be lifted by the terminals.
4.1.6
4.1.7
4.1.8
4.2.0 4.2.1
4.2.2
4.2.3
4.4.0
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4.6.0 4.6.1
Lighting System The lighting system installation work shall confirm to the latest applicable electricity rules, all currently applicable standards, codes of practice, regulations and safety codes of the locality where the installation is to be carried out. After installation of lighting fixtures / receptacles, panel number and circuit number shall be painted on them at suitable place. Fixture locations shall be co-ordinated with other work in the same area to prevent interference between lighting fixtures, cranes, monorails, ductwork and piping or other equipment. Any fixture shall be relocated if, after installation, it is found to interfere with other equipment or is so located to prevent its practical and intended use. No fixture shall be located to prevent the full use of any accessway beneath a removable grating or slab. Wooden plugs in walls and ceilings for fixing of lighting fixtures and accessories are not acceptable. A suitable fool proof method (preferably using nylon rawl plug) of fixing these shall be offered and this be subject to the Owner approval. In the rooms where false ceilings are provided, the lighting fixtures shall be supported separately by false ceiling grid over false ceiling if it is of steel structural or from ceiling or from cable trough / channel and not by the false ceiling board. The arrangement shall be to the approval of Owner. The erection rate of lighting fixtures shall include the supply of steel brackets, supporting / anchoring material, hardware and also steel brackets / hangers for bridging the gap above false ceilings, etc. required for installation of lighting fixtures as shown in the approved fixture mounting arrangement drawings. A four (4) way terminal junction box shall be provided near each lighting fixture, for loop-in, loop-out and off connection of lighting wires or as required. To distinguish emergency AC fixtures from normal AC fixtures, red painted circular mark of 1cm dia. shall be provided on emergency fixtures. Lighting fixtures shall not be suspended directly from the junction box in the main conduit run. Conduit Installation
4.6.2
4.6.3
4.6.4
4.6.5
4.6.6
4.6.7
4.6.8 4.6.9
4.6.10 All conduit not located in finished areas or cast in concrete shall be routed in exposed runs parallel or perpendicular to dominant surfaces with right-angle turns made of symmetrical bends or fittings. 4.6.11 Conduit in finished areas, such as office and control areas, shall be concealed. Conduit shall be routed at lest 250mm from the insulated surfaces of hot water, steam pipes and other hot surfaces. Where conduit must be routed parallel to hot surfaces, special high temperature cable shall be used. 4.6.12 Conduits supports shall be provided at an interval of 750 mm for horizontal runs and 1000 mm vertical runs. Conduit shall be clamped on to approved type spacer plates or brackets by saddles or U-bolts. The spacer plates or brackets in turn, shall be securely fixed to the building steel by welding and to concrete or brick work by grouting or by nylon rawl plugs. 4.6.13 Spacing of embedded conduits shall be such as to permit flow of concrete between them and in no case shall be less then 40 mm. 4.6.14 For long conduit runs junction / pull boxes shall be provided at suitable intervals (not exceeding 10 m) to facilitate wiring. 4.6.15 Conduits shall be securely terminated at LPs / junction boxes or lighting fixtures by proper fastening with a lock put on inside and outside. The number of conduits terminating at LPs
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shall not exceed the permissible number considering the glanding area of lighting panel. Conduit terminations shall be made water & vermin proof. 4.6.16 The entire metallic conduit system, whether embedded or exposed, shall be electrically continuous and thoroughly grounded where slip joints used, suitable bending shall be provided around the joint to ensure a continuous ground circuit. GI pull wire of adequate size shall be laid in all conduits before installation. 4.6.17 Flexible conduits shall be used between fixed conduits and equipment terminal boxes, where vibration is anticipated. Flexible conduit shall be terminated using suitable end coupler and check nut at both ends. 4.6.18 All conduits installed outdoor shall be sloped towards pull boxes, hand holes/manholes for drainage. Low points of conduits not terminating in pull boxes, handholes/manholes shall be provided with weep holes for drainage. Care shall be taken to see that no rough edge is left around the weep holes. Where no provision for drainage can be made, both end of conduits shall be sealed after cable is laid through. Minimum slopes of 1 in 400 shall be provided. 4.7.0 4.7.1 Installation of Lighting Poles/Masts All poles shall be carefully plumbed with heavy square nuts on the anchor bolts under the pole base plate and hex nuts on the top. The erection work shall include making of foundations (with supply of all materials). Installation of necessary wiring / cabling, junction box and mounting of assembled fittings. After the pole has been installed and aligned, the luminaire, mastarm, and cable shall be assembled and installed on the pole, cable connections completed in the handhole near the base of the pole, and the pole ground connected. The underground portion of the lighting system shall be multiple conductor Type PVC. Pole riser cable for use between the pole base and the luminaire terminals shall be PVC. Connections in the base of the pole shall be made with split bolt connectors and insulated. The cable from junction box at the bottom of pole up to the lighting fixture shall be supplied by the bidder. All the above erection work shall be done by bidder for lighting masks including making of foundations. 50 mm GI pipe shall be provided for cable protection from trench to junction box by the bidder for loop-in-loop-out cables. Each lighting poles shall be earthed by 25 x 3 mm GS flat bonded to one (1) 20 mm dia MS earth electrode of 3 meter length driven vertically in the ground. The flat and electrode shall be supplied by the bidder and price of these shall be included in the erection price of individual pole / mast. 14 SWG GI wire shall be taken from fixture to JB. Cable Tray Installation Pre installation checks for cable tray installation shall be as under: a) Availability of clear passage/ path for the cable tray network as per approved drawings. b) Cold galvanization / paint treatment for all damaged portions of galvanization due to cutting / repairs etc. c) Correctness of installation of number and type of tray / tray accessories /support material as per approved drawings. d) Firmness/ tightness of all bolted joints e) Alignment / inter tray separation as per approved layout drawings f) Grounding connections for trays I cable boxes I marshalling boxes 4.8.2 The Bidder shall install galvanized MS sheet covers over top most tray of outdoor cable trays. The width of the covers shall be same as that of cable trays. Bolting shall be done to fasten covers to the cable trays, elbows, reducers, tees, crosses etc.
4.7.2
4.7.3
4.7.4
4.8.0 4.8.1
4.8.3
4.8.4
Straight pieces of standard MS angles/channels shall be used for fabrication of supports/racks. All welded joints shall be smooth enough to provide a good appearance and shall not cause" injury to working personnel. Cable trays/racks shall be so arranged that they do not obstruct or impair clearances of passage way, maintenance of adjacent equipment, if any. Cabling Work Laying, dressing, clamping and jointing / termination process of power, control and instrumentation cables shall follow the requirements of IS:1255 Suitable extra length of cables shall be provided for all feeders for any future contingency. Additional lengths shall be as under: Power cables: one loop with permissible bending radius. Control cables: 1 -1.5 metre Cable runs shall be uniformly spaced, properly supported and protected in an approved manner. All bends in runs shall be well defined and made with due consideration to avoid sharp bending and kinking of cable. The bending radius of various types of cables shall not be less than those specified by cable manufacturers and that specified in IS: 1255. All cables shall be provided with identification tags indicating the cable numbers in accordance with the cable schedule. Cable tags shall be fixed at terminal ends, at tray intersection / bend and at each side of floor / wall / duct crossings etc and at every 20m in cable trench / tray. Marker shall be provided for every 30 metres for directly buried cables. Single core cables for a. c. circuits shall form a complete circuit in trefoil formation supported by means of trefoil clamps of nonmagnetic material. Segregation of cables on the basis of their types and their functions shall be as under for horizontal formations: a) HT cables shall be laid in the top tier(s) b) LT power cables to be aid in the tray(s) below the HT cable trays. c) Non-shielded control cables d) Instrumentation (shielded control) and special noise sensitive cables. In case of duplicate feeders to essential loads, the respective cables shall be laid through separate raceways. Alternatively, such cables shall be laid on the opposite sides of a trench/tunnel/basement. For Directly Buried cables, construction of cable trench for cables shall include excavation, preparation of sieved sand bedding, riddled soil cover, supply and installation of brick or concrete protective covers, back filling and compacting, supply and installation of route markers and joint markers. Before the cables are placed, the excavated portion shall be filled with a layer of sand. This sand layer shall be leveled and the cables laid over it. The cables shall then be covered with 150 mm sand on top of the largest diameter cable and sand shall be lightly pressed. A protective covering with 70 mm thick bricks shall then be provided on top. The remaining portion of the excavated trench shall then be back filled with soil, rammed and leveled. RCC cable route and RCC joint markers shall be provided wherever required. The voltage grade of the higher voltage cables in route shall be engraved on the marker. Location of underground cable joints shall be indicated with cable marker with an additional inscription "Cable Joint'. The marker shall project 150mm above ground and shall be spaced at an interval of 30 meters and at every change in direction. They shall be located on both sides of road crossings and drain crossings. Top of cable marker/joint marker shall be sloped to avoid accumulation of water/dust on marker.
4.9.0 4.9.1
4.9.2
4.9.3
4.9.4
4.9.5
4.9.6
4.9.7
4.9.8
4.9.9
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4.9.10 Where a cable route crosses a permanent road/railway line cables shall be drawn through hume pipes or G.I. pipes. Pipes should be laid in a straight configuration. Filling criteria in any pipe shall not be more than 40%. 4.10.0 Cable Termination and Jointing 4.10.1 All cable entries in the equipment shall be sealed by cable glands. 4.10.2 Adequate length of cables shall be pulled inside the switchboards, control panels, terminal boxes etc so as to permit neat termination of each core/conductor. 4.10.3 Power cable terminations shall be carried out in a manner such as to avoid strain on the terminals by providing suitable clamps near the terminals. 4.10.4 Control cable cores entering switchboard or control panels shall be neatly bunched and strapped with PVC perforated tapes/nylon ties and suitably supported to keep them in position at the terminal block. All spare cores shall be connected to spare terminals wherever possible If spare terminals are not available, spare cores shall be neatly dressed and suitably taped at both ends. 4.10.5 Individual cores of control cables shall have ferrules for identification. Ferrule numbers shall be provided as per the control schemes and other related documents supplied by the Owner. 4.11.0 Earthing & Lightning Protection System Installation Work 4.11.1 Installation of earth conductors in outdoor areas, buried in ground, shall include excavation of earth upto 600 mm deep and 450 mm wide, laying of conductor at 600 mm depth brazing / welding / cad welding if required, of main grid conductor, joints as well as risers of length 500 mm above ground at required locations and then backfilling. Backfilling material to be placed over buried conductor shall be free from stones and other harmful mixtures. Backfill shall be placed in layers of 150 mm, uniformly spread along the ditch, and tampered utilizing pneumatic tampers or other approved means, If the excavated soil is found unsuitable for backfilling, the Bidder shall arrange for suitable soil from outside. 4.11.2 Installation of earth connection leads to equipment and risers on steel structures/walls shall include laying the conductors, welding/cleaning at specified intervals, welding/brazing to the main earth grids, risers, bolting at equipment terminals and coating welded/brazed joints by bitumastic paint. Galvanized conductors shall be touched up with zinc rich paint where holes are drilled at site for bolting to equipment/structure. 4.11.3 Installation of earth pit shall include excavation, construction of the earth pits including all materials required for construction of earth pits, placing the rod and fixing test links on those pipe/rod/plate electrodes in test pits and connecting to main earth grid conductors. 4.11.4 Installation of lightning conductors on the roofs of buildings shall include construction of upstands, laying, anchoring, fastening and cleaning of horizontal conductors, laying, fastening / cleaning / welding of the downcomers on the walls / columns of the building and connection to the test links to be provided above ground level. 4.12.0 Safety Material 4.12.1 The Bidder shall supply and install all danger plates as per IS : 2551. The danger plates shall be written in Hindi, local language and English and shall be provided as required for Electrical equipment. 4.12.2 Rubber mats of checkered profile shall be laid before each switchboard in all switchgear rooms. They shall be suitable voltage grade and of black color. In the switchgear room and
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inside plant area, first aid boxes shall be supplied as per the requirements of Indian Electricity Rules & Regulations. 4.12.3 The Bidder shall supply and install steel buckets with stand as per applicable standards near oil filled equipment such as Transformers. The bucket shall be painted red. The bucket shall be filled with sand. 4.12.4 All safety rules and codes as applicable to work shall be followed without exception. All safety appliance and protective devices including belts, hand gloves, aprons, helmets, shields, goggles, safety shoes etc. shall be provided by the Bidder for his personnel. 4.12.5 The Bidder shall provide guards and prominently display caution notices if access to any equipment / area is considered unsafe and hazardous 4.12.6 The Bidder shall provide shock treatment chart, danger notice boards and portable fire extinguisher in each switchgear room and control room. 5.0.0 5.1.0 TESTING & COMMISSIONING The Bidder shall take full responsibility of testing at erection, pre-commissioning and commissioning stages of all the equipment/system system being installed by him.. The Bidder shall submit to the Engineer a checklist for testing and commissioning and the activities shall be carried out in accordance with the checklist. The Bidder shall carry out the commissioning tests and checks after erection at site as per applicable standards and also as recommended by the Manufacturers. On completion of erection work, the bidder shall request the Owner for inspection & test. The Owner shall arrange for joint inspection of the installation for completeness and correctness of the work. Any defect pointed out during such inspection shall be promptly rectified by the Bidder. The installation shall be then tested and commissioned in presence of the representative of Owner and put on trial run for stipulated contract period. The Bidder shall arrange for inspection of his installation work by Electrical Inspector and shall obtain necessary approval certificate for his installation work. Any modification work required by Electrical Inspector must be undertaken by the Bidder at his own cost. All rectification, repair or adjustment work found necessary during inspection, testing, commissioning and trial run shall be carried out by the Bidder without any extra cost. Following successful inspection and testing, all the equipment shall be commissioned and put on trial run in a manner mutually agreed upon based on the commissioning schedule of main plant. The Bidder shall have to bring all testing equipment & instruments in sufficient numbers to carry out the job simultaneously in more than one area. Tests shall be conducted by qualified & experienced personnel. Valid calibration certificates for the testing equipments shall be produced All documents/records regarding test data and all other measured values shall be submitted to Engineer for approval and subsequent record and reference. The results of all tests shall conform to the specification requirements as well as any specific performance data guaranteed during finalization of contract. All checks and tests as per the Manufacturers drawings/manuals, relevant code of installation and commissioning check lists for various electrical equipment e.g. Transformers, breakers, motors, switchgear, relays, meters etc. shall be carried out. The Bidder shall perform operating tests on all switchgear and panels to verify operation of switchgear/panels and correctness of the interconnections between various items of the equipment. This shall be done by applying normal AC or DC voltage to the circuits and operating the equipment for functional checking of all control circuits, e.g., closing, tripping,
5.2.0
5.3.0
5.4.0
5.5.0
5.6.0
5.7.0
5.8.0
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control interlock, supervision and alarm circuits. All connections in the switchgear shall be tested from point to point for possible grounds or short circuit. 5.9.0 For Transformers, the following checks shall be carried out: Checking of ratio, polarity and phase relationship Resistance Measurement of Windings at all tap positions. Insulation Resistance Buchholtz relay operation for alarm and trip are checked by injecting air through the test petcock. The low oil level alarm of the oil gauge shall be checked The contacts of WTI and OTI for alarm and trip are checked and set at required temperatures depending upon ambient temperatures and loading conditions. The wiring from various accessories to marshalling box shall be checked.
5.10.0 The Bidder shall ensure the continuity of all conductors and joints. The Owner may ask for earth continuity tests, earth resistance measurements and other tests which in his opinion are necessary to prove that the system is in accordance with the design, specifications, code of practice and Electricity Rules. 5.11.0 Insulation resistance tests shall be carried out by following rating meggers: 5.12.0 Control circuits up to 220V a) Power circuits, bus bars, connections upto 11kV b) Power circuits, bus bars, connections above 11 kV : by 500 V megger
: 1000 V megger : by 5000 V motor operated megger
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JHABUA POWER LIMITED

1 X 600 MW + 1X 660 MW JPL SEONI Project Specification for River Water Intake System
SECTION 5
DETAILED TECHNICAL SPECIFICATION CONTROL & INSTRUMENTATION
Doc.No. 3109142-ME-SPC-108-001-Rev0 Volume II Technical Specification
Section: 5
Page 1 of 21
Detailed Technical Specification C&I

TABLE OF CONTENTS
Clause No.
Description
Page No.
1.0 2.0 3.0 4.0 5.0 6.0
GENERAL...3 CODES ANDSTANDARDS..5 DESIGN ANDCONSTRUCTION.6 TESTING AND INSPECTION ...20 TECHNICAL DATASHEETS.....21 MANDATORY SPARES.....22
Section: 5
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1.0 1.1
GENERAL SCOPE OF WORK The scope of work shall include the design, detailed engineering, manufacturing, shop inspection and testing, supply, packing, forwarding, unloading, storage & handling at site, erection, field calibration, testing and commissioning, trial operation and performance testing at site, of a PLC-based control system, back-up hardwired control panel, all field instruments and sensors, all cables, junction boxes etc., all erection hardware, spares, consumables, tools and tackles and testing instruments for the River Water Intake System. The scope shall include complete cabling works, including supply and installation of cable tray erection hardware and all necessary accessories, between any two equipment/system in the scope of the Bidder, including field instruments to field junction boxes and then up to PLC cabinets. All power cabling from UPS to the PLC cabinets, HMI, Hardwired Annunciation back-up panel, VMS cabinets, and reverse rotation sensors and other powered components of the respective control systems of these plants / systems is also included in the scope of the Bidder. Communication of PLC with unified PLC system shall be either from Wireless connectivity, preferably on GPRS based wireless communication or through redundant fibre optical for status monitoring of the pumps and other process measurements. Submission of all as-built drawings/documents, O&M manuals, and training of Owners personnel shall also be in the scope of the Bidder.
1.2
OPERATION AND CONTROL PHILOSOPHY The complete operation, monitoring and control of the River Water Intake System shall be performed from an exclusive, standalone, state-of-the-art redundant PLC-based control system with redundancies provided for power supplies, processors and communication modules and non-redundant I/O modules. The PLC shall be based on the latest software applications. The PLC shall be designed considering future expansion by way of additional I/O modules, processor capacity and power supply rating. It shall also be possible to perform the start/stop operations of the River water intake pumps and their discharge valves manually from a back-up control panel with necessary indicating lamp push buttons, local/remote selection switch, hardwired annunciators and hooter. The hardwired annunciator shall display alarms/annunciations driven from the PLCs outputs. The Human Machine Interface (HMI) equipment of the River Water Intake System shall consist of one (1) nos. of operator-cum-engineering station with keyboard, mouse and other input peripheral devices and one (1) no. 132 column dot matrix printer located in the River water Intake System control room. The HMI station shall be configured with appropriate password protections and shall be suitably networked with the PLC for real-time exchange of data. All operator graphics, plant mimics, graphic building and engineering applications shall be configured in the HMI. As stated above, a back-up control panel shall also be provided for manual operation of the pumps. The PLC including racks and HMI shall be located suitably in air-conditioned control rooms. Suitable free standing control desks, ergonomically and aesthetically designed, will be provided for housing all HMI equipment.
1.3
CONTROLS IMPLEMENTED IN PLCs All major controls of the River Water Intake System shall be implemented in the PLC-based control system, ensuring safe and reliable operation. The controls implemented shall be, but not limited to, the following:
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a. River water intake pumps selection and logics for auto changeover of pumps in the event of a trip. b. Interlocking of start / trip of individual pumps with water level in the respective suction of the intake well. c. River water pumps recirculation valve position control based on pressure in pumps discharge header. d. Water flow metering and totalizing on discharge line to raw water reservoir. e. Monitoring of bearing and winding temperatures of the river water pump and motor. f. Monitoring of Vibration on pumps by vibration monitoring system. f. Control and monitoring of all electrical equipment such as switchgear incomers, breakers, transformers, UPS & 220V DC system. Typical alarm, interlocks and protections are as follows, However, Bidder shall note that the complete details shall be decided during detailed engineering. 1.3.1 River water pumps start permissive interlock River water pumps start permissive shall be provided, but not limited to the following: 1.3.2 Sump water level Adequate Pump discharge valve Closed Switchgear not Disturbed Motor winding temperature not high Pump/Motor bearing temperature not high Switchgear master trip relay not operated Switchgear available Reverse rotation not existing
Auto start of Standby pump Standby pumps shall be started automatically in following conditions, but not limited to the following: Running pump trip due to any fault Discharge Header pressure Low Pump protection interlocks for tripping Sump water level Very Low Motor winding temperature Very high Pump/Motor bearing temperature Very high Pump/Motor vibration Very high Pump running and discharge valve closed Pump running and pump discharge pressure Very Low Pump discharge pressure Very High
Note: - Alarm to be annunciated for the above conditions in Control panel. 1.3.3 Pumps Discharge valve interlocks Start command to pump shall simultaneously open the valve to 10% Valve opens to 100% when the discharge header pressure reaches adequate Recirculation valve interlocks Discharge header pressure High opens the valve Discharge header pressure adequate closes the valve
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1.3.4
Status of the following shall be indicated in the Control Panel Pumps status Discharge valve status Level in the raw water reservoir (located in the power plant area) : : : On/Off/Trip Open/Close Level High (Alarm)
2.0
CODES AND STANDARDS The design, manufacture, inspection, testing and installation of all equipment and systems covered under this section shall conform to the latest editions of codes and standards mentioned below:
2.1 i) ii) iii) iv) v) 2.2 i) ii) 2.3 i) 2.4 i) ii) 2.5 i) 2.6 i) 2.7 i) ii) 2.8 i) ii) iii)
Temperature Measurement Performance Test Code-Temperature Measurement Temperature Measurement-Thermocouples Temperature Measurement - Guide to Electrical Resistance Thermometry Specification for Industrial Platinum Resistance Thermometer Sensors RTD Design Code Pressure Measurement Pressure Measurement Instruments and Apparatus - Part 2 Specification for Pressure and Vacuum Gauges Flow Measurement Flow Measurement (Revision 2) Enclosures Industrial Controls And Systems Enclosures Degrees of Protection provided by enclosures (IP Code) Installation Practices in Hazardous Area Classification of Hazardous Areas Instrument Tubing Forged Fittings, Socket-Welding and Threaded Instrument End Connections Pipe Threads, General Purpose (Inch) Pipe Flanges and Flanged Fittings: NPS through 24 Metric/Inch Standard Cables PVC insulated (heavy duty) electric cables: Part 1 - For working voltages up to and including 1100 V PVC insulation and sheath of electric cables Mild steel wires, formed wires and tapes for armouring of cables ANSI/ASME B1.20.1-1983 (R2006) ASME B16.5-2009 ANSI/ASME B16.11-2005 NFPA 70-1984 Article 300 NEMA ICS-6-1993 (R2006) IEC 60529 Ed.2.1-2001-02 ASME PTC 19.5-2004 ANSI/ASME PTC 19.2-1987 (R1998) IS 3624 :1987 ASME PTC 19.3-1974 (R1998) ANSI MC 96.1-1982 IS 2806 :1992 IS 2848 :1986 DIN 43760, BS 1904 Class II
IS 1554: Part I:1988 IS 5831:1984 IS 3975:1999
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iv) v) 2.9 i)
Tests on electric and optical fibre cables under fire conditions Oxygen Index Standard Test Method Surge Protection Standard Surge Withstand Capability (SWC) Tests for Relays and Relay Systems Associated with Electric Power Apparatus
IEC 60332 ASTM D2863-00
ANSI C37.90.1-200x
Where: i) ii) IEEE ISA Institute of Electrical and Electronics Engineers International Society for Automation National Electrical Manufacturers Association American National Standards Institute National Fire Protection Association American Society of Mechanical Engineers Indian Standards International Electrotechnical Commission American Society for Testing Materials Electronic Industries Association British Standards
iii) NEMA iv) ANSI v) NFPA vi) ASME vii) IS viii) IEC ix) ASTM x) EIA xi) BS 3.0 3.1
DESIGN AND CONSTRUCTION CONTROL SYSTEM SPECIFICATIONS The control system offered shall be of state-of-the-art PLC-based architecture with redundancies provided for processors, communication modules and power supplies and nonredundant I/O modules with the latest software applications.
3.1.1
General Design & Construction Requirements Proven and functional design from reputed manufacturer/vendor. Rugged design to withstand shock and vibration, ESD, EMI and high temperatures. Parts and components designed for interchangeability, re-configurability expandability. Satisfactory control system performance at 50 deg C and 95% relative humidity.
and
3.1.2
Uniformity in PLC Vendors The Owner intends to have uniform PLCs with unified PLC supervisory system for major offsite control islands, accordingly, the Owner has nominated Rockwell Automation India Ltd (ControLogix hardware & RSView HMI) as the standardized automation solution provider for implementation of these system. The successful Bidder shall place order on Rockwell Automation as per the agreed BOM and configuration.
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3.1.3
Control System Hardware Functional Features The functional features of the control system shall include, but not limited to, the following: S. No. a. b. c. d. e. f. g. h. Feature Scan time for digital and pulse inputs not greater than 250 msec. Scan time for all analog inputs not greater than 500 msec. Execution time not greater than 120 msec. Maximum system loading of 60% under worst loading conditions. Overall accuracy of signal measurement shall be 0.5%. Independent measurement circuits for each measurement. Failure of one logic shall not result in failure of the other logics. Extensive self diagnostic and power supply failure alarms.
The control system shall have the following self-diagnostic and monitoring features as a minimum: Alarms for power failure, subsystem failure, low battery back-up and earth faults. Power supply and communication monitoring. Fuse protection and fuse failure alarm. Power supply isolation for ground detection without physical removal. Individual signal isolation for ground detection without field wiring removal. LEDs for fault indication on each type of card. LEDs for watch dog timer failure. Fail-safe operation by freezing final control element position and changing to manual mode with alarm. Hardware Design Features The control system hardware shall be designed with the following features as a minimum: Optical isolation for all digital inputs and outputs. Galvanic / optical isolation for all analog inputs and outputs. 24VDC power supply to transmitters from internal power pack. 24VDC contact interrogation voltage. Cold junction compensation for thermocouples. Open circuit detection for thermocouples and RTDs. Modular and tropicalised electronic cards. Plug-in type PCB with gold plated contacts in both plug and socket. Card type and/or function designation inscribed on each card. On-line card replacement capability. In-rush current limiting. Short circuit and voltage surge proof circuits. Filters for noise rejection. Input signal distribution to various devices within the control system by multiplication. Non volatile memory for storing programs, standard software to perform logic functions, data acquisition and diagnostic features. Redundant internal power packs rated for 110% of maximum load requirements and powered from two (2) independent sources. The power packs shall generate all necessary system level voltages. Buses shall be formed at the power pack output for each voltage level.
Controller Features & Functions Minimum 32 bit processor with floating point capability. Data acquisition from all input signals.
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Validation of all inputs and outputs. Performing logical, Boolean, open loop and closed loop operations on inputs. Executing self diagnostic and communications monitoring routines. Monitoring of ADC / DAC performance and alarming for analog inputs. Redundant communications with I/O modules and MMI equipment. Battery back-up of not less than 72 hrs. Volatile memory to store dynamic plant data, control programs and self diagnostic routines.
I/O Assignment Philosophy Identical / redundant equipments (e.g. Pump A and Pump B) shall not be grouped in the same I/O module. To increase availability, the three pumps with their respective discharge valves and measurements shall be wired to modules in different racks e.g. Pump A, its discharge valve, its forebay level measurements. Its winding and vibration measurements in Rack A and so on. I/O assignment shall be identical for similar / redundant equipment, i.e., if Pump-A run th feedback is assigned to channel 4 of DI card in 7 slot Rack A, Pump-B run feedback shall also be assigned to channel 4 of DI card in 7th slot Rack B. Also, these cards shall be located in identical slots in different racks. Redundant field devices shall be connected to different modules. A card shall have I/O related to specific equipment and its auxiliaries only. Any spare channels available after such assignment may be used for common signals. If any equipment and auxiliaries require more than one card, I/O related to auxiliaries shall be in different cards. Inputs and outputs shall not be combined in a single module. 10% of each type of I/O module shall be mounted and wired up to the cabinet TBs as hot spares. 10% of channels in each I/O module shall be allotted as spare channels.
3.1.4
Control System Software The Real Time Operating System (RTOS) offered with the control system shall be proven, able to support all equipment/peripherals of the system and support software development, logic modifications and offline simulation without affecting real-time system performance. The data acquisition, processing and alarm monitoring/reporting software shall perform real time processing of raw process data including engineering unit conversions and alarm/event time stamping. The control software resident in the controllers shall perform mathematical function routines/algorithms and other logic functions for modulating and sequential control loops. The control logics shall be generated using logic function blocks and ladder diagrams and shall not require programming knowledge of any machine language. Utility applications for report and display generation, data base management, file handling, communication, online system back up, online diagnostics, graphic screen editing, online debugging, alarm management, log generation, test and maintenance programs, antivirus, OPC server/client, human machine interface software etc. shall also be a part of the Bidders scope. Bidder shall supply licensed copies of RTOS, engineering and all other utility application software.
3.1.5
Communication Data Bus / Network The PLC-based control system shall communicate with its HMI over a suitable redundant communication data bus/network. All necessary cables, network interface modules, switches and other devices shall be provided such that redundancy of the network is ensured. In the event of failure of the
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primary network, the secondary network shall be capable of handling complete data traffic under worst loading conditions. The network and its components shall have monitoring and diagnostic capabilities for troubleshooting.
3.1.6
Human Machine Interface (HMI) The HMI for the PLC-based control systems offered shall include the following, as a minimum: S.No. Item Description Quantity
PLC System for River Water Intake System $ 1. 2. 3. 4. Operator-cum-engineering workstation with desk mounted 22 LCD/TFT monitors, keyboard, mouse and other accessories. 132 col. Dot matrix printer Network switches, GSM/GPRS accessories (if applicable $$) router, cables and other One (1) No. One (1) No. One (1) Set One (1) Nos.
Control Desk for mounting workstation, components and other accessories
printers
network
One (1) Set 5. Operator Chairs and other furniture $ A back-up hardwired control panel with indicating lamp push buttons and hardwired annunciator shall be provided for manual operation of the river water intake pumps and valves. Annunciations shall be driven from the PLC. $$ Applicable only for Option 1 (Please refer clause 3.9 for details). The PC-based workstations shall have a 22 TFT monitor, QWERTY keyboard and optical mouse/track ball facility. The monitor shall be provided with anti-reflection feature and suitable for desktop mounting. The workstation shall be provided with a DVD read / write drive. Speakers (in-built or external) shall be provided in the workstations for audible annunciation of alarms with distinct tones based on alarm priority. The volume shall be adequate to make the annunciation audible over ambient control room noise. The control desk shall be a free standing, ergonomically and aesthetically designed structure for locating the workstation and other peripherals.
3.1.7
HMI Functions The operator-cum-engineering station shall be configured for the following functions: Display of plant/equipment/process graphics and mimics with individual point data. Alarms notification using soft alarm windows in LVS/OS and display with chronological summaries for process alarms, bad input points, system diagnostics and faults etc. Operator actions for auto/manual selection, local/remote selection, open loop and closed loop controls, alarm acknowledge actions etc. Trend plot and X-Y plot features. Generation of logs and reports. Equipment operation history. Control logic modifications. Offline logic simulation. Modifications to plant/equipment graphic screens and mimics
3.1.8
Back-up Control Panel A hardwired back-up panel shall be provided for the manual operation of the river water intake pumps and discharge valves, complete with indicating lamp push buttons (ILPBs), hardwired annunciator with suitable number of windows (as decided during detailed engineering) and local/remote selection switch.
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The hardwired annunciator shall be driven from the PLCs digital outputs. However all drives shall be operated through the PLC. Only the operator interface shall be possible both from back-up panel as well as OWS, the priority lying with the back-up panel. The back-up panel shall be so designed that the basic monitoring and operation of the pump house shall be possible without the operator work station.
3.2
FIELD INSTRUMENTATION The provisions of specific field instruments for each CW pump shall be, but not limited to the following:a. One no. duplex RTD and temperature indicator for temperature measurement at each pump/motor bearing for Riveriver Water (Make up water) pumps a. One no. reverse rotation monitor complete with probe assembly, cables and monitor/display unit for each CW pump for RiverRiver Water (Make up water) pumps. b. Two number of level switches and one no. of level transmitter on the intake well. c. One no. of pressure gauges at the individual pumps. d. Two number of pressure transmitter at the discharge header of the pumps. e. One number of Electromagnetic full bore type flowmeter shall be provided on discharge line to raw water reservoir. f. One no. of Vibration probe/sensor for each pump. g. One no. of Keyphasor for each pump. Bidder shall note that for all switches and transmitters, Cable connectors to field instruments shall be of Harting HAN plug and socket type and all transmitters shall be HART compatible type.
3.2.1
Pressure Gauges Direct reading, pipe mounted gauges with die-cast aluminium body, and 6 inch (150mm) phenolic dial (white dial with black numerals). Sensing element shall be SS316/SS304 Bourdon tube for high pressure applications and SS316 diaphragm/bellow for low pressure applications. Accuracy shall be +/-1.0% of span. Movement mechanism shall be made of AISI 304 with micrometer type adjustable aluminium pointer. Accessories like siphons for steam services, snubbers for pump discharge applications, and chemical diaphragm for corrosive and oil services shall be provided. Material of accessories shall be SS. IP65 or equivalent degree of protection for enclosure. Over-range protection shall be 50% above maximum pressure. Armoured capillary of 10m (min.) shall be provided as required. Process connection shall be NPT (F).
3.2.2
Smart Transmitters for Pressure Measurements Transmitters shall be smart, microprocessor-based, 2 wire indicating type (LCD display) with accuracy of +/-0.1% of span or better. Provision for external zero and span adjustment, self diagnostics and temperature compensation. Transmitter shall be 24V DC powered, with a 4-20mA DC output signal and superimposed digital HART signal. Load impedance shall be 600 ohms (min.) Process connection shall be NPT (F). Turndown ratio shall be 100:1 generally and 50:1 for very low pressure applications. Diecast aluminum housing with epoxy coating confirming to IP 65 or equivalent degree of protection. Accessories like snubbers for pump discharge applications, chemical diaphragms, 10m PVC covered SS armoured capillary for corrosive and oil services, three way manifold, nameplates etc. shall be provided. Manifolds shall have 2 valves for absolute pressure, 3 valves for gauge/vacuum and 5 valves for DP/level/flow measurements.
3.2.3
Bearing Temperature Indicators
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Direct reading, local gauge board/body mounted temperature gauges with die-cast aluminium body, and 6 inch (150mm) phenolic dial (white dial with black numerals) shall be provided for local indication of bearing temperatures. The sensing element shall be a liquid-in-steel thermometer with SS316 sensing bulb and stem having a measurement accuracy of +/- 1.0% of span. The movement mechanism shall be made of AISI 304 with micrometer type adjustable aluminium pointer. Accessories like capillary tubes of adequate length shall be provided with the temperature gauges. The gauge enclosure shall be of IP65 or equivalent degree of protection. 3.2.4 Bearing and Winding Temperature RTDs Three (3) wire, Pt100 duplex RTDs with accuracy of +/-0.5% of span and typical response time of 1-2 seconds shall be provided for bearing temperature measurements. The sensor shall be tip sensitive, of SS316 or suitable metal sheath and mineral (MgO) insulated construction designed to withstand a high degree of vibration and temperature. The sensor lead wires shall also be insulated with Teflon or other material suited for high operating temperatures. All RTDs shall be wired to and terminated in their respective junction boxes for further cabling to the River water intake PLC cabinets. 3.2.5 Ultrasonic Level Transmitters Non-contact, microprocessor-based 2 wire indicating type (LCD display) with sensor accuracy of +/-0.2% of span or better. Provision for external zero and span adjustment, self diagnostics and temperature compensation. Transmitter shall be 24V DC powered, with a 4-20mA DC output signal and superimposed digital HART signal. Load impedance shall be 500 ohms (min.) The range of the transmitter shall such as to cover the complete level span of the forebay/tank taking care of blocking distance and frequency attenuation due to obstructions. Suitable weather-proof housing with epoxy coating confirming to IP 65 or equivalent degree of protection. Suitable mounting brackets and all weather canopies for protection from direct sunlight and direct rain shall be provided. Suitable flanged or threaded connection shall be provided for tank mounted instruments. Spring loaded RTD assembly housed in an epoxy coated die-cast aluminium casing confirming to IP 65 or equivalent degree of protection. SS316 thermowell with M33x2 threaded process connection. Accessories shall include name plate, screwed cover and chain made of SS. 3.2.6 Electromagnetic Flow Meter Full bore electromagnetic flow meter with an integral top mounted indicating transmitter shall be provided for measuring river water flow to raw water reservoir. The smart transmitter shall be HART compatible and shall have an accuracy of 0.5% and repeatability of 0.1% of flow rate/volume flow output. The casing shall be made of corrosion resistant aluminium alloy confirming to IP67 or equivalent degree of protection and the flow tube and extension pipe shall be of SS 304 construction with a fluorocarbon or elastomer lining. The flow meter shall be powered from 240V AC UPS supply. The transmitter shall provide a 4-20mA DC output signal with superimposed digital HART signal. Load impedance shall be 500 ohms (min.). Flow totalizing shall be performed in the PLC. 3.2.7 Level Switches Capacitance probe type level switches shall be mounted in the River water forebay. It shall function as single point or two point level switch with adjustable time delay and probe failure alarm.
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The enclosure shall be cast aluminium, polyurethane painted and IP67 rating. The control operations shall be potentiometer to set Level alarm; Time delay and DIP for switch setting. The level switch shall have LED indications for level alarm and probe failure. The probe shall have a temperature rating of -25 Deg to +80 Deg C with cable entries of NPT (F) and sensitivity shall be +/- 0.5% of probe output. The electrode shall be of rigid PTFE construction. The capacitance type level switch shall be powered from 240 V AC UPS supply.
3.2.8 Vibration Monitoring System (VMS) A vibration monitoring system shall be provided for all applicable HT drives in the River water intake system. The VMS shall comprise of 2-wire, loop powered bearing vibration transducers providing 4-20 mA outputs. The outputs from these vibration sensors shall be directly cabled to the respective PLC cabinets for monitoring and analysis. Necessary cabling from the vibration sensors to the PLCs shall also be in the scope of the Bidder. 3.2.9 Reverse Rotation Monitors Reverse rotation monitors shall be provided for detection and alarming on reverse rotation of the River water pumps. The reverse rotation monitor shall be complete with proximity probes, collar/disc with keyway/notch, signal cables from the proximity probes to the monitor/display unit, signal conditioning hardware, relays with user configurable actuation points and potentialfree relay contacts for wiring to the PLC cabinets. The monitor/display unit shall have a LCD display and LEDs for status indication of the healthiness of the monitor, power supply availability and occurrence of an alarm condition. The reverse rotation monitors of all the river water pumps shall preferably be mounted centrally in a panel supplied by the Bidder. 3.2.10 HART Communicators (if applicable) One no. hand held HART communicators with anti-glare colour LCD graphic display, tactile membrane keypad and rechargeable Li-ion battery module shall be provided to facilitate field calibration and diagnosis of all HART compatible field instruments being supplied as part of this package. 3.2.10 Instruments for Performance Testing All instruments required for performance testing to prove the guaranteed performance of the plant shall be supplied by the Bidder for the Performance Test. These test instruments shall have test certificates from reputed test houses, valid for the duration of the performance test. 3.2.11 Instrument Racks & Enclosures Local instrument racks and enclosures shall be provided wherever deemed necessary for mounting instruments. Impulse piping of appropriate grade and schedule shall be provided from the process connection to the enclosure / rack. Suitable manifolds shall be provided for isolation and draining. The enclosures and racks and the instruments within, shall be suitably located considering ease of access, maintenance and proximity to the process. Access platforms shall be provided wherever necessary. Where instruments are locally mounted, all weather canopies shall be provided for adequate protection. 3.2.12 Impulse Piping Impulse piping shall be provided from the tapping point up to the remote transmitter envisaged for process measurement. Selection of the schedule and grade of the impulse pipes shall be based on maximum design pressure and temperature of the process. As a general practice, pipes of
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suitable grade and material shall be provided for all steam and water applications, and pipes for air and gas applications. The material specification and size of instrument impulse piping & fittings shall conform to ASME B 31.1 standards. Instrument impulse piping shall be supported at intervals of 2000 mm. Capillary tubing, and instrument air tubing shall be continuously supported in steel channel. The correct size of tube clips shall be used to suit the tube outside diameter. Impulse lines shall have venting, draining and blow down facilities. Impulse lines between process and sensor shall be as direct as possible and shall include allowance for vibration and vertical and horizontal movement. Joints in impulse lines shall be kept to a minimum. All pneumatic instrument lines shall be soap tested and any leakage shall be rectified. While process instrument lines are being pressure tested all instruments shall be completely isolated or disconnected. 3.3 CABINETS AND ENCLOSURES The control system cabinets located inside the air conditioned control room and back up panel located in non-air conditioned area shall be totally enclosed, free standing type with a 2.0mm (min.) CRCA steel sheet construction and dimensions measuring 2200mm (H) x 800mm (W) x 800mm (D). The cabinets shall have full height front and rear double leaf doors with louvers and filters, suitable gland plates for bottom cable entry, isolated system and electronic shield earthing buses, eye bolts and lifting hooks, 100mm thick black base frame and 15mm anti-vibration pad. The panel surfaces shall be painted (epoxy based, powder coated) of appropriate colour and adequate paint film thickness. The colors for exterior and interior surfaces shall conform to the following shades: Doors, Canopy & Plain End covers - Off white to RAL 9002 semi glossy (both interior & Exterior) Folded End covers - Exterior Blue to RAL 5012 - Interior - Off white to RAL 9002, semi glossy The cabinets shall be provided with the accessories namely, space heater with thermostat, panel lamp with door switch, auxiliary power socket, cooling fan, document holder, door latch and name plates. The cabinets shall be designed for a grounded installation on the building structure. The ingress protection rating for panels/cabinets shall be as under:
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Ambient Temperature (outside cabinets) Outdoor Locations 55 degree C max.
Atmosphere & Pressure
Relative Humidity (RH)
Required Protection Class
Dirty Air @ Atmospheric Pressure Dirty Air @ Atmospheric Pressure
100 % Max.
IP 65***
4 degree C min.
5 % Min.
IP 65***
Indoor Locations 55 degree C max. Air @ Atmospheric Pressure Air @ Atmospheric Pressure 95 % Max. IP 54**
4 degree C min.
5 % Min.
IP 54**
Air Conditioned Areas 245 degree C (normal) Air @ Atmospheric Pressure Air @ Atmospheric Pressure 95 % Max. IP 42
50 degree C max.*
5 % Min.
IP 42
* During air conditioning failure. ** For non-ventilated enclosures. For ventilated enclosures, protection class shall be IP 42. *** With a suitable canopy at the top to prevent ingress of dripping water.
3.4
JUNCTION BOXES Junction Box shall be of 3.0 mm MS sheet construction confirming to IP 65 class as per IS 2147 and suitable for wall or column mounting. It shall have single lockable door with neoprene gasket opening sideways with common keys. Painting shall be exterior color, basic pretreatment to be used before powder coating 7/8 tank Hot process for cleaning & applying a thin phosphate coat before final coating paint is carried out. All locally mounted JBs shall be provided with individual canopies. The JBs shall be designed for bottom cable entry with a removable gland plate, Fire proof compound sealing shall be provided at cable entries. Terminal shall be cage clamp or maxi termi type suitable for 0.5 to 2.5 sq.mm wire sizes. Name plate shall be of anodised aluminium name plate (Black ground with white letter). Top of box shall be constructed to slope towards rear. Undrilled gland plate of 3 mm MS sheet shall be at the bottom. The JBs shall also have provision to add 10% additional terminals. Accessories shall include metal tag (SS), clamps, fixtures, bolts (SS), nuts (SS), 6 mm neoprene gaskets for door and bottom plate, lock & key etc.
3.5
CABLES Supply, laying and termination of all instrumentation, signal, control and special cables shall be in the scope of the Bidder. As a general philosophy, individual pair shielded & overall shield twisted pair copper cables shall be used for analog signals while only overall shielded cables
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shall be used for digital signals. Sleeve type printed ferrules indicating terminal numbers at both end terminations shall be provided. Cross ferruling philosophy shall be adopted. 3.5.1 Instrumentation Cables Instrumentation cables shall be 225V AC grade, stranded high conductivity annealed, tinned copper, twisted pair (with min. 20 twists per meter) extruded PVC insulated with overall and / or individual screening, extruded PVC inner sheathed, extruded outer sheathed with FRLS PVC compound. The conductor size shall be minimum 0.5 sq.mm. For wiring RTDs, normal 4P*0.5 sq mm copper cables shall be used. No separate Triad cable shall be envisaged. Instrumentation cables carrying digital signals shall have overall screening along with drain wire and analogue and RTD signal carrying cables shall have individual pair screening and overall screening along with pair drain wires and overall drain wire. Shields shall have 25% overlap and 100% coverage. Shield thickness shall be 0.06 mm (min.) and tinned copper drain wire of 0.8mm ND. Spare cores / pairs shall be provided as below: Local cable for transmitters (2-wire type) shall be through 2 pair cables only. Local control panel for valve open & close limit switches shall be through 4 pair cables. For main cable, minimum one pair cable shall be kept as spare. For cable size till 8 pair, minimum two pairs shall be kept as spare. For cable size till 16 pair and above, minimum three pairs cable shall be kept as spare. 3.5.2 Control Cables Control cables shall be 600V AC grade, multi-core, minimum 1.5 sq.mm cross section, stranded copper conductor having 7 strands, PVC insulated, inner FRLS PVC sheathed of type ST-1, galvanized steel wire unarmoured and outer sheath made of FRLS PVC compound of type ST-1. In situations where accuracy of measurement or voltage drop in control circuit, warrant, higher cross sections as required shall be used. Solenoid valve power supply cables shall be minimum of 2.5 sq.mm. 3.5.3 Fiber Optic cables (as applicable $$$) Single mode type fiber optic cable with following parameters: Wavelength band optimized: 850nm / 1300nm / 1550nm Mode field diameter: 9-10m + 10% of nominal value Cladding diameter: 125m + 3 Cut-off wavelength: 1200mm Attenuation: less than 0.3-0.4 dB/km at 1300nm less than 0.15-0.25 dB/km at 1550nm $$$ Applicable only for Option 1 (Please refer clause 3.9 for details) 3.6 EARTHING Separate electronic earth shall be provided for the control system equipment located in the control room and elsewhere in the field. The electronic earth risers shall be exclusive and separate from the main plant equipment earthing. The control system equipment shall be earthed at two (2) separate points. Earthing cable and other accessories required for electronic earthing shall be in the Bidders scope. System or panel earthing shall be provided for earthing control system cabinets, panels, desks and other electronic equipment chassis. The system earthing points shall not be the same as those for electronic earthing. Earthing cable, flats and other accessories required for system earthing shall be in the Bidders scope. 3.7 POWER SUPPLY
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Redundant 415V, 3 phase AC feeders shall be envisaged as the power source for the PLC cabinets, back up panels and other control system components of the River water Intake system package. This shall be input to redundant UPS systems and all system specific voltage levels for powering the PLC panels including HMI equipment, back up panels and other network components shall be derived from the 240V AC, 50 Hz UPS output. The UPS systems shall be equipped with Lead Acid Plante batteries for providing a 1(One) hour back-up in case of power failure, to ensure the safe operation and/or emergency shut down of the system. A separate, non air-conditioned but adequately ventilated room adjacent to the air-conditioned control room shall be provided for housing the UPS batteries. 3.8 DRIVE CONTROL PHILOSOPHY
Bi-directional drives (Inching or Open/Close) The actuators/MCC shall accept command signals (24V DC) for drive Start and Stop from PLC and receive the following feedback signals (potential free contacts): Open feedback Close feedback Open torque switch not actuated feedback Close torque switch not actuated feedback Actuator Integral Starter fault/disturbed 4-20 mA position feedback (applicable for inching drives)
Unidirectional LT Drives The actuators/MCC shall accept command signals (24V DC) for drive Start and Stop from PLC and receive the following feedback signals (potential free contacts): - On/Running feedback - Off/Stop feedback - MCC disturbed feedback
Unidirectional HT Drives HT Drives like pumps and fans shall have the following interface between PLC and MCC: Potential free On-Off commands from PLC to MCC Feed backs from MCC to PLC shall include: - On/Running - Off/Stop - Switchgear disturbed - Switchgear healthy - Breaker in Service - Breaker in Test Position - Breaker Lockout Relay operated.
Local Emergency Stop push button stations shall be provided for all drives except motorized and solenoid valves. The push button contacts shall be wired directly to the MCC for protection purposes. For HT drives, ON-OFF commands and Running/Stop feedbacks shall be wired to redundant channels. 3.9 INTERACE WITH UNIFIED PLC SUPERVISORY SYSTEM There are two options suggested for interface of River water intake system PLC with unified PLC for monitoring and control of River water intake system (make up water system). Option 1: Communication through Wireless:
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The Bidder shall envisage a secure redundant wireless connection, preferably using a GSM/GPRS router between the River water intake system PLC and the unified PLC supervisory system (by others) for monitoring of the status of pumps and other process measurements. All the components required to make the above communication system complete at both ends, i.e., at the River water intake PLC end and the unified PLC supervisory system end shall be included in the scope of the Bidder with facility to interface with the unified PLC supervisory system. The GSM/GPRS router shall have the following features as a minimum requirement: a. Establish a Virtual Private Network (VPN) between the River water intake PLC and the unified PLC supervisory system and protect it against unauthorised access. b. Stateful inspection firewalls, Network Address Translation (NAT), port forwarding and other security features. c. Dial-in data connection through the GSM (Global System for Mobile Communication) operator network for maintenance and remote configuration. Alternately, remote configuration through a web-based user interface may also be provided. d. Network Time Protocol (NTP) for precise time synchronisation with the unified PLC supervisory system network. e. Periodic GPRS (General Packet Radio Service) connection monitoring and checking. f. Status logs with remote logging facility for periodic transfer of logged data to the unified PLC data network. The GSM/GPRS router shall have a plastic body construction confirming to IP20 rating with DIN rail mounting arrangement for installation inside a panel/enclosure. The device shall have provision for connecting an external antenna mounted outdoors if necessary. In such cases, the outdoor antenna shall be provided with appropriate lightning protection. Any statutory approvals and clearances required from concerned authorities, governing bodies etc. for implementing the wireless communication link shall be obtained by the Bidder. The communication system shall conform to industry standards with high level of security and should not interfere with other communication equipment in the vicinity. Option 2: Communication through Optical Fibre Cable: The River water intake system PLC shall be connected on redundant fiber optic links to the Owners unified PLC control station/OES (Rockwell Automation FTView SE Station) for monitoring, control and operation of the River water intake system from the main plant CER at 17.0m. The PLC shall also receive GPS time synchronisation signals through this control station. The parameters available at the unified PLC supervisory system (owners scope) at the main plant control room for monitoring and control shall include: Status of Pumps Status of River water Intake system Electrical Equipments Abnormal/Alarm Condition of Equipment/Process Apart from the above provision of individual pump start/stop and drive open/close commands shall also be available to the operator in the main plant control room. The distances between control nodes shall be as follows: Source Destination Approximate Distance
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River water Intake System PLC (RWPH)
Unified PLC supervisory system (CCR)
12 km (approx.)
3.10
ERECTION & COMMISSIONING SERVICES The Bidder shall be responsible for the erection, testing and commissioning of all equipment covered in the scope of this package. The Bidder shall operate and maintain all C&I systems in his scope till the completion of contract period or until it is taken over by customer, which ever is earlier. The laying and termination of all cables viz. pair, control/core cable, triad cables and power cables with cable glands, lugs, junction boxes, cable jointing kits and auxiliaries required shall be in Bidders scope. Perforated GI cable trays for control and instrument cables with all necessary hardware shall be in Bidders scope.
3.10.1 Erection, Field Calibration, Testing and Commissioning The Bidder shall erect, calibrate, test and commission all instrumentation and control equipment supplied under this contract to the complete satisfaction of the Owner / Consultant. The scope shall include the following: All necessary co-ordination with other contractors at site for erection, calibration, testing and commissioning of instruments and accessories. Furnishing all approved test certificates, calibration certificates and traceability certificates for calibration, testing and commissioning of C&I equipment as applicable.
3.10.2 Installation Requirements All instrument installations and impulse piping shall comply with relevant standards. The exact routing of impulse pipes / tubes shall be decided at site during erection by the Bidder depending upon the location of measurement tap points. Size and location of field junction boxes shall be decided based on the density and distribution of I/Os in a particular equipment / system. The Owner / Consultant reserve the right to approve location of the field mounted junction boxes. The Bidder shall prepare isometric drawings for installation of instruments and routing of impulse pipes, including sampling lines, from the tapping point to each instrument and device supplied by him. The Bidder shall also furnish as built drawings to the Owner / Consultant. The actual locations of instrument racks and enclosures shall be decided by the Bidder depending on site conditions, considering equipment layout and maintenance aspects. Single transmitters and switches shall be mounted on stanchions or pipes with suitable canopy. The Bidder shall get prior approval of the Owner / Consultant before any installation work starts. If any work is carried out by the Bidder before prior approval from Owner / Consultant and modification is sought by Owner / Consultant later, then the work will be redone by the Bidder without any cost / material implications to the Owner / Consultant. All panels, cabinets supplied by the Bidder shall be welded or bolted to floor channels. Supply of local supports / mounting brackets, local instrument enclosures and racks with necessary fixtures for all the equipment supplied shall be in Bidders scope.
3.10.3
Field Calibration and Testing Requirements The Bidder shall set up his own instrument laboratory at site for calibration of various instruments. The calibration equipment shall cover the complete necessary range with a desired accuracy of not less than +/-0.1%. All calibration equipment shall be certified by the National Physical Laboratory (NPL) or Institute of Design of Electrical Measuring Instruments (IDEMI) for the complete duration of the Contract.
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The Bidder shall follow standard procedures for calibration of various instruments and as instructed by the Owner including any requirements of field calibration. Calibrations shall be carried out independently by the Bidder and in the presence of the Owner. Proper documentation in this regard shall be maintained and handed over to the Owner. All the instruments shall be calibrated for the entire range for which it is designed. Calibration shall include test for repeatability. After first commissioning, the instruments shall be tested for calibration again to check whether the instrument maintains its zero and span. All instruments and control equipment shall be calibrated to read correctly to the satisfaction of equipment supplier / Owner / Consultant. All switches (use of switches shall be restricted to the minimum possible. Transmitters shall be used in their places) shall be tested for the actuation of both normally open and normally closed contacts at the desired set points and also for the fixed / differential settings. Air leak tests shall be performed on air supply and pneumatic lines. Necessary equipment such as portable compressor, connecting pipes, materials, cables and test gauges shall be provided by the Bidder. Hydro test shall be performed for all other impulse lines / sampling lines. Necessary equipment such as hydro test pumps and temporary piping, fill pump etc., materials such as temporary gaskets, miscellaneous fasteners etc. tools and tackles including test pressure gauges etc. are to be provided by the Bidder. For all electrical valve actuators, functioning, setting and performance of limit switches/torque switches at various positions shall be checked before and after installation of the actuators. The position transmitters for inching application shall also be calibrated accordingly. The C&I system availability shall not be less that 99.7% and shall be demonstrated by an analysis during system design and by test after actual installation in plant. Supply of performance test instrumentation is included in the Bidders scope.
3.10.4
Commissioning Requirements All impulse lines and air supply lines shall be blown with adequate line pressure and actual temperature conditions to ensure cleanliness prior to taking instruments into service, to the satisfaction of Owner. Once the instrument is taken in service, the Bidder shall physically inspect the various joints and pipes for leakage and repair any defects found. On-line calibration i.e., without removing control valves from service, of the positioners and stroking of control valves / control dampers shall be carried out as required by Owner during control system tuning. Manufacturer's instructions shall be thoroughly understood and followed before commissioning each instrument. After delivery of the equipment, the Bidder shall locate all the equipment including electronic cards in its final position, check all the power wiring, grounding and interconnection cables, all in accordance with manufacturer's recommendations. The Bidder shall perform initialization of system power, field loading of system configuration/software and data base, demonstration of system functionality to verify conformance with manufacturer's instructions and specifications, tuning of control loops, implementation of any configuration changes as required and providing general trouble shooting and final solutions to application and/or instrument problems.
3.10.5
Erection and Maintenance Tools All special maintenance and erection tools and tackles like module puller, terminal connectors & test/simulation jig as required for the system is in Bidders scope. If in the opinion of Owner / Consultant, the tools and tackles etc. provided by Bidder are not adequate; the Bidder shall suitably augment the same as directed by Owner/Consultant. In the event of non-compliance by the Bidder, the Owner reserves the right to augment such facilities and back charge the Bidder all expenses incurred in this connection including the Owners overheads.
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3.11
TRAINING The personnel to be trained shall be as follows: Two (2) Control Engineers The Contractor shall involve Owners engineers and I&C equipment supplier at their Works, from the detailed engineering stage and train them in all design and engineering aspects of all field instruments, PLCs & UPS offered for a period not less than one month.
The Contractors personnel at site shall continuously and intensively instruct and train adequate number of the Owner's operating and maintenance personnel during erection and commissioning of the equipment to enable them take over the complete operation and maintenance of the equipment after commissioning. 4.0 4.1 TESTING & INSPECTION Factory Acceptance Test (Pre-FAT & FAT) The control system being offered shall be fully tested and inspected at the manufacturers works. The tests shall be witnessed by the Owner / Owners Engineer. The Bidder shall prepare and submit detailed test procedures and test sheets for the Owner / Owners Engineer approval. The Bidder shall provide all supervision, specialized personnel and material to fully accomplish the testing at the manufacturers works and at the Owners site. Punch lists shall be prepared during the course of testing and all issues, non-conformities and resolutions brought out shall be addressed and resolved. Before the system is delivered to the site, satisfactory performance of the entire system shall be demonstrated. The system shall simulate the final onsite configuration as closely as possible. Detailed test schedules, including at least the tests listed below, shall be submitted for the Companys approval one month before the testing. The Bidder shall have a technician and test equipment available full time during testing. The FAT shall be conducted after the 48 hour heat soak test on the control panels. The FAT procedure shall include, but not limited to, the following aspects: Inspection of equipment, shock or vibration test, power supply variation test, radio interference test, functional tests, including operator control panel functions, module replacement and standby changeover, operation of multiple processors, operation of communication channels, including PLC to unified PLC supervisory system communication links, operation of power supplies, failures and interaction between different parts of the system, systematic diagnostic test, including self-test facilities, System and report alarms, electrical isolation test, application logic test, application software functional change test as per the logic and / or the Cause and Effect diagrams, system responsiveness (e.g. scan time, alarm discrimination, logging and screen updates), spare capacity verification.
4.2
Site Acceptance Test (SAT) Site Acceptance Tests (SAT) are to be carried out by the Bidder after erection. After the site acceptance test & commissioning of the system, the Bidders service engineers shall be positioned at site till the commissioned system stabilizes completely d, at no extra cost. The Bidders representative shall be made available at site for the period during commissioning, site acceptance, and stabilization. Bidder shall carry out this activity without any cost and time implications to the Owner. The SAT shall essentially be a repeat of the FAT procedure with the following additions: The connecting wiring between distributed components shall be the actual fieldinstalled wiring and cable, The field inputs and shutdown devices shall be connected
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and exercised to confirm the correct connection and compatibility of the field components, Test of interfaces with actual systems i.e., unified PLC supervisory system, PLC etc, A repeat of the FAT shall be required after field connections of the actual system connections are made. 4.3 Final Acceptance Test The control system offered shall be accepted when the equipment is complete in every detail including spares and documentation and the Bidders/Purchasers site resident engineers are satisfied that the equipment has met the requirement of this specification. The Bidder shall performing testing and inspection of all instrumentation and control equipment supplied under this contract to the complete satisfaction of the Owner / Consultant. The responsibility of work shall also include but not limited to the following: All necessary co-ordination with other Contractors at site for testing and inspection of Instruments and accessories. Making available all necessary test equipment with approved test certificates, calibration certificates and traceability certificates as applicable.
4.4
Guarantee Tests The Bidder shall conduct integrated test, inspection and checking of the system offered at manufacturers works and pre-commissioning tests at site as detailed in the specification. The Bidder shall prove the guarantee of the system and equipment supplied by him. The necessary documentation for the above services shall be submitted by the Bidder for Owner / Consultants approval.
5.0
TECHNICAL DATASHEETS Please refer Schedule 8.3 of Section 8, Volume II of this specification for technical datasheets. Technical requirements for various other C&I equipment not furnished in this section, have otherwise been outlined in the respective sub sections under Section 5, Clause 3.0 of the specification.
6.0
MANDATORY SPARES For a list of mandatory spares, refer Section 10, Volume II of this specification.
Section: 5
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SECTION 6
DETAILED TECHNICAL SPECIFICATION PAINTING
Section 6 Painting
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JHABUA POWER LIMITED 1x600MW + 1x660MW JPL SEONI Project TABLE OF CONTENTS CLAUSE NO. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 DESCRIPTION PAGE NO. Specification for River Water Intake System
GENERAL......................................................................................................................................... 3 CODES AND STANDARDS .............................................................................................................3 SURFACE PREPARATION STANDARDS ......................................................................................4 EQUIPMENT ....................................................................................................................................4 MECHANICAL CLEANING AT MANUFACTURER'S WORKS........................................................4 ALTERNATIVE CHEMICAL CLEANING AT MANUFACTURER'S WORKS ................................... 5 PROTECTION AT MANUFACTURER'S WORKS ...........................................................................5 WEATHER CONDITIONS ................................................................................................................5 SURFACE PREPARATION..............................................................................................................5 PRIMER PAINT ................................................................................................................................7 RUB DOWN AND TOUCH UP OF PRIMER ....................................................................................7 NON COMPATIBLE SHOP COAT PRIMER ....................................................................................7 STEEL STRUCTURES PAINTING ..................................................................................................8 PAINT MATERIALS ..........................................................................................................................8 STORAGE ........................................................................................................................................8 SCHEDULE OF PRIMER AND FINISH COATS ..............................................................................8 PREPARATION OF COATING MATERIALS ...................................................................................8 APPLICATION ..................................................................................................................................9 SAFETY REQUIREMENTS..............................................................................................................9 DRY FILM THICKNESS (DFT) .........................................................................................................9 TOUCHUP PAINT ............................................................................................................................9 FIELD PAINTINGS/COATINGS AND LININGS ...............................................................................9 IMMERSION SERVICE ..................................................................................................................10 ARCHITECTURAL COMPONENTS ..............................................................................................10 COLOUR CODE FOR PIPING .......................................................................................................10 IDENTIFICATION OF VESSELS, PIPING ETC. ............................................................................10 INSPECTION AND TESTING ........................................................................................................11 GUARANTEE .................................................................................................................................11 GALVANIZING................................................................................................................................11
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SECTION 6 DETAILED TECHNICAL SPECIFICATION FOR PAINTING SURFACE PREPARATION AND PAINTING
1.0 General This document covers the painting requirements for the equipment, components and systems. The requirements for mechanical or chemical cleaning, protective coating and painting of equipment components and systems during the various stages of the contract are detailed below. Cleaning of fabricated items shall be carried out after fabrication and final heat treatment or welding at manufacturer's works or at site, as appropriate. For cleaning in workshop and before painting, mechanical cleaning as opposed to alternative chemical cleaning is the preferred method except where this is precluded by design or access considerations. Machined surfaces shall be protected during the cleaning operations. In the event of the surfaces not being cleaned to the Owner's satisfaction, such parts of the cleaning procedures or agreed alternatives as are deemed necessary to overcome the deficiencies shall be carried out at the Contractor's sole expense. For reclining small areas, hand cleaning by wire brushing (with austenitic steel bristles) is permitted. Austenitic stainless steels, copper and aluminium alloys, cast iron, bimetallic and metallic/plastic items, and components fabricated by spot welding or riveting shall not be chemically cleaned. All welded areas shall be suitably stress relieved before chemical cleaning. 2.0 Codes and Standards Painting of equipment shall be carried out as per the specifications indicated below and shall conform to the relevant IS Standards for the material and workmanship. The following Standards may be referred to for carrying out the painting job: IS:5 IS:1303 IS:2379 IS:1477 : Colours for ready mixed paints and enamels. : : Glossary of terms relating to paints. Colour code for identification of pipelines.
: Code of practice for painting of ferrous metals in buildings (Parts I & II). : Code of practice for painting of non-ferrous metals in buildings (Parts I & II). : Code of practice for painting of concrete, masonry and plaster surfaces (Parts I & II). : Code of practice for finishing of wood and wood based materials (Parts I & II). Code of practice for white washing and colour Washing. Ready mixed paint, brushing, bituminous, black, lead free, acid, alkali, water and heat resisting. Ready mixed paint, air drying, red Oxide Zinc Chrome, priming. Ready mixed paint, brushing, Zinc Chrome, priming.
IS:2524
IS:2395
IS:2338
IS:6278
IS:158
IS:2074 IS:104
: :
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JHABUA POWER LIMITED 1x600MW + 1x660MW JPL SEONI Project IS: 2932 BS: 5493 3.0 : : Specification for River Water Intake System
Enamel, synthetic, exterior (a) undercoating (b) finishing. Inorganic Zinc rich systems.
Surface Preparation Standards The following standards shall be followed for surface preparations: Swedish standard Institution - SIS-05 5900-1967 (Surface preparation standards for painting steel surfaces). Steel structures painting council, U.S.A. (Surface Preparation Specifications (SSPC-SP). British Standards Institution (Surface Finish of Blast cleaned steel for painting) BS-4232. National Association of Corrosion Engineers, U.S.A. (NACE). IS: 1477-2000 (Part - I) - code of practice for painting of Ferrous metals in buildings (Part 1, pre-treatment). Various international standards equivalent to Swedish standard for surface preparation are given in Table-1.
The Contractor shall arrange, at his own cost, to keep a set of latest edition of the above standards and codes at site. The paint manufacturer's instruction shall be followed particularly to the proper storage to avoid exposure to extremes of temperature, surface preparation prior to painting, mixing and thinning, application of paints and the recommended limit on time intervals between coats, shelf life for storage. Any painting work including surface preparation on piping or equipment shall be commenced only after completion of the system tests and clearance for taking up painting work is given by the Engineer. 4.0 Equipment All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning and all equipment, scaffolding materials, shot/sand blasting equipment & air compressors etc.(which ever applicable) shall be arranged by the Contractor at the site in sufficient quantity along with suitable paint thickness measuring instruments such as Elkometers acceptable to the Engineer (with calibration facilities). Mechanical mixing shall be used for paint mixing operations in case of two pack systems except that the Engineer may allow the hand mixing of small quantities at his discretion. 5.0 Mechanical Cleaning At Manufacturer's Works Mechanical cleaning shall be carried out by abrasive blasting or alternative methods to Owners approval, provided they achieve the necessary surface condition. The metal surfaces shall be clean and free of mill scale, rust, dirt, grease and any other deleterious matter. Where metal surfaces are to be painted, the surface profiles shall conform to the painting specification requirements. Where this does not apply, surfaces shall have a surface texture not coarser than Grade 80 abrasive paper. Abrasives containing silica, silicates or slag residues shall not be used for water/steam side surfaces of plant except for cleaning sand castings, where hydro blasting with sand may be used. Only for austenitic materials, abrasives containing 98% or more of alumina, Al2 O3, shall be used. After cleaning, abrasive and debris shall be thoroughly removed from components.
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JHABUA POWER LIMITED 1x600MW + 1x660MW JPL SEONI Project 6.0 Alternative Chemical Cleaning At Manufacturer's Works Chemical cleaning shall be preferred where mechanical cleaning is precluded by design or access considerations. Machined surfaces shall be protected during the cleaning operations. The procedure shall comprise pre-treatment and acid treatment to achieve cleanliness equivalent to that specified for mechanical cleaning to Owner's approval. 7.0 Protection At Manufacturer's Works As soon as all items have been cleaned and within four hours of the subsequent drying, they shall be given suitable anti-corrosion protection. All water, air and steam side surfaces shall be protected by the application of approved water soluble corrosion inhibitors, or vapor phase inhibitors that shall be subsequently removed by site water washing or steam blowing. The rate of application of volatile corrosion inhibitors shall be at least 10 grams per square meter or 35 grams per cubic meter, whichever is the greater, except for pipes up to 300 mm diameter for which the minimum application rates shall be 5 grams per square meter. Immediately after the protective treatment has been applied all vessels and pipes shall be suitably sealed off by discs or caps or approved alternatives to prevent ingress from the surrounding. Cylindrical plugs shall not be driven into the ends of pipes. These protective covers shall not be removed until immediately before final connection is made to the associated equipment. 8.0 Weather Conditions Painting shall be done only when the surface temperature is at least 3C above dew point to ensure that condensation does not occur on the surface. Reasonable protection against precipitation, corrosive fumes and vapors shall be exercised for the painting of outdoor parts. Precautions shall also be taken against solar radiation to ensure that the specified dry film thickness of priming or finish coats is obtained. Any prime coat exposed to excess humidity, rain, dust etc., before drying, shall be permitted to dry and the damaged area of primer shall be removed and the surface prepared and primed again. Sheltered or unventilated horizontal surfaces on which dew may collect require more protection, and to achieve this, an additional top coat of paint shall be applied. 9.0 Surface Preparation a) In preparing any surface to be coated, all loose paint, dirt, grease, rust, scale, weld slag or spatter or any other extraneous material shall be removed and defects repaired, so as to obtain a clean, dry, even surface to receive the priming or finishing coat (s) as called for in the painting schedules. Sharp edges shall be rounded, especially when tank linings have to be applied. All machined surfaces, including flange faces, shall be suitably covered to prevent damage during surface preparation. All surfaces shall be blast cleaned whenever possible. b) Bare steel surfaces shall be prepared by one of the methods described below in order of preference and in accordance with Swedish Standard SIS 05 59 00 or Steel Surfaces Painting Council, SSPC, Vis 1, or DIN 55928, Section 4. (i) White metal blast cleaning: Sa 3 or SSPC - SP 5 Sa 3 blast cleaning to bare metal. Mill scale rust and foreign matter must be removed completely. Subsequently, the surface shall be cleaned with vacuum cleaner, clean dry compressed air or a clean brush. It must then have a uniform metallic color and correspond in appearance to the prints designated Sa 3. (ii) Near white metal blast cleaning: Sa 2 or SSPC - SP 10 Specification for River Water Intake System
Sa 2. is a very thorough blast cleaning process. Mill scale, rust and foreign matter shall be removed to the extent that the only traces remaining are slight imperfections in the form of spots or strips. Subsequently, the surface shall be cleaned with a vacuum cleaner, clean
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dry compressed air or a clean brush. It must then correspond in appearance to the prints designated Sa 2. (iii) Mechanical cleaning shall only be used when procedures (a) and (b) are not practicable. c) Commercial Blast Cleaning: Sa 2 Sa 2 Blast cleaning until, at least two-thirds of each element of surface area is free of all visible residues. This method of cleaning shall be suitable for steel required to be painted with conventional paints for exposure to mildly corrosive atmosphere to ensure longer life of the paint systems. d) Near white metal blast cleaning: Sa 2 DIN 55928
From all other surface mill scale and rust are to be removed to such an extent that the only traces remaining are slight imperfections in the form of spots or stripes. Further treatment refer to b(ii) above. The adhesivity of residual coatings in the transition zone shall be tested even after the application of the primer. e) Very thorough mechanical scraping and wire brushing: St 3
St 3 is very thorough scraping and wire-brushing - machine brushing - grinding - etc. Surface preparation is as per St 2 but much more thorough. After the removal of dust, the surface must have a pronounced metallic sheen and correspond to the prints designated St. 3. f) Thorough scraping and wire brushing: St 2
St 2 is thorough scraping and wire-brushing - machine brushing - grinding - etc. The treatment shall remove loose mill scale, rust and foreign matter. Subsequently, the surface is cleaned with a vacuum cleaner, clean dry compressed air or a clean brush. It shall then have a faint metallic sheen. The appearance must correspond to the prints designated St 2. Table-1 Surface Preparation Standards a) Surface preparation method b) Blasting acc.to item a (i) c) Blasting acc. to item b (ii) d) Blasting acc. to item c e) f) Hand/or power tool derusting acc to item (f) Acc. to items (e) SIS 055900 Sa 3 DIN 559 BS 4232 only fo SSPC-Vis Part 4 blasting First quality White metal SP 5 Second near Sa 2 White SP 10 quality Commercial Third quality blast SP 6 Hand tool Cleaning St 2 SP 2 Power tool Cleaning St 3 SP 3 F1 Flame cleaning SP 4 Be Pickling
g) Flame jet cleaning h) Pickling
Steel structures to be blast cleaned have to be free of pitting and other severely corroded places in accordance with B.S. 4232 and SIS 055900. The abrasives used for blast-cleaning shall be graded flint, grit, shot or silica sand and shall be such that they will produce an average keying profile on the blast-cleaned surface of not more than 40 microns. An air pressure of 7 bar (g) at the nozzle shall be used. After blast-cleaning, all accumulated grit, sand, dust, etc., must be removed leaving the surface clean, dry and free of mill scale, rust grease and other foreign matter. In the event of rusting after completion of the surface preparation, the surface must be cleaned again in the manner specified. Cleaning with solvents shall be resorted to only in such areas where other methods specified
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above have not achieved the desired results. Oil, grease, soil, cement, salts, acids or other corrosive chemicals shall be cleaned from steel surfaces by the use of solvents, emulsions or cleaning compounds. The final wiping shall be with clean solvent and clean rags or brushes. There shall be no detrimental residue left on the surface. Cleaning with solvents shall be adopted only after written approval of the Engineer. Primed areas, which suffer damage must be spot blasted on site to a degree of cleanliness equivalent to Sa 2 before touching up. Protective coating must be applied as quickly as possible after the completion of surface preparation no matter what cleaning method has been used. No blast-cleaned surface shall be allowed to remain uncoated overnight. Steel work protected by shop primer after arrival on site must be cleaned of salt, sand, oil etc. before the first coat of paint is applied on site. Shop primer damaged during transport must be rectified by blast-cleaning and coating before application of the site coats. Wood surfaces shall be sanded clean. All nail holes shall be puttied and sanded before priming. If a protective coating is required, concrete shall be allowed to cure before painting. 10.0 Primer Paint The primer should be worked by brush application to cover the crevices, corners, sharp edges etc. in the presence of inspector. The shades of successive coats should be slightly different in colour in order to ensure application of individual coats, the thickness of each coat and complete coverage could be checked as per specification approved by Engineer before application of successive coats. The Contractor shall provide standard thickness measurement instrument with appropriate range(s) for measuring. Elkometer for measuring the Dry film thickness of each coat, surface profile gauge for checking of surface profile in case of sand blasting. Holiday detectors and pinhole detectors for checking the painted surface discontinuities should be provided by the Contractor. The Contractor shall make arrangements for paint manufacturer to provide expert technical service at site as and when required free of cost and without any obligation to the Owner, as it would be in the interest of the manufacturer to ensure that both surface preparation and application are carried out as per their recommendations. Final inspection shall include measurement of paint dry film thickness, check of finish and workmanship. 11.0 Rub Down and Touch Up Of Primer The shop coated surfaces shall be rubbed down thoroughly with emery paper to remove all dust, rust and other foreign matters, washed, degreased, then cleaned with warm fresh water and air dried. The portions, from where the shop coat has peeled off, shall be touched up and allowed to dry before applying a coat of primer. The compatibility between shop coat and field primer shall be ascertained from the paint manufacturer. In case degreasing with white spirit is not effective, the surface shall be finally wiped clean with aromatic solvent like xylol or light naphtha. 12.0 Non Compatible Shop Coat Primer a) The compatibility of finishing coat shall be confirmed from the paint manufacturer. In the event of use of primer such as zinc rich epoxy, inorganic zinc silicate etc., the paint system shall depend on condition of shop coat. If, the shop coat is in satisfactory condition showing no major defect, the shop coat shall not be removed. The touch up primer and finishing coat(s) shall be identified for application by Engineer. Shop coated (coated with primer & finishing coat) equipment shall not be repainted unless paint is damaged. b) Shop primed equipment and surfaces shall only be 'spot cleaned' in damaged areas by means of power tool brush cleaning or hand tool cleaning and then spot primed before applying one coat of field primer unless otherwise specified. If shop primer is not compatible with field primer then shop coated primer shall be completely removed before application of selected paint system for particular environment. For package units/equipment, shop primer shall be as per the paint system given for particular environment.
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c) In case of existing paint, compatibility between finishing coat and new selected finish coat shall be ascertained before application of finish coat. In case, the coat is selected for upgrading existing alkyd coating to high performance coating, then surface preparation shall be by manual/mechanical means to remove loose rust, peeled off/damaged paint, but sound old coating need not be removed. It shall be touched with red oxide zinc chromate primer wherever it has peeled of before application of tie coat. The tie coat shall be applied after 7 days of curing of red oxide zinc chromate primer. If new paint system is not suitable to upgrade existing coating then complete paint shall be removed by mechanical or blast cleaning before application of new coating system. 13.0 Steel Structures Painting All steel structures shall receive primer coats and finish coats of painting as per Table-2. First coat of primer shall be given in shop after fabrication before dispatch to erection site after surface preparation. The second coat of primer and intermediate coat shall be applied after erection and final alignment of the erected structures. The finish coats shall also be applied after erection. Surface preparation and paints to be applied shall be as per Table 1 and Table-2 respectively. 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. 14.0 Paint Materials The paints shall conform to the specifications given in Table 3 and class - 1 quality in the products range of any of the renowned paint company which satisfies all the criteria. 15.0 Storage All paints and painting material shall be stored only in rooms to Engineer's approval. All necessary precautions shall be taken to prevent fire. The storage building shall preferably be separated from adjacent buildings. A signboard bearing the words "PAINT STORAGE - NO NAKED LIGHT HIGHLY INFLAMMABLE - DANGER - NO SMOKING" shall be clearly displayed outside. All paints shall be stored in the safest manner so that no container rolls down and causes accidents. The shelf life of the paints shall be ensured so that the paint materials are not in storage and use after the date of expiry. 16.0 Schedule Of Primer And Finish Coats Schedule of primer and finish coats is given in Table-3 of this section. 17.0 Preparation of Coating Materials All containers shall remain un-opened until required for use. Primers and paints, which have livered, gelled or otherwise deteriorated shall not be used. The oldest primer or paint of each kind shall be used first. All ingredients in any container shall be thoroughly mixed before use and shall be agitated frequently during application to keep the primer in suspension. Primer or paint mixed in the original container shall not be transferred until all settled pigment is incorporated into the body of the liquid. Mixing in open containers shall be done in a well ventilated area. Primer or paint shall be mixed in a manner ensuring the breakdown of all lumps, complete dispersion of pigment and uniform composition. Two-component primers shall be mixed in accordance with the
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manufacturer's instructions. Thinners shall not be added to primers or paints unless necessary for proper application according to the manufacturer's instructions. When use of thinners is permitted, it must be added to the primer or paint during mixing. 18.0 Application The supplier shall check all painting work to be carried out according to the specification of the paint supplier further to all relevant prescriptions and regulations concerning the health and safety of work. The paint supplier shall present a written specification including the flash point of the paints, ventilation requirements, handling precautions such as inhalation, eye and skin protection, and first aid procedure, storage requirements, spill or leak procedure, fire precaution, waste disposal. 19.0 Safety Requirements a) Protection of the blast cleaner operator's eyes and respiratory system shall be given prime consideration in any open blast cleaning operation. Air fed helmets, respiratory filters, air conditioned hoods etc. shall be provided in sufficient number to the blast cleaning operators to avoid the harmful effect of blast cleaning abrasives. Also, an automatic shut-off device which will shut-off the air supply to the blasting machine shall be installed which will prevent the dangerous whipping of an operating blast hose if an operator becomes disabled. b) Temporary corrosion protections are to be completely removed prior to applying the definite one. All prime coatings shall be applied by brush or airless spray or a combination of these methods, as approved by the coating manufacturer. All doors, windows, stairways, handrails (if painted), bolts, flanges and equipment supports shall be finish painted by brush. Spray guns shall not be used outside in windy weather or near surfaces of a contrasting color unless the latter is properly protected. All cold-spray painting shall be done using standard equipment in accordance with accepted standards and methods. Care shall be taken not to connect spraying devices for nitro and backelite paints simultaneously to oil based paints. Paint applied to items that are not be painted shall be removed at the supplier's expense, leaving the surface clean, unstained and undamaged. 20.0 Dry Film Thickness (DFT) The paint coats shall be applied as a continuous film of uniform thickness and free of pores. Overspray, skips, runs, sags and drips shall be avoided. The different coats shall not be of the same color. Each coat of paint shall be allowed to harden before the next is applied. For epoxy paint, the hardening time normally is 12-14 hours. Supplier's recommendations regarding hardening time of epoxy paints must be followed. Particular attention must be paid to full film thickness at edges. The minimum total dry film thickness of the paint systems shall be as recommended in the Table-3. The DFT is given in microns (millionths of a metre). 21.0 Touchup Paint Touchup paint shall be provided for repair painting of at least 25 percent of shop finish painted equipment surfaces. The touchup paint shall be the same type and colour as the shop applied material. Surface preparation and application instructions shall be provided. 22.0 Field Paintings/Coatings And Linings All surfaces of erected equipment, piping, tanks, structures, and building components shall be finish painted. Surfaces of connections, field welds, and damaged areas shall be cleaned, prepared, and primed before application of the finish system.
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JHABUA POWER LIMITED 1x600MW + 1x660MW JPL SEONI Project 23.0 Immersion Service Interior surfaces of shop fabricated and field erected tanks shall be cleaned and lined with materials designed for the specific application. Cleaning shall be in accordance with SSPC-SP5, White Metal Blast Cleaning. 24.0 Architectural Components Interior non-metallic architectural components, including concrete block/ cement plastered brick walls, in neutral environments shall be painted with low gloss water-borne materials. Finishes for metallic architectural components, including doors and frames, shall provide a smooth, semi-gloss, and durable surface. 25.0 Colour Code For Piping a) The color code scheme is intended for identification of the individual group of the pipeline. The system of color coding consists of a ground color and color bands superimposed on it. The color coding for the identification of pipelines shall comply with Table 4 of this section. Ground Color shall be applied throughout the entire length for uninsulated pipes. For insulated pipes, on the metal cladding or on the pipes of material such as non-ferrous metals, austenitic stainless steel etc., ground color coating of minimum 2m length or of adequate length not to be mistaken as color band shall be applied at places requiring color bands. Color band(s) shall be applied at the following location. i. ii. iii. At battery limit points Intersection points & change of direction points in piping ways. Other points, such as midway of each piping way, near valves, junction joints of service appliances, walls, on either side of pipe culverts. For long stretch/yard piping at 50 M interval. At start and terminating points. Specification for River Water Intake System
iv. v.
b) Flow direction shall be indicated by an arrow in the location stated above and as directed by Engineer. Colors of arrows shall be black or white and in contrast to the color on which they are superimposed. The size of the arrows shall conform to IS:2379. Product names shall be marked at pump inlet, outlet and battery limit in a suitable size as approved by Engineer. As a rule minimum width of color band shall conform to 75 mm upto 300 NB and to 100 mm over 350 NB. Whenever it is required by the Engineer to indicate that a pipeline carries a hazardous material, a hazard marking of diagonal stripes of red and golden yellow as per IS:2379 shall be painted on the ground color. c) All uninsulated piping systems, hangers and supports shall be as per Table-2. Before application of paint, Contractor shall clean the pipes of all mill scale, dirt dust, soot, grease, rust etc. All pipelines, piping components shall be adequately protected against corrosion during manufacture, fabrication, shipment and storage by appropriate protective paint. 26.0 Identification of Vessels, Piping etc. Equipment number shall be stenciled in black or white on each vessel, column, equipment and machinery after painting. Line number in black or white shall be stenciled on all the pipelines at more than one location as directed by Engineer, size of letters printed shall be 150 mm (high) for
Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Detailed Technical Specification Section 6 Painting Page : 10 of 25
column & vessels; 50 mm (high) for pump compressor and other machinery and shall be as per IS:9404 for piping. The storage tanks shall be marked as detailed in the respective drawing. 27.0 Inspection and Testing a) All painting materials including primers and thinners brought to site for application shall be procured directly from manufacturer as per specifications and shall be accompanied by manufacturer's test certificates. Paint formulations without certificates are not acceptable. Engineer at his discretion, may call for tests for paint formulations. Contractor shall arrange to have such tests performed including batch wise test of wet paints for physical & chemical analysis. All costs thereof shall be borne by the Contractor. The paints shall be tested as per IS: 101 and approved by the Owner. b) The painting work shall be subject to inspection by Engineer at all times. In particular, following stage wise inspection shall be performed and Contractor shall offer the work for inspection and approval of every stage before proceeding with the next stage. The record of inspection shall be maintained in the registers. Stages of inspection shall be surface preparation, primer application and each coat of paint. In addition to above, record shall include type of shop primer already applied on equipment. c) Any defect noticed during the various stages of inspection shall be rectified by the Contractor to the entire satisfaction of Engineer before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages of work, Contractor shall be responsible for making good any defects found during final inspection/guarantee period/defect liability period as defined in General Conditions of Contract. Dry film thickness (DFT) shall be checked and recorded after application of each coat and extra coat of paint shall be applied to make-up the DFT specified without any extra cost to Purchaser. 28.0 Guarantee The Contractor shall assure specifically that the chemical and physical properties of paint materials used are in accordance with the specifications contained herein/to be provided during execution of work. The Contractor shall produce test reports from the manufacturer regarding the quality of the particular batch of paint supplied. The Engineer shall have the right to test wet samples of paint at random for quality of the same. Batch test reports of the manufacturer's for each batch of paints supplied shall be made available by the Contractor. 29.0 Galvanizing a) Galvanizing works shall conform to IS.6158 performed by the hot dip process. It is essential that details of steel members and assemblies, which are to be hot-dip galvanized shall be designed in accordance with IS 6159. Vent-holes and drain-holes shall be provided to avoid high internal pressures and air-locks during immersion, which may cause explosions and to ensure that molten zinc is not retained in pockets during withdrawal. Careful cleaning of welds is necessary before welded assemblies are dipped. The welds and the surrounding metal shall be cleaned separately, preferably by blast-cleaning, because the usual preliminary pickling cannot be relied on to remove the welding slag. b) All defects of the steel surface including cracks, surface laminations, laps and folds shall be removed in accordance with relevant IS standards. All drilling, cutting, welding, forming and final fabrication of unit members and assemblies shall be completed before the structures are galvanized. The surface of the steelwork to be galvanized shall be free from paint, oil, grease and similar contaminants. The weight of zinc coating per unit area shall be noted in the manufacturing documents. Structural steel items shall be initially grit blasted to BS:4232 second quality (Sa 2) or by pickling in a bath and the minimum average coating weight on steel sections 5 mm thick and over shall be 900 g/m.
Section 6 Painting
Page : 11 of 25
c) On removal from the galvanizing bath, the resultant coating shall be smooth, continuous, free from gross surface imperfections such as bare spots, lumps, blisters and inclusions of flux, ash or dross. Galvanized contact surfaces to be joined by high-tensile friction-grip bolts shall be roughened before assembly so that the required slip factor is achieved. Care shall be taken to ensure that the roughening is confined to the area of the mating faces. d) Bolts, nuts and washers, including general grade high-tensile friction grip bolts shall be hot dip galvanized and subsequently centrifuged. Nuts shall be tapped up to 0.4 mm oversize after galvanizing and the threads oiled to permit the nuts to be finger-turned on the bolt for the full depth of the nut. No lubricant, applied to the projecting threads of galvanized high-tensile friction-grip bolt after the bolt has been inserted through the steelwork must be allowed to come into contact with the mating faces of the steelwork. A local remelting of the galvanized parts to achieve the nuts to be finger turned on the bolt shall be done as per the relevant standards. Protected slings must be used for offloading and erection. Galvanized work, which is to be stored at the works or on site shall be stacked, so as to provide adequate ventilation to all surfaces to avoid wet storage staining (white rust). e) Small areas of the galvanized coating damaged in any way shall be restored in accordance with relevant standards. i) Cleaning the area of any weld slag rust and other impurities and by thorough wire brushing to give a metallic clean surface. Application of suitable number of coats of zinc-rich paint containing more than 90% w/w of zinc in dried film. The dry film thickness shall exceed at least 50% the thickness of the desired galvanization. In case of application of a low melting point zinc alloy repair rod, the rods shall be in accordance with IS:6158, the thickness of the alloy shall be at least as of the desired galvanization.
ii)
iii) The restored area is not to exceed 1% of the galvanized surface. iv) Surface restoration of parts in contact with drinking water is not allowed and the quality of the galvanization shall be in accordance with relevant IS standards. v) After fixing, bolt heads, washers and nuts shall receive two coats of zinc-rich paint. Connections between galvanized surfaces and copper, copper alloy or aluminum surfaces shall be protected by suitable preferably hydrophone tape wrappings to the Owner's approval.
Section 6 Painting
Page : 12 of 25
JHABUA POWER LIMITED 1x600MW +1x660MW JPL SEONI Project TABLE- 2 DATA SHEET FOR PAINTING SYSTEM DRY ARID CLIMATE S. No 1 Surface / Location Temp. Deg. Surface Prepn. Sa 2 Paint System No. of Generic type coats 2 P6 Per coat microns dft. 35 Application In shop On site X Specification for River Water Intake System
Coat Prime
INDOOR AND OUTDOOR Structural steel work like technological structures, pipe rack, junction towers, piping (oil+water), tanks outside surface, cranes, steel floors, galleries, stairways INDOOR AND OUTDOOR Structural steel work, piping.
Upto 130 Deg.C
Intermediate
P7
100
Finish
F2
30
2.
130 to 200 Deg. C
Sa 2
Prime Intermediate Finish
1 1 2
Total min. dft P9 P9 F11 Total min. dft P9 P9 F12 Total min. dft P8 F6
230 60 60 20 160 60 60 20 160 30 100
X X X
3.
INDOOR AND OUTDOOR Structural steelwork, piping, un-insulated carbon steel (EXTREME AGGRESSIVE ATMOSPHERE) Structural steel work in the battery rooms,
200 to 400 Deg.C
Sa 3
Prime Intermediate Finish
1 1 2 2 2
X X X X X
5(a)
Ambient
Sa3
Prime Finish
Section 6 Painting
Page : 13 of 25
JHABUA POWER LIMITED 1x600MW +1x660MW JPL SEONI Project S. No Surface / Location Temp. Deg. Surface Prepn. Paint System No. of Generic type coats Per coat microns dft. Specification for River Water Intake System Application In shop On site
Coat
chlorination plant and water treatment plant (b) Uninsulated equipment, tanks and piping etc. Up to 80 Deg. C Sa 3 Prime Finish 2 2 Total min. dft P3 F6 Total min. dft. P3 F6 Total min. dft P2 F3 260 50 100 300 50 100 300 50 30 X Total min. dft F7 160 125 X X
INSIDE SURFACE Steel tanks (total)for oil storage
Normal
Sa 2
Prime Finish
2 2
X X
INSIDE SURFACE Steel tanks inside surface (total) for DM water
Normal
Sa 2
Prime Finish
2 2
Surfaces permanently or predominantly in contact with water; except buried water lines.
Up to 60 Deg. C
Sa 3
Finish
X,X
X,X
Total min. dft 10 INDOOR Water pipelines outside surface Up to 60 Deg. C Sa 3 Prime 2 P2
500 50 X
Finish
F3
30
Total min. dft

190
JHABUA POWER LIMITED 1x600MW +1x660MW JPL SEONI Project S. No 11 Surface / Location Temp. Deg. Surface Prepn. Sa 3 Paint System No. of Generic type coats P3 2 Per coat microns dft. 50 Specification for River Water Intake System Application In shop On site X
Coat Prime
Oil pipelines outside surface, above ground
Up to 90 Deg. C
Finish
F6 Total min. dft
100 300
Section 6 Painting
Page : 15 of 25
JHABUA POWER LIMITED 1x600MW + 1x660MW JPL SEONI Project TABLE- 3 SCHEDULE OF PRIMER & FINISH COATS PRIMERS: P-1 P-2 P-3 P-4 P-5 P-6 P-7 P-8 P-9 FINISH COATS F-1 F-2 F-3 F-4 F-5 F-6 F-7 F-8 F-9 F-10 F-11 F-12 F-13 1.1.0 1.1.1 Redoxide Zinc chromate primer High build chlorinated rubber zinc phosphate primer High build zinc phosphate primer Etch primer / wash primer Epoxy zinc chromate primer Epoxy zinc phosphate primer Epoxy high build MIO paint Epoxy red oxide zinc phosphate primer Ethyl silicate zinc dust primer Specification for River Water Intake System
Synthetic enamel Acrylic polyurethane paint Chlorinated rubber paint High build chlorinated rubber MIO paint Chemical resistant phenolic based Enamel Epoxy high build coating High build coal tar epoxy Self priming epoxy high build coating Inorganic zinc silicate coating High Building Black Heat resistant silicon acryl paint suitable upto 250 Deg.C Heat resistant silicon aluminium suitable upto 400 Deg.C Synthetic rubber based aluminium paint suitable upto 150 Deg.C Primer Primer (P-1) Redoxide zinc chromate primer Type and composition Volume solids DFT Covering capacity Primer (P-2) High build chlorinated rubber zinc phosphate primer Type and composition
Single pack modified phenolic alkyd medium pigmented with redoxide and zinc chromate 30 35% 25 microns / coat (min) 12-13 sq.m / Lit / coat
1.1.2
Volume solids DFT Covering capacity 1.1.3 Primer (P-3) High build zinc phosphate primer Type and composition Volume solids DFT Covering capacity
Single pack Chlorinated rubber medium plasticised with unsaponifiable plasticiser, pigmented with zinc phosphate 35-40% 50 microns / coat (min) 7-8 sq m/lit/coat
Single pack synthetic medium, pigmented with zinc phosphate 40 45% 35 50 microns / coat 10-12 sq.m/lit/coat
JHABUA POWER LIMITED 1x600MW + 1x660MW JPL SEONI Project Heat resistant Primer (P-4) Etch primer / wash primer Type and composition Specification for River Water Intake System Up to 100 C (dry)
1.1.4
1.1.5
Volume solids DFT Covering capacity Primer (P-5) Epoxy zinc chromate primer Type and composition
Two pack Poly vinyl butyral resin medium cured with phosphoric acid solution pigmented with zinc tetroxy chromate 7 8% 8 10 microns / coat 7 8 sq.m / lit / coat
1.1.6
Volume solids DFT Covering capacity Primer (P-6) Epoxy zinc phosphat primer Type and composition
Two pack Polyamide cured epoxy medium pigmented with chromate 40% (min) 35 microns / coat 11 12 sq.m. /lit/coat
resin zinc
1.1.6
Volume solids DFT Covering capacity Primer (P-6) Epoxy zinc phosphate primer Type and composition
Two pack Polyamide cured epoxy medium pigmented with phosphate 40% (min) 35 microns / coat 11 12 sq.m / lit / coat
resin zinc
1.1.7
Volume solids DFT Covering capacity Primer (P-7) Epoxy build MIO paint (Intermediate coat) Type and composition
Two pack Polyamide cured epoxy medium pigmented with phosphate 40% (min) 35 microns / coat (min) 11 12 sq. m. / lit / coat
resin zinc
Two pack
1.1.8
Volume solids DFT Covering capacity Primer (P-8) Epoxy red oxide zinc phosphate primer Type and composition
Polyamide cured epoxy resin medium pigmented with micaceous iron oxide 50% (min) 100 MICRONS / COAT (MIN) 5.0 sq. m / lit / coat
Volume solids DFT Covering capacity

Two pack Polyamide cured epoxy resin medium pigmented with red oxide and zinc phosphate 42% (min) 30 microns / coat (min) 13-14 sq.m / lit / coat
JHABUA POWER LIMITED 1x600MW + 1x660MW JPL SEONI Project 1.1.9 Primer (P-9) Ethyl silicate zinc dust primer Type and composition Volume solids DFT Covering capacity Finish coats Finish coat (F-1) Synthetic enamel Type and composition Specification for River Water Intake System
Two pack 82 84% 60 microns / coat (min) 10-12 sq.m / lit / coat
1.2.0 1.2.1
1.2.2
Volume solids DFT Covering capacity Finish coat (F-2) Acrylic Polyurethane paint Type and composition
Single pack Alkyd medium pigmented with superior quality water & weather resistant pigments 30 40% 20 25 microns / coat (min) 16 18 sq.m/lit/coat
1.2.3
Volume solids DFT Covering capacity Finish coat (F-3) Chlorinated rubber paint Type and composition
Two pack Acrylic resin and isocyanate hardener suitably pigmented. 40% (min) 30 40 microns / coat 10-12 sqm / lit / coat
Single pack Plasticised chlorinated rubber medium with chemical & weather resistant pigments
1.2.4
Volume solids DFT Covering capacity Finish coat (F-4) High build chlorinated rubber MIO paint Type and composition
30% (min) 30 microns / coat (min) 10 sq.m. / lit / coat
1.2.5
Volume solids DFT Covering capacity Finish coat (F-5) Chemical Resistant Phenolic based Enamel Type and composition
Single pack Chlorinated rubber based high build pigmented with micaceous iron oxide 40-50% 65-75 microns / coat 6-7 sq.m. / lit / coat
1.2.6
Volume solids DFT Covering capacity Finish coat (F-6) Epoxy high build coating Type and composition
Single pack Phenolic medium pigmented. 35-40% 25 microns / coat (min) 15 sqm / lit / coat
suitably
Volume solids
Two pack Polyamide cured epoxy medium suitably pigmented 60-65%

Section 6 Painting
resin
Page : 18 of 25
JHABUA POWER LIMITED 1x600MW + 1x660MW JPL SEONI Project DFT Covering capacity Finish coat (F-7) High building coal tar epoxy Type and composition Specification for River Water Intake System 100 microns / coat (min) 6.0 6.5 sq.m./lit/coat
1.2.7
1.2.8
Volume solids DFT Covering capacity Finish coat (F-8) Self priming epoxy, high build (complete rust control coating) Type and composition
Two pack Polyamine cured epoxy blended with coal tar 65% (min) 100-125 microns / coat 6.0 6.5 sq.m. / lit / coat coating
resin
Volume solids DFT Covering capacity Finish coat (F-9) Inorganic zinc silicate coating Type and composition
Two pack Polyamido-amine cured epoxy resin suitably pigmented. Capable of adhering to manual prepared surface and old coatings 65-80% 125-150 microns / coat (min) 4 5 sq.m./lit/coat
1.2.9
1.2.10
Volume solids DFT Covering capacity Finish coat (F-10) High build black Type and composition
Two pack Self cured Ethyl silicate solvent passed Inorganic zinc coating 60% (min) 65-70 microns / coat (min) 8-9 sq.m./lit/coat
1.2.11
1.2.12
Volume solids DFT Covering capacity Finish coat (F-11) Heat Resistant Silicon acryl Paint Suitable upto 250 Deg. C Type and composition Volume solids DFT Covering capacity Finish coat (F-12) Heat resistant silicon aluminium paint suitable upto 400 Deg. C Type and composition
Single pack Reinforced Bituminous composition phenolic based resin 55-60% 100 microns / coat (min) 5.5 6.0 sq.m./lit/coat
Dual container (paste & medium) 20-25% 20 microns / coat (min) 10 12 sq.m./lit/coat
1.2.13
Volume solids DFT Covering capacity Finish coat (F-13) Synthetic rubber based suitable upto 150 Deg.C
Single pack Silicone resin based with aluminium flakes 20-25% 20 microns / coat (min) 10 12 sq.m./lit/coat
aluminium
paint
Section 6 Painting
Page : 19 of 25
JHABUA POWER LIMITED 1x600MW + 1x660MW JPL SEONI Project Type and composition Specification for River Water Intake System Single pack Synthetic rubber medium combined with leafing aluminium 25 microns / coat (min) 9.5 sq.m./lit/coat
DFT Covering capacity Notes: 1.
Covering capacity and DFT depends on method of application covering capacity specified above are theoretical. Allowing the losses during application. Min specified DFT should be maintained. All primers and finish coats should be cold cured and air- dried unless otherwise specified. Selected chlorinated rubber paint should have resistance to corrosive atmosphere and suitable for marine / saline environment. All paints shall conform to relevant Indian Standard and shall be applied in accordance with manufacturers instructions for surface preparation, intervals, curing and application. The surface preparation, quality and workmanship should be ensured. Technical data sheets for all paints shall be supplied at the time of submission of quotation. Cement mortar lining and inside epoxy coating shall be provided as Protection of all buried piping including the cross-country river water intake piping. The detailed specification for lining and coating is described in the respective piping specifications. QAP/QCP for painting shall be submitted for Purchaser/Consultants Approval before application.
2. 3.
4.
5. 6.
7.
Section 6 Painting
Page : 20 of 25
TABLE-4 STANDARD COLOUR CODES COLOUR CODE FOR EQUIPMENT
SL NO. 1.0 2.0 2.1 2.2 3.0 4.0 5.0 6.0 7.0 8.0 9.0. 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 10.0 10.1 10.2 11.0 11.1 11.2 11.3 11.4 12.0 13.0 14.0 15.0 Notes: 1. 2. 3.
ITEM/SERVICE Fans, pumps, motors, compressors Tanks (without insulation and cladding) Outdoor Indoor
COLOUR Light Grey Aluminium Light grey
IS-5 631 631 631
COLOUR (BAND) IS-5 Light brown Light orange French blue French blue French blue French blue White French blue White French Brilliant green Light grey Light orange Light grey Black -
Vessels & all other proprietary Light grey equipment (without insulation & cladding) Switchgear RAL 7032 Control & relay panels Transformers(Outdoor) Machinery guards Ash Transmitting Vessels and pipe lines Water Condensate D M Water Soft water Bearing cooling water Potable & filtered water Service & clarified water Raw water Cooling water Air System Station air Control air Oil system Fuel oil Light oil Lubricating oil Transformer oil Carbon dioxide Fire services Ash slurry pipes Vacuum pipes RAL 7032 Signal red Aluminium Sea green Sea green Sea green Sea green Sea green Sea green Sea green Sea green Sky blue Sky blue Light brown Light Brown Light brown Light brown Canary yellow Fire red Black Sky blue
631 537 217 217 217 217 217 217 217 217 101 101 410 410 410 410 309 536 101
410 557 166 166 166 166 166 166 221 631 557 631 -
This color code basically refers to IS:2379 for piping with necessary modifications Where band color is specified, same shall be provided at 30 meter intervals on long uninterrupted lines and also adjacent to valves and junctions. For any item left out, color coding will be decided after Owners approval.
Section 6 Painting
Page : 21 of 25
JHABUA POWER LIMITED 1x600MW + 1x660MW JPL SEONI Project COLOUR CODE FOR STRUCTURAL STEEL Gantry girder & monorail Gantry girder & monorail stopper Building structural steel columns brackets, beams bracings, roof truss, purlins, side girts, louvers, stringers Pipe rack structure & trestle Chequered plate (Plain Face) Grating Ladder Hand railing Hand rail / Middle rail/ Toe plate Middle rail Toe Plate Vertical post : : : : Signal red Signal red Signal red Black : : : Dark green Signal red Dark admiralty grey Specification for River Water Intake System
: : :
Dark admiralty grey Black Black
STANDARD COLOUR CODE FOR PIPING Ground Shade Colour Colour No. as per IS Band Shade Colour Colour No. as per IS
Sl.No
Medium
Remarks
1 a)
Water Untreated or raw/ service Sea green 217 White White is not included in IS - 5-1978
b) c) (i)
Treated/demineralised Condensate LP bypass attemperation
Sea green Sea green Sea green
217 217 217
Light orange Light brown Light brown
557 410 410
(ii) Condensate make up Sea green line to condenser from surge tank and from DM supply header d) Boiler feed Sea green
217
Light brown
410
217
Section 6 Painting
Page : 22 of 25
JHABUA POWER LIMITED 1x600MW + 1x660MW JPL SEONI Project Ground Shade Colour Colour No. as per IS Sea green 217 Specification for River Water Intake System Band Shade Colour Colour No. as per IS -
Sl.No
Medium
Remarks
(i)
HP bypass attemperation
(ii) Super heater attemperation
Sea green
217
(iii) Reheater attemperation Sea green (iv) Aux. PRDS attemperation e) f) g) h) Drains back to cycle Drains to waste Sea green
217 217
Sea green Sea green
217 217 217 217
Black Black French blue Light orange
166 557
Black is not included in IS- 5 1961
Cooling/circulating water Sea green Demineralised water (cooling purpose) Potable water Blow down Steam Main steam IP steam LP steam Auxiliary steam Seal steam Hot reheat Cold reheat HP bypass LP bypass Sea green
i) j) 2 a) b) c) d) e) f) g) h) i) j)
Sea green Sea green
217 217
Golden yellow 356 Signal red 537
Aluminium Aluminium Aluminium Aluminium Aluminium Aluminium Aluminium Aluminium Aluminium
Signal red Signal red Signal red Signal red Signal red Signal red Signal red Light brown
537 537 537 537 537 537 537 410
Alumnium is to be used only in cases, where the pipes are not already clad with aluminium sheets
Exhaust/vent (open to Aluminium atmosphere) and safety valve Air
Hazard mark to be given
Section 6 Painting
Page : 23 of 25
JHABUA POWER LIMITED 1x600MW + 1x660MW JPL SEONI Project Ground Shade Colour Colour No. as per IS Sky Blue Sky Blue 101 101 White Specification for River Water Intake System Band Shade Colour Colour No. as per IS White not included in IS-5 - 1961 Black not included in IS-5-1961
Sl.No
Medium
Remarks
a) b)
Instrument Service/Plant
c)
Vacuum
Sky Blue
101
Black
Air steam mixture From turbine glands to gland steam condenser From condenser to vacuum pumps Aluminium
Sky blue 101 Aluminium is to be used only in cases, where the pipes are not already clad with aluminium sheets.
Aluminium
Sky blue
101
5 a) b) c) d) e) f)
Gas Natural gas Other fuel gas Hydrogen Chlorine Carbon dioxide Non condensable gas mixtures Oxygen Canary yellow 309 Canary yellow 309 Canary yellow 309 Canary yellow 309 Canary yellow 309 Canary yellow 309 Light grey Signal red Dark violet Light grey 631 537 796 631
Middle bruns- 226 wick green White White is not included in IS-5-1961
g)
Canary yellow 309
h)
Oils Naphtha Light brown 410 410 410 French Blue 166
Diesel Fuel (Light/HSD) Light brown Lubricating oil including Light brown governing oil if lube oil is
Brilliant green 221 Light grey 631
Section 6 Painting
Page : 24 of 25
JHABUA POWER LIMITED 1x600MW + 1x660MW JPL SEONI Project Ground Shade Colour Colour No. as per IS Specification for River Water Intake System Band Shade Colour Colour No. as per IS
Sl.No
Medium
Remarks
used for governing purposes Control fluid Transformer oil Fire Installations Chemical feed HP dosing to boiler (Phosphate) Light brown Light brown Fire red 410 410 536 Dark violet Light orange 796 557 -
Dark 632 admiralty grey 796
HF dosing to Dark violet condensate (hydrazine)
Fire red
536
Hazard mark is given
Acid piping (in water treatment plant) Alkali Piping (in water treatment plant)
Dark admiralty 632 grey Dark violet 796
Signal red
537
-do-
Golden yellow 356
Hazard mark is given
Section 6 Painting
Page : 25 of 25
VOLUME II SECTION - 7 LIST OF DRAWINGS
Section 7 LIST OF DRAWINGS
SL.NO.
DRAWING NO. CIVIL
DESCRIPTION
00-3109142-C-501
Alignment plan of main corridor(with trial pit details)
00-3109142-C-502
Plan showing the ground profile of main corridor
00-3109142-C-503
Longitudinal section of pumping main from intake well to plant (3 Sheets) Plan showing offshore intake well with approach bridge
00-3109142-C-504
00-3109142-C-505
Plan showing intake well location at Gadaghat area
00-3109142-C-506
Tentative location of intake well with bathymetry survey (2 sheets) MECHANCIAL
00-3109142-M-286
P&ID of River water intake system
ELECTRICAL 8 9 10 30-3109142-E-105 30-3109142-E-106 00-3109142-E-107 Single line diagram for 220V DC system Typical schematic for UPS system Electrical Key single line diagram CONTROL & INSTRUMENTATION 11 30-3109142-I-168 Control System Configuration for River Water intake system
7.1 - CIVIL DRAWING
7.2 - MECHANICAL DRAWING
7.3 - ELECTRICAL DRAWING
7.4 - C&I DRAWING
JHABUA POWER LIMITED 1X600 MW + 1x660MW JPL SEONI Project Specification for River Water Intake System
SECTION- 8 TECHNICAL DATA SHEETS & SCHEDULES

8
Section 8
Page : 1 of 57
Technical Data Sheets & Schedules
SECTION 8 TECHNICAL DATA SHEETS (TO BE FILLED IN AND SUBMITTED BY THE BIDDER WITH OFFER)
TABLE OF CONTENTS
SCHEDULE - 8.1 SCHEDULE - 8.2 SCHEDULE - 8.3 SCHEDULE 8.4 SCHEDULE 8.5 SCHEDULE 8.6 SCHEDULE 8.7
TECHNICAL DATA SHEETS - MECHANICAL ................................................ 3 TECHNICAL DATA SHEET - ELECTRICAL .................................................. 10 TECHNICAL DATA SHEET CONTROL & INSTRUMENTATION ............... 43 DRAWING ENCLOSURE .............................................................................. 54 DETAILS OF SIMILAR WORKS DONE DURING PAST FIVE YEARS .......... 55 UTILITY CONSUMPTION LIST ..................................................................... 56 LUBRICANTS LIST ....................................................................................... 57

8
Section 8
Page : 2 of 57
SCHEDULE - 8.1 TECHNICAL DATA SHEETS - MECHANICAL
VERTICAL TURBINE PUMPS
Cl. No. Description TECHNICAL PARTICULARS 1.0.0 1.1.0 1.2.0 1.3.0 1.4.0 1.2.0 1.3.0 1.4.0 1.5.0 1.6.0 1.7.0 1.8.0 1.9.0 1.10.0 1.11.0 1.12.0 1.13.0 1.14.0 2.0.0 2.1.0 2.2.0 2.3.0 3.0.0 3.1.0 Service Equipment No. Equipment Name Name of Manufacturer Model No Pump design code No. of stage Speed Rotation Duty Location Drive No. of pumps required No. of pumps working Parallel operation Area classification Maximum allowable particle size LIQUID DATA Liquid handled Specific gravity Temperature (maximum) PERFORMANCE DETAILS Capacity - Normal
8
Unit
Data
: : : : : : : rpm : : : : : Nos. Nos. : : : : mm :
: : C :
m3/hr
:
Cl. No. - Rated 3.2.0
Description
Unit m3/hr
Data :
Total differential head - Normal - Rated MWC MWC : :
3.3.0
Hydraulic power - Normal - Rated kW kW : :
3.4.0
Efficiency - Normal - Rated % % : :
3.5.0
NPSH required - Normal - Rated MWC MWC : :
4.0.0 4.1.0 4.2.0 4.3.0 4.4.0 4.5.0
TECHNICAL DETAILS Shut-off head Run-out flow Power at run-out flow Recommended drive power Minimum continuous stable Flow Maximum continuous stable Flow Range of Operation Suction specific speed Maximum noise level at 1.0 m distance Flow at BEP Head at BEP Maximum input power required by pump GD value for pump with coupling with Motor Radial clearance Impeller ring/Casing ring - Normal - Worn-out mm mm : :
Section 8 Page : 4 of 57 Technical Data Sheets & Schedules
MWC m3/hr kW kW m3/hr m3/hr
: : : : :
4.6.0
4.7.0 4.8.0 4.9.0 4.10.0 4.11.0 4.12.0 4.13.0
: :
dBA M3/hr MWC kW Kg/m
: : : : :
4.14.0 4.15.0

8
Cl. No. 4.16.0 4.16.1 Critical speed Dry - First - Second 4.16.2
Description
Unit
Data
rpm rpm
: :
Wet (normal clearances) - First - Second rpm rpm : :
4.16.3
Wet (Worn clearances) - First - Second rpm rpm : :
5.0.0 5.1.0 5.1.1 5.1.2 5.1.3 5.2.0 5.2.1 5.2.2 5.2.3 5.2.4 5.3.0 5.3.1
CONSTRUCTION FEATURES Casing Type Type of support Design pressure Impeller Type Rated diameter Maximum diameter Minimum diameter Bearings Thrust bearings a. Type b. Make & Model No. c. Type of lubrication d. Lubricator e. Sight gauge in case of oil lubricated pump f. API cooling plan g. Cooling water - capacity - Pressure lpm bar(g) : :
Section 8 Page : 5 of 57 Technical Data Sheets & Schedules
: : kg/cm(g) : : : : : :
: : : : : Automatic / Manual Yes / No

8
Cl. No.
Description h. Design life in terms of hours of continuous operation i. Rating j. Maximum axial thrust on bearing k. Percentage of thrust being absorbed by thrust bearing at normal condition
Unit :
Data
: : :
5.3.2
Radial bearings a. Type b. Make & Model No. c. Design life in terms continuous operation of hours of : : :
5.4.0
Coupling between pump & Drive a. Type b. Make & Mode No. c. Rating d. Spacer length e. Guard provided : : : : :
5.5.0
Suction Strainer a. Type b. Design pressure of wire netting c. Size of wire netting d. Pressure drop at rated, normal, trip condition e. Pressure drop at 50% Clogged condition f. End connection details : : : :
5.6.0 5.6.1 5.6.2 5.6.3 5.6.4
Gland packing No. of packing Size No. of lantern rings API cooling plan : : : :

8
Cl. No. Description 5.6.5 API flushing plan 5.7.0 5.7.1 5.7.2 5.7.3 5.7.4 5.8.0 5.8.1 Mechanical sealing Make Type Size Material Nozzle size Suction connection -Size/schedule - Flange drilling standard - Type of connection with piping 5.8.2 Discharge connection -Size/schedule - Flange drilling standard - Type of connection with piping 6.0.0 6.1.0 6.2.0 6.3.0 6.4.0 6.5.0 6.6.0 6.7.0 6.8.0 6.9.0 6.10.0 6.11.0 6.12.0 6.13.0 7.0.0 MATERIAL OF CONSTRUCTION Casing Impeller Casing wearing Impeller wearing Shaft Shaft sleeve Gland Impeller nut Packing Lantern ring Shaft coupling Base plate Fasteners in Wetted Condition WEIGHT DATA
Unit :
Data
: : : :
: : :
: : :
: : : : : : : : : : : : :

8
Section 8
Page : 7 of 57
Cl. No. 7.1.0 7.2.0 7.3.0 7.4.0 7.5.0 7.6.0 7.7.0 Pump Motor Base frame Coupling Strainer
Description
Unit : : : : : : :
Data
Weight of complete assembly Weight of Single Largest Piece handled for Erection & Mainteanance Recommended crane capacity Minimum Hook Lift required from Floor level ALLOWABLE FORCE ON PUMP FLANGES Suction side Fx Fy Fz Direction of above
7.8.0 7.9.0 8.0.0
: :
8.1.0
: : :
8.2.0
Discharge side Fx Fy Fz Direction of above : : : :
9.0.0
ALLOWABLE MOMENTS ON PUMP FLANGES Suction side Fx Fy Fz Direction of above : : : :
9.1.0
9.2.0
Discharge side Fx Fy Fz Direction of above : : : :
10.0.0
Line Shaft Losses & Thrust Bearing Losses (if Applicable)

8
Section 8
Page : 8 of 57
SIGNATURE OF BIDDER _____________________ NAME _____________________
DESIGNATION _____________________ COMPANY SEAL DATE _____________________

8
Section 8
Page : 9 of 57
SCHEDULE - 8.2 TECHNICAL DATA SHEET - ELECTRICAL 1. 11 kV SWITCHGEAR S.No. Description Switchgear Assembly 1. a) Make & country of manufacturer b) Type c) Reference Standard d) Voltage (Nom./Max.) e) Phase, Frequency f) Short Circuit Rating g) Peak withstand h) Short-time withstand for 3s i) Momentary withstand capacity of the entire switchgear j) Insulation level k) Impulse voltage withstand l) One minute power frequency withstand voltage m) Degree of protection 2. Construction a) Minimum clear space required at b) Front for breaker withdrawal c) Rear 3. Busbar a) Material & Grade b) Cross sectional Area/Size c) Continuous Current (at site condition, d) 50C ambient and within cubicle) e) Maximum temperature (absolute) for an f) ambient of 50C Bus support insulator a) Type/Material b) Voltage Class Circuit Breaker a) Make b) Type c) Reference standard d) Rated voltage e) Rated Currents f) Continuous current at site condition, 50C g) ambient & within cubicle h) Short-time current for 3s i) Max. temperature (absolute) for an ambient of 50C j) Rated operating duty k) Interrupting capacity at rated voltage and Operating duty Symmetrical Asymmetrical KA peak Maximum DC component l) Type & Material of contacts Unit kV No, Hz kAp kA rms kA Details by bidder
kVp kV -
mm mm mm/ mm A C
4.
kV
5.
kV A kA rms C -
kA rms kA %

8
Section 8
Page : 10 of 57
S.No.
6.
7.
8.
9.
Description Main Arcing m) Whether contacts silver plated n) Spring charging motor Rating & Type Voltage (D.C.) Speed Class of Insulation Time required to charge the spring from fully discharged condition o) Closing Coil Voltage Permissible voltage variation Burden p) Tripping Coil Voltage Permissible voltage variation Burden Push Buttons Make Type Contact ratings Lamps Make Type Voltage Selector Switch Make Type Contact ratings Current Transformer ( Details for each type shall be submitted ) Make Type Reference standard Rated secondary current Short Circuit Withstand Short-time current for 1s / 3s Dynamic current Class of insulation Temp. rise over 50C ambient Accuracy class for differential protection Voltage Transformer Make Type Reference standard Voltage ratio Burden Over voltage factor - Continuous - 30 seconds Class of insulation Temp-rise over 50C ambient
Unit kW V rpm s
Details by bidder
V % VA V % VA A V A
kA rms kA peak C
10.
V/V VA C

8
S.No.
Description Winding Connection - Primary - Secondary Protection Relay (furnish details for each feeder separately) Make Draw out type with built-in test facilities (Yes/No) Type of mounting Reference Standard Burden Setting range (for each type of protection) No. of contacts Aux. Voltage Rated current Indication Meter (Furnish details for each type of meter separately) Make Type Reference Standard Burden on CT Burden on VT Transducers (Details to be furnished separately for each type) Make Output range Aux. power supply Secondary Wiring Type and insulation Voltage grade Conductor material Conductor size Potential & control circuit Current circuit Terminal Blocks Make Type Rating Voltage grade Ground Bus Material Size Name Plate Material Thickness Size for - Panel - Equipment/devices
Unit -
Details by bidder
11.
12.
VA VA
13.
mA V V mm mm A V mm mm mm mm
14.
15.
16.
17.
18.

8
Section 8
Page : 12 of 57
S.No. Description 19. Painting Finish of switchgear Inside Outside 20. Bus Conductor Material Grade Shape Cross-sectional area Current density Support spacing 21. Bus insulator Type Make Reference standard Rated Voltage 2. LT SWITCHGEAR S.No 1. 2. 3. 4. 5. General Make Type Reference standard For MCC a) Voltage b) Phase / frequency c) Short circuit withstand current rating d) Peak withstand current rating e) Short-time rating for 1 Sec. Duration One minute power frequency withstand voltage: For DC Distribution boards a) Voltage b) Short circuit withstand current rating 7. Construction a) Degree of protection b) Type & Thickness of sheet metal used, c) Enclosure d) Door e) cable gland plate
8
Unit -
Details by bidder
mm A/mm mm kV
Description
Unit
Details by bidder
kA kAp kA kV
f)
6.
V kA
mm mm mm
S.No 8. Circuit breaker a) Make b) Type
Description
Unit
Details by bidder
c) Reference Standard d) Rated voltage, e) Rated frequency, f) Rated current (at design ambient of 50 C & within cubicle) amp g) Max. temperature rise over design ambient temperature of 50 C at rated current h) Rated operating duty i) j) Short-time current for 1 sec. Rated short circuit breaking current, kV Hz
kA rms kA kAP kV VA VA Sec Sec
k) Rated short circuit making current , l) One minute 50 Hz voltage withstand
m) Closing coil VA Burden n) Tripping coil VA Burden o) Total tripping time (max) p) Total closing time (max) q) Control supply voltage & current for r) Closing coil Tripping coil
V/A V/A
Spring charging motor Make Type Rating Class of insulation Voltage Type of O/C protection V W
9.
Contactors a) Make b) Type c) Reference Standard d) Rated voltage, e) Rated frequency, kV Hz

8
Section 8
Page : 14 of 57
S.No f)
Description Rated current of each rating provided (at 40 C), g) Rated current for the above (at 50 C site ambient condition & within cubicle) h) Type & material of Main contacts i) j) VA burden during pick up & seal in Type & material of auxiliary contacts
Unit A A
Details by bidder
VA
k) Control supply voltage 10. Aux. Contactor a) Make b) Rating c) Voltage d) No. of NO+NC contacts provided e) Control supply voltage 11. MCCB a) Make b) Type c) Rating d) Range e) Duty 12. MCB a) Make b) Type c) Rating d) Reference Standard e) Short circuit rating 13. Fuse a) Make b) Type c) Current rating d) Application standard e) Short circuit rating 14. Over load relay a) Make
8
A V
A V
kA
kAp
Section 8
Page : 15 of 57
S.No b) Type c) Rating
Description
Unit
Details by bidder
d) Reference Standard e) Type of single phasing preventor f) Minimum rating for CT operated relay
g) Type & material of bimetallic strip h) No.of changeover contacts 15. Relays a) (Relay make & type) b) Numerical over current and Earth fault relay c) Under voltage relay (27) d) Anti pumping feature (94) e) Breaker contact multiplication relay f) Trip supervision relay (74)
g) High speed lockout relay (86) h) Auxiliary relays i) 16. Numerical motor protection relay ( 99 )
Busbar a) Material & grade b) Bus bar size c) Continuous Current rating at site condition of Main bus bar at final temp. of 90 C for d) Enclosure temperature rise over design ambient temperature of 50 C e) Maximum temperature rise over design ambient temperate of 50 C - at busbar - at joints f) Minimum clearance of bare bus bar and connection Phase to phase Phase to ground
C C
mm mm
g) Bus connection ( Silver plated / Anti oxide grease) h) Type of bus bar sleeving i) j) Short-time withstand current for 1 sec. Peak withstand current kA kAp

8
Section 8
Page : 16 of 57
S.No
Description k) Current density l) Bus bar support spacing
Unit
Details by bidder
mm
m) Bus support insulator Make Type Reference standard Voltage class Minimum creepage distance Cantilever strength Net weight 17. Earthing a) Earth bus material b) Earth bus size 18. Painting a) Inside shade b) Outside shade c) Paint thickness 19. Current transformer a) Make b) Type c) Applicable standard d) Rated Current e) Short-time withstand current & duration f) Dynamic withstand current A kA/Sec KAp Microns V mm Kg
g) Class of insulation h) CT Ratio i) j) Accuracy class of each core VA burden of each core VA Ohms
k) CT Resistance 20. Voltage transformer a) Make b) Type c) Rated Voltage

8
Section 8
Page : 17 of 57
S.No
Description d) Applicable standard e) Class of insulation f) One minute 50 Hz voltage withstand
Unit
Details by bidder
kV
g) Voltage ratio h) Rating of primary fuse & secondary MCB i) j) Accuracy class VA Burden VA A
k) Winding connection l) Over voltage factor Continuous 30 seconds Transducers
21.
a) Make b) Type c) Output range d) Auxiliary power supply e) Voltage & load f) Accuracy Multifunction meter a) Make b) Type c) Measuring pararameters d) Auxiliary power supply e) Accuracy Push buttons Make Type & Cat. No Contact rating Lamps Make Type & Cat. No Voltage Watts Local / Remote selector Switch Make Type & Cat. No Contact rating Control switch Make Type Cat. No Contact rating V V V/W
22.
23.
24.
V W
25.
26.
A

8
S.No 27.
Description Ammeters Make Type Size Range Space heaters Make Type Rating Thermostat Make Type Rating Cubicle lamp Type Rating Cubicle socket Make Type Rating Power Terminal blocks Make Type Rating Size Voltage grade Local push button stations a) Type b) Make c) No. of push buttons d) Dimension e) Rating f) No. of NO+NC Contacts
Unit
Details by bidder
28.
29.
30.
31.
32.
A V
33.
mmxmmxmm A
3. SERVICE TRANSFORMER Sl.No Description 1.0 Manufacturer & Place 2.0 3.0 4.0 5.0 6.0 6.1 6.2 6.3 6.4 Service Type Reference standard Type of cooling Rating Rated kVA Rated voltage HV/LV Number of phases Rated Frequency
Unit
Details by bidder
KVA kV
HZ

8
Sl.No 7.0 7.1 7.2 7.3 8.0
Description Rated current HV & LV side HV no load current at rated voltage No load charging KVA & PF Maximum guaranteed Temperature rise above 50 C ambient - in oil by thermometer
Unit
Details by bidder
Amps Amps KVA
C C
9.0 9.1 9.2 10.0 10.1 10.2 10.3 11.0
- in winding by resistance Connections HV / LV side Vector group Winding material Winding insulation category Windings fully insulated/graded insulation Type of winding Hot spot temperature in winding limited to (over yearly weighted ambient temperature of 32C) Guaranteed losses No-load loss at rated voltage & frequency (Max.) Load loss at rated current at 75 C (Max.) Impedance Positive / zero sequence impedance Resistance at 75 deg C Guaranteed Efficiency at 75 C winding temperature and at 0.8 p.f. lag At 100% of full Load At 75% of full Load At 50% of full Load Regulation at full load and at 75 C At UPF At 0.8 P.F lagging Maximum flux density at 100% & 110% rated voltage Maximum current density for HV & LV Winding Magnetizing current at rated voltage and frequency ( % of full load current ) Type of oil preservation system Type of Pressure relief device
12.0 12.1 12.2 13.0 13.1 13.2 14.0 14.1 14.2 14.3 15.0 15.1 15.2 16.0 17.0 18.0 19.0 20.0
kW kW
% Ohms
% % %
% % Wb / m2 Amp 2 /mm

8
Section 8
Page : 20 of 57
Sl.No 21.0 22.0 23.0 26.0 26.1 26.2 26.3 27.0 27.1 27.2 28.0 28.1 28.2 28.3 28.4 28.5 28.6 29.0 29.1 29.2 29.3 30.0 30.1 30.2 30.3
Description Oil quantity Transport dimensions L x W x H Transport weight of largest item Termination arrangement HV side LV side LV Neutral Details of bushings Manufacturer Reference standard HV Bushing Type Voltage class Rated current Power frequency withstand voltage (wet & dry) Impulse withstand voltage Creepage distance LV Bushing Type Voltage class Rated current LV Neutral Bushing Type Voltage class Rated current
Unit Litre mxmxm Kg
Details by bidder
kV Amps kV kV mm
kV Amps
kV Amps
31.0 31.1 31.2 31.3 32.0 32.1 32.2 32.3 33.0 33.1
HV Cable box Degree of protection Phase to Phase Clearances Phase to earth Clearances LV / LVN Cable box Degree of protection Phase to Phase Clearances Phase to earth Clearances LV Neutral Bushing Current transformers Make
mm Mm
mm Mm

8
Sl.No 33.2 33.3 33.4 33.5 33.6 34.0 34.1 34.2 34.3 34.4 35.0 35.1 35.2 35.3 37.0 37.1 37.2 38.0 39.0 39.1 39.2 39.3 39.4
Description Type Voltage class Current ratio Burden and accuracy class Short time withstand current and duration Radiator Type Material No. of radiators / bank Thickness of steel Tank details Thickness of side/top/bottom plate Pressure withstand capacity Vacuum withstand capacity Marshalling box Degree of protection Terminal Blocks make & type Material of gasket Wheels Plain / flanged Unidirection / Bidirectional Quantity Gauges Longitudinal Transverse Painting Transformer a) Shade (inside/outside) & paint thickness
Unit kV
Details by bidder
kA & sec
mm
Mm Kg /m2 mm of Hg
mm mm
40.0 40.1
40.2
Marshalling box a) Shade (inside/outside) & paint thickness
41.0 41.1 41.2 41.3 41.4 42.0 42.1
Gas and oil actuated relay / Sudden pressure relay Make Type Number of contacts ( NO + NC ) Contacts voltage and current rating Magnetic oil gauge Make

8
Sl.No 42.2 42.3 42.4 43.0 43.1 43.2 43.3 43.4 44.0 44.1 44.2 44.3 44.4
Description Type Number of Contacts ( NO + NC ) Contact voltage and rating Winding Temperature indicator( Local) Make Type Number of contacts Contacts voltage and rating Oil Temperature indicator Make Type Number of contacts Contacts voltage and current rating
Unit
Details by bidder
4. HT / LT MOTORS S.No MOTOR 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 Make & Place of manufacture Application Type of Motor Service (Outdoor / Indoor / Hazardous) Rating Applicable standard Frame size Duty cycle/ designation Required BKW rating of the driven equipment Design Margin Considered Rated continuous output of Motor at 50C ambient Ambient Temperature Rated speed Rated voltage & variation range Rated frequency & variation range Full load current / No load current Power factor at 100% / 75% / 50% Load
Description
Unit
Details by bidder
kW
kW % kW C RPM Volts Hz Amps

8
S.No 18.0 18.1 18.2 18.3 19.0 20.0 21.0 22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 32.1 32.2 32.3 33.0 33.1 33.2 33.3 33.4 34.0 34.1 34.2 34.3 34.4 35.0 35.1 35.2
Description Efficiency at rated voltage and frequency At 100% Load At 75% Load At 50% Load Method of Starting Starting current at rated voltage Starting & Pull out Torque Rated Torque No load starting time Starting time with full load Locked rotor with stand time (Hot /Cold Condition) No. of Hot / Cold starts Degree of protection of enclosure Method of cooling Insulation class Temperature rise over 50C ambient. (by resistance) Winding connection Bearing Make Type Recommended lubricant Winding RTD (As Applicable) Make Type Simplex/Duplex No. of RTDs provided Bearing RTD (As Applicable) Make Type Simplex/Duplex No. of RTDs provided Motor Terminal Box Type Fault withstand current & time
Unit
Details by bidder
% % %
% of FLC % of FLT KgM Sec Sec Sec

8
Section 8
Page : 24 of 57
S.No 35.3 36.0 37.0 38.0 39.0 40.0
Description Location looking from drive end. Type of Mounting Overall Dimensions ( L x W x H ) Weight Moment of Inertia Paint Shade & Material
Unit
Details by bidder
m Kg
5. ELECTRICAL ACTUATORS S.No 1.0 1.1 1.2 1.3 1.4 1.5 1.6 2.0 2.1 2.2 2.3 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 3.0 3.1 3.2 3.3 3.4 Description General Application Make Type (Integral /Non Integral) Duty Size Enclosure protection Motor Type of motor Service ( Outdoor / indoor/hazardous ) Duty cycle / designation Rated output at 50 ambient Rated speed Rated voltage & % variation Rated frequency & % variation Full load / No load current Rated power factor Efficiency at rated voltage and frequency Starting current at rated voltage Current at Max torque Tripping Torque in both directions Degree of protection of enclosure Insulation class Temperature rise over 50 ambient (by resistance) Winding connection ACCESSORIES Space heater rating Thermistor contact rating No. of limit switch contact (OPEN) No. of limit switch contact (CLOSE)
Unit
Details by bidder
RPM Volts Hz Amps

8
S.No 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12
Description No. of torque limit switch contact (OPEN) No. of torque limit switch contact (CLOSE) Limit switch contact rating Make of position transmitter No. of cable entries Paint shade and material Overall Dimension Weight
Unit
Details by bidder
6. POWER / CONTROL CABLES S.No 1.0 2.0 3.0 4.0 5.0 6.0 Make Type Applicable standard Rated voltage Earthed/Unearthed grade Maximum temperature: - Continuous, - Short time, Continuous current rating at 40C air ambient temperature (For HT single core cables rating shall be based on bonding screen at both the ends) Continuous current rating at 30C ground ambient temperature Short circuit withstand current for 1 sec duration for - Conductor - Metallic screen - Armour Conductor - Material - Grade - Nominal cross sectional area - Number and diameter of wire - Conductor strands (Nos./mm) - Shape of conductor - Approx. diameter over conductor - Direction of lay of stranded layers - Conductor resistance (DC) at 20 C - Conductor resistance (AC) at 90 C (for XLPE Cables)
8
Description
Unit
Details By Bidder
V C C
7.0
8.0 9.0
A kA
10.0
Sq.mm
mm
Ohm / KM Ohm / KM
Section 8
Page : 26 of 57
S.No
Description - Conductor resistance (AC)at 70 C (for PVC cables) - Reactance for multi core cables at maximumoperating temp at 50 Hz - Reactance for single core cables laid in trefoil formation at maximum operating temp at 50 Hz - Capacitance at 50 Hz
Unit Ohm/KM Ohm / km Ohm / km MF/km
Details By Bidder
11.0
Conductor screening (wherever applicable) - Material and type - Approx. thickness of extruded layer Insulation - Composition of insulation - Nominal thickness of insulation - Tolerance on thickness of insulation - Type of curing (for XLPE only) - Min. insulation resistance at 20 C - Identification of cores Insulation screening (wherever applicable) - Material & type - Approx. thickness of extruded layer Metallic Screen - Material - Size of tape/wire - No. of wires/tapes - Short circuit capacity of metallic screen - Cross section area of screen - Diameter below metallic screen Inner sheath - Material - Diameter over the laid up cores - Thickness of sheath (min) - Colour of sheath Armour (in case of armoured cables) - Type of material of armour - Strip/wire - Nominal diameter of cable over inner sheath (under armour) - Dimension of strip/wire - No. of armour wires/strips - Approx. Cross sectional area of armour - DC resistance of armour wires/strip at 20C - AC resistance of armour wires at 80C (ohm/km) - Direction of lay of armour
mm
12.0
mm
Mega Ohms
13.0
mm
14.0
Sq.mm mm
15.0
mm mm
16.0
mm mmx mm sq.mm ohms ohms

8
Section 8
Page : 27 of 57
S.No 17.0
Description Outer sheath - Material and type - Calculated diameter under the sheath - Thickness of sheath & Tolerance - Colour of sheath Overall diameters of cable Weight per 1000 metres. Recommended min. bending radius Safe pulling force when pulled by pulling eye on the conductor Cable Drums - Type - Material - Flange diameter (mm) - Barrel diameter (mm) - Traverse (mm) Weight of cable drum with cables (Kg.) Derating factor for following ambient Temperature in air at 40C at 50C Group factor for cables Muticore cables a) For laying on racks in touching formation b) For laying on racks in touching formation in RCC trench with restricted air circulation c) For laying in pipes in ground d) For laying direct in ground FRLS Properties - Oxygen - Smoke density - Acid gas emission Group factor for cables Single core cables a) For laying on racks in trefoil formation b) For laying in on racks in trefoil formation RCC trench with restricted air circulation c) For laying in flat formation in pipes in ground d) For laying in trefoil formation direct in ground Derating factor for soil resistivity factor Derating factor for depth of laying in ground factor
Unit
Details By Bidder
mm mm mm mm Kg m Kg
18.0 19.0 20.0 21.0 22.0
23.0 24.0
25.0
26.0 27.0
28.0 29.0

8
Section 8
Page : 28 of 57
7. CABLE TRAYS AND ACCESSORIES S.No. 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4.0 4.1 4.2 4.3 Description Ladder type Trays Make & Place of manufacture Type Size (Width x Height) Thickness Material Thickness of galvanisation Standard Length Weight / metre Spacing between rungs Rung dimensions Thickness of Rung Perforated type trays Make & Place of manufacture Type Size (Width x Height) Thickness Material Thickness of galvanisation Standard Length Weight / metre Tray Covers Make & Place of manufacture Type Size (Width x Height) Thickness Material Thickness of galvanisation Standard Length Weight / metre Cable Tray Accessories Couplers, Tees etc) Make & Place of manufacture Type Thickness mm (Bends, m kg mm x mm mm m Kg mm x mm mm m kg mm mmx mm mm mm x mm mm Unit Details by bidder

8
Section 8
Page : 29 of 57
S.No. 4.4 4.5 5.0 5.1 5.2 5.3
Description Material Thickness of galvanisation Cable Tray Hardwares Type Material Thickness of galvanization
Unit
Details by bidder
6.0 6.1 6.2 6.3 6.4 7.0 7.1 7.2 7.3 7.4 8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 9.0 9.1 9.2 9.3 9.4 9.5 9.6 10.0 10.1 10.2
Cable glands Make & Place of manufacture Type Applicable standard Material Cable lugs Make & Place of manufacture Type Applicable standard Material Rigid steel Conduit Make & Place of manufacture Type Size Applicable standard Thickness of wall Material Standard length Thickness of galvanising Conduit Fittings Make & Place of manufacture Type Size Applicable standard Material Thickness of galvanising Flexible steel Conduit Make & Place of manufacture Type mm mm mm

8
Section 8
Page : 30 of 57
S.No. 10.3 10.4 10.5 10.6 10.7 11.0 11.1 11.2 11.3 11.4 11.5 11.6 12.0 12.1 12.2 12.3 12.4 12.5 13.0 13.1 13.2 13.3 13.4 13.5
Description Size Applicable standard Thickness of wall Material Standard length Trefoil clamps Make & Place of manufacture Type Size Applicable standard Material Recommended spacing between clamps Junction Boxes Make & Place of manufacture Type Type of enclosure Overall dimension Type & rating terminal blocks Earthing material Make & Place of manufacture Type Size Material Thickness of galvanising
Unit mm
Details by bidder
mm
mmxmmxmm VA
8. BATTERY AND BATTERY CHARGER S.No A 1.0 2.0 3.0 4.0 5.0 6.0 Description BATTERY Manufacturer of battery Applicable standard Battery type Type of the cell Cell designation as per IS Weight of complete cell Without acid With acid Plates No. of positive plates per cell Types of positive plates Types of negative plates kg Unit Details by bidder
7.0

8
Section 8
Page : 31 of 57
S.No 8.0
Description Separators Type Material Thickness Intercell connector Type Material Insulator Material of cell container Insulator Material of rack Cell dimensions Container dimensions Life of the battery Rated battery voltage No. of Batteries Rated cell voltage Ampere Hour rating Battery capacity referred to a cell end voltage of 1.8 No. of cells Load cycle duration 10 hour rating at 27C to 1.8V per cell 1 hour discharge rate to 1.8V per cell 1 minute discharge rate to 1.8 V per cell Minimum cell voltage during duty cycle WH efficiency AH efficiency at 10 hour discharge rate Recommended charging rate for Float charging ( Volt / cell , Amp) Boost charging in 10 hours ( Volt / cell , Amp) Start Finish Amount and specific gravity of electrolyte per cell required for first filling at 27C. Recommended specific gravity at 27C For first filling At full charge At end of 10 hour discharge Maximum short circuit current for a dead short across terminals when Battery is under float charging Battery is under boost charging V AH AH
Unit
Details by bidder
9.0
10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0
mmxmmxmm mmxmmxmm Year V
Hours A A A V % %
V, Amp V, Amp
31.0
32.0
33.0
KA

8
Section 8
Page : 32 of 57
S.No 34.0
Description Internal resistance of Battery Each cell of battery Minimum clearance required at the front / back Racks No. of racks per battery No. of cells per rack Type of racks rows/tiers Total weight Overall dimension of rack BATTERY CHARGER Manufacturers name and address Type of charger Battery charger rating - Float - Boost No. of Chargers Reference Standard Ambient temperature AC Input rating Voltage Frequency AC input current float mode AC input current boost mode DC output rating Voltage - float mode Voltage - Boost mode current float mode current boost mode Battery charging current Float mode Boost Mode Rectifier Transformer Make Rating Insulation class Type Temperature limited to Blocking diode
Unit Ohm
Details by bidder
35.0 36.0
37.0 38.0 B 1.0 2.0 3.0
kg mxmxm
4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0
V HZ A A
V V A A A
18.0 18.1 18.2 18.3 18.4 18.5 19.0

8
Section 8
Page : 33 of 57
S.No 19.1 19.2 19.3 19.4 19.5 19.6 19.7 20.0 20.1 20.2
Description Make Current rating Voltage rating SCR Make rating Type AC Switch fuse Unit Make Rating i) Float Charger ii) Boost Charger Interrupting capacity for HRC fuses DC Switch fuse Unit Make Rating i) Float Charger ii) Boost Charger Interrupting capacity for HRC fuses Efficiency of complete charger List of instruments provided Degree of Protection Type of sheet steel & Thickness of sheet metal Dimensions in mm (LxDxH) Weight of complete panel Paint shade inside Outside
Unit
Details by bidder
A V
20.3 21.0 21.1 21.2
21.3 22.0 22.1 22.2 22.3 22.4 22.5 22.6
mm mxmxm kg
9. LIGHTING SYSTEM S.No 1.0 1.1 1.2 1.3 1.4 1.5 Make Type Rating Degree of protection Enclosure material Description Well glass fixtures Unit Details by bidder

8
Section 8
Page : 34 of 57
S.No 2.0 2.1 2.2 2.3 2.4 2.5 4.0 4.1 4.2 4.3 4.4 4.5 5.0 5.1 5.2 5.3 5.4 5.5 6.0 6.1 6.2 6.3 6.4 7.0 7.1 7.2 7.4 7.5 9.0 9.1 9.2 9.3 9.4 9.5 10.0 10.1 10.2 10.3 10.4 10.5 Make Type Rating
Description Fluorescent Light fixtures
Unit
Details by bidder
Degree of protection Enclosure material High Bay Fixtures Make Type Rating Degree of protection Enclosure material Flood Lighting fixtures Make Type Rating Degree of protection Enclosure material Lighting panel Make No of ways/circuits Incoming TPN MCB with ELCB rating Rating & Qty of outgoing SP MCBS. Lighting poles Type Material Dimension Thickness of galvanising Junction boxes Make Type Rating Degree of protection Enclosure material 63A welding receptacles Make Type Rating Degree of protection Enclosure material

8
Section 8
Page : 35 of 57
S.No 11.0 11.1 11.2 11.3 11.4 11.5 12.0 12.1 12.2 12.3 12.4 12.5 Make Type Rating
Description 20A Industrial receptacles
Unit
Details by bidder
Degree of protection Enclosure material Flush type Single phase receptacles Make Type Rating Degree of protection Enclosure material
10. UPS Sl. No A 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 Equipment GENERAL UPS rating Make No. of UPS Type Input AC Voltage Input Frequency , Hz Output Voltage Output Frequency , Hz Degree of Protection Efficiency of complete UPS (AC to AC) DC System voltage Total Harmonic distortion Voltage regulation Frequency regulation Thickness of sheet metal Dimensions in mm (L x D x H) Weight of complete panel(kg) Paint shade inside out side
Unit
Offered
KVA
V Hz V Hz
% V V % %

8
Sl. No B 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0
Equipment UPS DB Make Type Quantity Voltage rating Current rating Short circuit rating Rating of incoming MCCB Rating of outgoing MCB Thickness of sheet metal Dimensions in mm (LxDxH) Weight of DB (kg) Paint shade - inside - out side
Unit
Offered
V A kA A A mm mxmxm
11. EOT CRANE S.No 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 2.0 2.1 2.2 Hoist Motor Make Rating Type and frame number Duty Cyclic duration factor No. of starts per hour Full load speed Degree of protection Motor Cooling method Class of insulation Temperature rise limited to Motor efficiency Motor PF Rated torque Pull out torque Cross Travel Motor Make Rating at 50 deg C kW
Description
Unit
Details by bidder
kW -
rpm

8
S.No 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 4.0 4.1 4.2 4.3 5.0 5.1 5.2 5.3 5.4 6.0
Description Type and frame number Duty Cyclic duration factor No.of starts per hour Full load speed Degree of protection Motor Cooling method Class of insulation for Stator & Rotor Temperature rise limited to Motor efficiency Motor PF Rated torque Pull out torque Long Travel Motor Make Rating at 50 deg C Type and frame number Duty Cyclic duration factor No.of starts per hour Full load speed Degree of protection Motor Cooling method Class of insulation for Stator & Rotor Temperature rise limited to Motor efficiency Motor PF Rated torque Pull out torque Guide rails Material Type Size Buffer Make Buffer stroke Max load Type & grade of oil to be used Suspension Rope
Unit -
Details by bidder
rpm
kW -
rpm

8
Section 8
Page : 38 of 57
S.No 6.1 6.2 6.3 7.0 7.1 7.2 7.3 8.0 8.1 8.2 9.0 9.1 9.2 10.0 10.1 10.2 11.0 11.1 11.2 11.3 11.4 11.5 12.0 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 13.0 13.1 13.2 13.3 13.4 13.5 13.6 13.7
Description Material & Size No.of ropes Factor of safety Brakes Make Type Size Screw type limit switch Make Type Gravity type limit switch Make Type Lever type limit switch Make Type Main disconnecting Switch Make Type Enclosure protection Thickness of sheet steel Rating of incoming switch Control Panel Make Type Enclosure protection Thickness of sheet steel Rating of incoming switch Rating of Contactor Rating of Overload relay Control supply voltage Power Cables Make Type Reference standard Conductor Material Size Insulation material & thickness Inner sheath material & thickness
Unit
Details by bidder
mm A
mm A A A V
mm mm

8
S.No 13.8 13.9 13.10 14.0 14.1 14.2 14.3 14.4 14.5 14.6 14.7 14.8 14.9 14.10 15.0 15.1 15.2 15.3 15.4 15.5 15.6 15.7 16.0 16.1 16.2 16.3 16.4 16.5 16.6 17.0 17.1 17.2 17.3 17.4 18.0 18.1 18.2 18.3 18.4
Description Armouring material & size Outer sheath material & thickness Whether FRLS Outer sheath provided Control Cables Make Type Reference standard Conductor Material Size Insulation material & thickness Inner sheath material & thickness Armouring material & size Outer sheath material & thickness Whether FRLS Outer sheath provided Trailing Cables Make Type Reference standard Conductor Material Size Insulation Sheath material & thickness Pendent push button station Make Type Size Enclosure protection Thickness of enclosure Push button type & rating Cable glands Make Type Applicable standard Material Cable lugs Make Type Applicable standard Material
Unit
Details by bidder
mm
mm mm mm mm
mm mm
mm A

8
Section 8
Page : 40 of 57
S.No 19.0 19.1 19.2 19.3 19.4 19.5 19.6 19.7 19.8 20.0 20.1 20.2 20.3 20.4 20.5 20.6 21.0 21.1 21.2 21.3 21.4 21.5 22.0 22.1 22.2 22.3 22.4 22.5 23.0 23.1 23.2 23.3 23.4 23.5
Description Rigid steel Conduit Make Type Size Applicable standard Thickness of wall Material Standard length Thickness of galvanising Conduit Fittings Make & Place of manufacture Type Size Applicable standard Material Thickness of galvanising Flexible steel Conduit Make Type Size Applicable standard Material Junction Boxes Make Type Type of enclosure Overall dimension Type & rating terminal blocks Earthing material Make Type Size Material Thickness of galvanising
Unit
Details by bidder
12. LOCAL PUSH BUTTON STATION

S.No 1 Technical parameter Make Offered

8
Section 8
Page : 41 of 57
JHABUA POWER LIMITED 1X600 MW + 1x660MW JPL SEONI Project

2 3 4 4 4 Type Construction Material Degree of protection No.of push buttons
Specification for River Water Intake System
13. HT CAPACITORS
S.No 1 2 3 4 5 6 Technical parameter Make Capacitor rating Capacitor type Rated voltage and frequency Maximum over voltage, the unit capacitor is capable of withstanding continuously. Quantity Offered
SIGNATURE OF BIDDER _____________________ NAME _____________________
DESIGNATION _____________________ COMPANY SEAL DATE _____________________

8
Section 8
Page : 42 of 57
SCHEDULE - 8.3 TECHNICAL DATA SHEET CONTROL & INSTRUMENTATION S No. 1.0 1 2 3 4 5 6 Description Control System General Make Model No. System configuration diagram Total power consumption Total heat load Control room environment Rockwell * * * * 22C, 50% RH in normal conditions & 50C, 95% RH on AC failure * IP-42 (min.) 230V 50 Hz 1 AC redundant UPS supply Required 10% 10% Required Required Required included in bidder's scope included in bidder's scope Required Lithium 72 hrs. or better 230V 50 Hz 1 AC redundant UPS supply Required Required Required Required Requirement * Bidder To Furnish
7 8 9 1 2 3
Total No. of system / marshalling / remote I/O cabinets Enclosure protection class of system / marshalling cabinets Control system power supply Features & Capabilities Card / module hot replacement Hot spare I/O modules wired up to marshalling cabinet Spare channels in each I/O module wired up to marshalling cabinet MCBs, terminals, fuses etc. for spare modules and I/O channels Commissioning spares and consumables Special tools and tackles Firmware upgrades at no additional cost Earthing cable supply Buffer battery back-up for all dynamic memories Type of batteries Back-up period Power Supply Modules Input voltage Redundancy for power supply modules Hot replacement capability for power supply modules Built in over load and short circuit protection Indications and contacts for module healthiness Control Processor / Controller
4 5 6 7 8 9 10 11 2 1 2 3 4 5 3

8
Section 8
Page : 43 of 57
S No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Description Type No. of loops Loop scan time Total memory Register capacity for data storage User memory Processor word length Real time clock resolution No. of I/O points supported No. of internal coils supported No. of retentive outputs supported No. of retentive internal coils supported MTBF value MTTR value Communication redundancy Processor redundancy Hot data backup interval between primary and redundant processors Output hold period on loss of power Sequence control functions Control modes
Requirement 32bit, microprocessor based, multi-loop, configurable online * * * * * * * * * * * * * Required Required less than one scan cycle 20 ms min, configurable Required Manual, Auto, Cascade * Required Lithium Required Input/Output Open check High High, High Low, Low Low PID Cascade control On-Off control
* Bidder To Furnish
20 21 22 23 24 25 a) Type of memory storage Battery back-up Type of batteries Battery drain alarm / indication Algorithms Alarm check functions
b)
Control algorithms
c)
Selections
Low High Mean value Mid value Override
26.0 a)
Processor / controller self diagnostic tests Input diagnostics Required (upto channel

8
S No.
Description
Requirement level) Required (upto channel level) Required (upto channel level) Required (upto channel level) Required (upto channel level) Required (upto channel level) Required (upto channel level) Required (upto channel level)
* Bidder To Furnish
b) c) d) e) f) g) h) 4.0 1a) 1b) 2a) 2b) 3 4 5 6 7 5.0 1 2 3 4 5 6 7 8
Configuration diagnostics Memory diagnostics System hardware check Output diagnostics External hardware check Power supply diagnostics Alarm indication
Communications Data highway network / protocol Interface physical layer Type of interface with remote I/O panels Interface physical layer Redundant communication cards Communications auto changeover Communication speed Maximum no. of supported nodes Maximum communications bus length Input / Output Modules General No. of I/O racks offered Signal isolation Optical isolation of 1.5 kV for input and output cards Individually fused input / output terminals (with fuse blown indicator) Quick Disconnect termination Individual I/O status indicator Module failure indication in module and PLC Online hot card replacement without disconnection of external wiring Direct switching of on/off inductive loads like solenoid valves, auxiliary relays etc. without extra hardware Contact multiplication Expandable and modular construction Maximum allowable distance between I/O rack and processor Analog Input Module Galvanic/Optical Required Required Required Required Required Required Required Required Required * Open Standard * * * Required Required 100 Mbps min. * *
9 10 11 12
No. of modules offered
*

8
S No. 2 3 4 5 6
Description No. of channels per module Type of input Accuracy Input impedance at 50 Hz Input update rate Analog Output Module
Requirement * Universal Inputs (4-20 mA DC, RTD 3 wire) 0.1% or better * *
* Bidder To Furnish
1 2 3 4 5
No. of modules offered No. of channels per module Type of output Accuracy Output update rate Data Conversion Accuracies Features
* * 4-20mA DC 0.1% or better *
ADC 16 bits 1 LSB LSB 0.1% full range
1 2 3 4
Resolution Linearity Repeatability Accuracy Digital Input Module
1 2 3 4 5 6 7
No. of modules offered No. of channels per module Type of input Accuracy Input impedance at 50 Hz Response time (On/Off) in ms Contact De-bounce filtering
* * 24V DC positive logic 0.1% or better * adjustable time constant
Digital Output module 1 2 3 4 5 6 7 8 1 2 3 No. of modules offered No. of channels per module Type of output Load current per channel Load current per module Response time (on/off) in ms Short circuit protection Over current protection Self Diagnostics for I/O modules A-D / D-A Convertor diagnostic Channel fault diagnostic Short circuit diagnostic Required Required Required
* * 24V DC nominal * * * * *

8
S No. 4 6 1 2 3 4
Description Wire break diagnostic Human Machine Interface (HMI) General Make/model No of security levels Interchangeability between operator & Engineering station Supports online configuration changes HMI
Requirement Required
* Bidder To Furnish
* * Required Required
1 2 3
Type of PC Operating System Applications supported (as applicable)
Industrial Grade Windows XP control system graphic development control system run time software Microsoft Office anti virus applications network management applications * * Required Required
4 5 6
Processor Hard disk capacity CD/DVD/ Color graphics adaptor Input Devices Mouse
1 2 3 1 2 3
Make/model Type Connectivity Keyboard Make/model Type Connectivity Output Devices Monitor
* Industrial Grade, optical USB * Industrial Grade, QWERTY USB
1 2 3 4 5 6
Size Pixel resolution Display refresh rate Colours (foreground/background) No. of display characters Display signal interfaces
22 TFT/LCD 1600 x 1280 min. 75 Hz min. * * *

8
Section 8
Page : 47 of 57
S No. 7 8 9 10
Description Brightness Contrast ratio Viewing angle Display tilt/height adjustment HMI Features & Capabilities
Requirement * * * Required
* Bidder To Furnish
1 2 3 4 5
No. of graphic pages No. of points in alarm summary No. of trends per display No. of multi trend display Trending Functions a. Real time No. of parameters Sampling time Time base b. Historical trending No. of parameters Sampling time Time base
* * * *
unlimited 100 ms 10 ms User configurable 100 ms 10 ms User definable User definable * Required Required Required Required Required 40 Required Required User definable User definable Required Required Required Required Required Required Required
Logging Functions No. of parameters Log formats Type of log reports Event logging Hourly logs Shift logs Daily logs Weekly logs
Alarm Display Functions No. of alarm/page Differentiation between process & system alarms Group display function Total no. of groups No. of loops per group
Information Display Group Input Output Set point Tag nos. Set point status Mode status Service description

8
S No. 7 1 1 2 3 4 5 6 7 8 9 10 11 8 1 2 3 4 5 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Description HMI Peripherals 132 Column Dot Matrix Printer Make/model Quantity Power supply (v, Hz) Ambient temperature (max.) Relative humidity (max.) Paper size Printing speed (min) in normal mode Resolution (min) Paper input capacity Network connectivity Consumables Network Interface Modules Make/model Supported interfaces Supported protocols Power supply Redundancy Control Cabinets Dimensions Paint colour (exterior-front & rear) Paint colour (exterior-sides) Paint colour (interior) Enclosure class Material of construction Anti-vibration pads Base frame Cable entry Panel lighting Smoke detector Fire proof sealing for cable entry Eye bolts for lifting Pre-treatment, phosphatising and painting Finished thickness of paint Utility power points Type of terminal blocks Cable Connectors to field instruments
Requirement
* Bidder To Furnish
* 1 no. 230V AC, 503 Hz 5-55 deg C 5-95% non-condensing * * * * Integrated Ethernet 500 sheets of paper included in scope * Ethernet / Serial Modbus TCP-IP * Required
2200 (h) x 800 (w) x 800 (d) RAL 9002 RAL 5012 Glossy white IP 42 min. CRCA 2.0mm thick front, rear & side 15mm thick 100mm thick Bottom Required Provision for mounting required Required Required Required 100-150 microns 1 no. 230V AC Cage clamp / Maxi termi Hartin-Hin Plug and Socket Type

8
S No. 19 20 21 22 23 24 25 10.0 1.0 2.0 3.0 4.0 5.0 11.0 11.1 a) b) c) d) 11.2 a) b) c) d) e) 11.3 a) b) c) d) e) f) g) h) 11.4 1 a) b) c)
Description Accessories - MCBs, fuses, cable glands Signal earthing Body earthing Cabinet cooling fans Rear door & front door Louvers Drawing pockets Control Desks Make Material of construction Type Dimensions Colour Field Instruments Pressure Gauge Make Sensing element Accuracy Enclosure Material of Construction (MOC) and IP rating Resistance Temperature Detector (RTD) Sensing element Insulation Terminal head MOC and IP rating Accuracy Response time (without thermowell) Pressure Transmitter Make Type Sensing element & MOC Over range protection Sensor IP rating Diaphragm Seal Accuracy HART Compatible Vibration Monitoring System General Make Model Number Type
Requirement as Required copper shield bus earthing bolt / strip Required Required Required Required
* Bidder To Furnish
* Medium Density Fiber (MDF) free standing type * shall match colour scheme of control room and PLC panels to maintain aesthetics
* * % of span *
* * * % of span *
Required % of span Required
* * *

8
S No. d) e) f) g) h) 2 a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s) t) 3 a) b) c) d) e) f) g) h) i) 4 a) b) c) d) 11.5 a)
Description Instrument Tag number Service (Machine Number) Machine Type Machine RPM System Type Monitor Frequency Range. Display Scale Range Display Time Power Supply Enclosure Type Ambient Temperature Range Mounting Type Alert Relay operating modes Alert Relay Power Voltage Alert Relay Time Delay Shut Down Relay Operating Modes Shut Down Relay Power Voltage Shut Down Relay Time Delay Circuit Failure Relay Modes Channels (Quantity) Alert Relay Set Point Shut Down Relay Set Point Alert Reset Shut down reset Multiple Monitors Pick Up Type Frequency Range Sensitivity Operating Temperature Damping Factor Mounting Orientation Displacement limits Enclosure Types Extension Cable Length Output Analog Digital Serial Connectivity Enclosure Type Reverse Rotation Monitor Make
Requirement * * * * * Hz * * * * Degree C * * V Seconds * * * * * * * * * * * Hz * Degree C * * * * * * * * * *

Section 8
* Bidder To Furnish

8
Page : 51 of 57
S No. b) c) d) e) f) g) h) i) 12.0 1 2 3 4 5 a) b) c) d) e) f) g) h) 6 a) b) c) 7 a) b) c) d) 8 a) b) c) d) 9 a) b) c) d) 10 a)
Description Model Number Transducer Type Input Impedance Accuracy 4-20 mA DC output Buffered Transducer Output Relay Output LCD Display Indicator Instrumentation Cables Make Type Voltage Grade Continuous operating temperature Conductor Reference Standard Material Grade No. of strands Diameter of strands (nominal) Cross sectional area Max conductor resistance per km Color code Insulation Material of Insulation Nominal insulation thickness Volume Resistivity Individual Shield Material Thickness Coverage/Overlap Noise Interference Overall Shield Material Thickness Coverage/Overlap Noise Interference Drain Wire Reference Standard Size/ No. of strands Material Resistance per km Outer Sheath Material
Requirement * * Kilo ohms % of span * * * * * * 600 V AC 70 deg C * Annealed bare copper Electrolytic Grade No. mm sq. mm Ohm
* Bidder To Furnish
mm Ohm mm Aluminium Mylar tape mm % dB Aluminium Mylar tape mm % dB
sq.mm / No. Annealed Tinned Copper Ohm Extruded PVC with


8
S No. b) c) d) e) f) g) h) i) j) k) 11 a) b) c) d)
Description Reference Standard Diameter Minimal Thickness Nominal Thickness Color Resistance to water, fungus, termite and rodent attacks Temperature Index Oxygen Index Max. Acid Gas Generation Max. Smoke Density Rating Electrical Parameters Mutual Capacitance Insulation Resistance Characteristic Impedance Attenuation at 1kHz
Requirement FRLS properties * mm mm mm * Required C % % % nF/km M Ohm Ohm dB/km
* Bidder To Furnish
SIGNATURE OF BIDDER ___________________________ NAME ___________________________
DESIGNATION ___________________________ COMPANY SEAL DATE ___________________________

8
Section 8
Page : 53 of 57
JHABUA POWER LIMITED 1 X 600MW + 1 X 660MWJPL SEONI Project Specification for River water intake system
SCHEDULE 8.4 DRAWING ENCLOSURE
Sl. No.
Drawing / Sketch Title
Drawing No. / Sketch No.
Revision
SIGNATURE OF BIDDER _____________ NAME __________________ DESIGNATION ___________ COMPANY SEAL DATE ___________________

8
Section 8
Page : 54 of 57
JHABUA POWER LIMITED 1X600 MW +1x660 MW JPL SEONI Project Specification for River water intake system
SCHEDULE 8.5 DETAILS OF SIMILAR WORKS DONE DURING PAST FIVE YEARS
Sl. No.
Full postal address of client & name of officerin-charge with Telex/Tel. No. 2
Description of the work (shall indicate parameters) 3
Value of contract
Completion time as stated
Date of commencement of work
Actual completion time (Month)
Month & year of completion
Certified that documentary proof for above information is enclosed To include in Part-I of the Tender SIGNATURE OF BIDDER NAME DESIGNATION COMPANY SEAL DATE __________________________________
__________________________________ __________________________________ __________________________________
Section 8 Technical Data Sheets & Schedules
Page : 55 of 57
SCHEDULE 8.6 UTILITY CONSUMPTION LIST ITEM NO. Sl. No. System / Equipme nt Quantity Quantity per Operation Mode C I Electricity (KW) INST. AIR (NM3/HR) kg/cm2 (g) C I C I(*T) NAME OF EQPT. Plant Air (NM3/HR) kg/cm2 (g) I I(*T) Cooling Water 3 (M /HR) kg/cm2 (g) C I DM Water (M3/HR) kg/cm2 (g) C I Filtered Water (M3/HR) kg/cm2 (g) C I Aux. Steam (KG / HR) kg/cm2 (g) C I
C Continuous I Intermittent T Operating Hours per 24 Hours SIGNATURE OF BIDDER NAME DESIGNATION COMPANY SEAL DATE __________________________________
__________________________________ __________________________________ __________________________________
Page : 56 of 57
SCHEDULE 8.7 LUBRICANTS LIST
ITEM NO. Sl. No. GRADE MAKERS BRAND INTIAL CHARGE (L/SET) SHELL
EQUIPMENT REPLACEMENT CHARGE MAKE-UP LOCATIO N TO BE USED
CALTEX
MOBILE
ESSO
QUANTITY (L/SET)
INTERVAL
QUANTITY
INTERVA L
SIGNATURE OF BIDDER NAME DESIGNATION COMPANY SEAL DATE
__________________________________
__________________________________ __________________________________ __________________________________
Page : 57 of 57
JHABUA POWER LIMITED 1x600 MW+1x660MW JPL SEONI Project Specification for River Water Intake System
SECTION - 9
QUALITY ASSURANCE PROGRAM
Section 9
Page : 1 of 27
Quality Assurance Program
TABLE OF CONTENTS
CLAUSE. No. 1.0 2.0 3.0 4.0 5.0
DESCRIPTION
PAGE No.
QUALITY ASSURANCE PROGRAMME ................................................................. 3 GENERAL REQUIREMENT .................................................................................... 3 QUALITY ASSURANCE FOR CIVIL WORKS ......................................................... 5 QA & I CO ORDINATION PROCEDURE............................................................... 20 PUMPS, PIPES & VALVES ................................................................................... 21
ANNEXURE-9.1-MANUFACTURING QUALITY PLAN.......................................................... 24 ANNEXURE 9.2 FIELD QUALITY PLAN ......................................................................... 26
Section 9
Page : 2 of 27
1.0
QUALITY ASSURANCE PROGRAMME The Bidder shall adopt suitable quality assurance programme to ensure that the equipment and services under the scope of contract whether manufactured or performed within the Bidders works or at his sub-Bidders premises or at the Owners site or at any other place of work are in accordance with the specification. Such programme shall be outlined by the Bidder and shall be finally accepted by the Owner / authorized representative after discussion. The QA programme shall be generally in line with ISO-9001.
2.0
GENERAL REQUIREMENT All materials, components and equipments covered under this specification shall be procured, manufactured, erected, commissioned, and tested at all stages, as per a comprehensive Quality Assurance Programme. It is the Bidders responsibility to draw up and implement such programme duly approved by the Owner. The detailed Quality Plans for manufacturing (MQP) and field activities (FQP) shall be drawn up by the Bidder and will be finalized as per enclosed Annexures 9.1 & 9.2. Manufacturing Quality Plan (MQP) will detail out for all the components and equipments, various test/inspection, to be carried out as per the requirements of this specification and standard mentioned therein and quality practices and procedures followed by Bidders/sub-Bidders Quality Control Organization, the relevant reference documents and standards, acceptance norms etc. during all stages of manufacturing including raw material procurement, in-process manufacturing, assembly, and final testing/performance testing. All testing equipments, meters, gauges, tools shall be calibrated at periodic intervals and records shall be maintained at the manufacturing /testing places. Also copies all relevant BIS /ASME shall be made available at the place of inspection. The Quality Plans shall be submitted to Owner in soft form for review and Comment. Hard copies of Final Quality Plans shall be submitted for stamping and approval in addition to soft copies. Field Quality Plans (FQP) will detail out for all the equipments, the quality practices and procedures etc. to be followed by the Bidders site Quality Control Organization, during various stages of site activities starting from receipt of materials/equipment at site. The Bidder shall also furnish copies of the reference documents/plant. Standards/acceptance norm/test and inspection procedures etc. as referred in Quality Plans along with Manufacturing and Field Quality Plans. These Quality Plans will be subject to Owners approval without which manufacturer and erector shall not proceed with the manufacturing and erection activities. These approved documents shall form a part of the Contract. In these approved Manufacturing and Field Quality Plans, Owner shall identify Customer Hold Points (CHP), e.g. test/checks which shall be carried out in presence of the Owners representative or its nominated outside inspection agency and beyond which the work will not proceed without consent of Owners representative or its nominated outside inspection agency in writing. All deviations to this specification, approved quality plans and applicable standards must be documented and referred to Owner along with technical justification for approval and disposition. Suitable formats giving the details of Project, Package, Drawing No., Item description, details of deviation, approval by competent authority of vendor shall be submitted to the owner for final approval The Bidder shall submit to the Owner Field Welding Schedule for field welding activities Critical item. The field welding schedule shall be submitted to the Owner along with all supporting documents like welding procedures, heat treatment procedure, NDT procedures, etc. at least 90 (Ninety) days before start of erection work at Site. The Bidder shall have suitable Field Quality Organization with adequate manpower at Owners site, to implement the Field Quality Plans (FQP) and Field Quality Management System for site activities. The Bidder shall submit the details of the proposed FQA set up (organizational structure and manpower) for Owners approval. The FQA set up shall be in place at least one month before the start of site activities.
Section 9
Page : 3 of 27
No material shall be dispatched from the manufacturers works before the same is accepted, subsequent to pre-dispatch and final inspection including verification of records of all previous tests/inspection by Owners representative or their authorized outside inspection agency and authorized for dispatch by issuance of Material Despatch Clearance Certificate (MDCC). All materials used for equipment manufacture including casting and forging etc. shall be of tested quality as per relevant codes/standards. Details of results of the test conducted to determine the mechanical properties, Chemical properties, details of Heat Treatment procedure recommended and actually followed (H T Chart), results of NDT tests conducted shall be recorded on the test certificate. All tests shall be carried out as per applicable material specification, code requirement and as specified in this specification. All welding and brazing shall be carried out as per procedure drawn and qualified in accordance with requirement of ASME Section IX or any other equivalent International Standard acceptable to the Owner. All welding and brazing procedures shall be submitted to the Owner or its authorized outside inspection agency for approval prior to carrying out the welding/brazing. All welders, brazers, and welding operators employed on any part of the contract either at the Bidders/ sub- Bidders works or at site or elsewhere shall be qualified as per ASME Section IX or any other equivalent International Standards acceptable to the Owner. Welding procedure qualification, welders qualification, Brazing procedure qualification and brazers qualification test results shall be furnished to the Owner or its authorized outside inspection agency for approval. However, where required by the Owner, tests shall be conducted in presence of Owners representative or its authorized outside Inspection agency. All statutory and safety requirements for the equipments/systems shall also be complied with. Unless otherwise proven and specifically agreed with the Owner, Welding of dissimilar materials and high alloy materials shall be carried out at shop only. No welding shall be carried out on cast iron components for repair and up gradation of casting. All the heat treatment results shall be recorded on time temperature Chart and verified with recommended regimes. All non-destructive examination shall be performed in accordance with written procedures as per International Standards. The NDT operators shall be qualified as per American Society of NonDestructive Testing or any other International Standard acceptable to Owner. The result of NDT shall be recorded in a report, which includes details of methods and equipment used, job identification no. job detail, identification of personnel performing the test, result of evaluation and correlation of the test report with the job. All bar stock/forging of diameter equal to or greater than 50 mm shall be ultrasonically tested. In general all plates of thickness 40 mm and above used for non pressure application and plates of thickness 25 mm and above used for pressure parts shall be ultrasonically tested unless otherwise specified in respective specification. The Bidder shall list out all major items/equipments/components to be manufactured in house as well as to be procured from their suppliers and sub-suppliers. All suppliers and their sub-suppliers proposed by the Bidder for procurement of major items including casting, forging, semi-finished and finished items /equipments etc. list of which shall be drawn up by the Bidder and shall be subject to Owners approval. The Bidder shall submit their proposal for approval of suppliers and their sub-suppliers prior to placement of orders which will include details of manufacturing facilities established at the respective works, their Quality Management System followed, and experience list in manufacturing and supply
Section 9
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of items for which proposal has been submitted for approval along with their own technical evaluation of proposed manufacturer with in the period agreed at the time of pre-awards discussion. The Bidder should have their own QA and Inspection organization for carrying out inspection at manufacturers works and at site as per approved Quality Plan. In case, the Bidder proposes to engage third party Inspection Agency for carrying out inspection on his behalf, the same shall be done only after obtaining due approval from the Owner/ Purchaser well in advance. Owner reserves the right to carry out quality audit and quality surveillance of the system and procedures of the Bidder and their sub-Bidders Quality Management and control activities. The Bidder shall provide all necessary assistance to enable the Owner carry audit and surveillance. The Bidder shall carry out an inspection and testing of component and equipment during manufacture at his work and at his sub-suppliers work and at site to ensure to ensure the compliance with the drawing, quality, conformance to functional and performance requirements of the parts and equipments. Bidder shall carry out all tests/inspection required to establish that the items/equipments conform to the requirements of the specification and relevant codes/standards specified in the specification, in addition to carrying out tests as per the approved Quality Plans. Quality audit/ surveillance/approval of the test results, inspection and acceptance of material will not, however, prejudice the right of the Owner to reject the equipment if it does not comply with the Specification when erected or does not give complete satisfaction in service and the above shall in no way limit the liabilities and responsibilities of the Bidder in ensuring complete conformance of the materials/equipments supplied to relevant specification, standard, data sheet, drawing etc. For all spares and replacement items, the quality requirements as agreed for the supply of main equipments shall be applicable. Repair/rectification procedures to be adopted to make the job acceptable shall be subject to the approval of the Owner/ authorized Inspection Agency. 3.0 3.1 3.1.1 QUALITY ASSURANCE FOR CIVIL WORKS INTRODUCTION This part of the specification covers the sampling, testing and quality assurance requirement (including construction tolerances and acceptance criteria) for all civil and structural works covered in this specification including excavation and filling, cast in situ concrete and allied works, fabrication and erection of structural steel works, masonry / sheeting and allied works, finishing items,etc. This part of the technical specification shall be read in conjunction with other Parts of the technical specifications, general technical requirements & erection conditions of the contract. Wherever IS code or standards have been referred they shall be the latest revisions. All tests required for all materials (bought by Bidder) and workmanship shall be done / got done by the Bidder at his own cost. The rate for respective items of work or price shall include the cost for all works, activities, equipment, instrument, personnel, material etc. whatsoever associated to comply with sampling, testing and quality assurance requirement including construction tolerances and acceptance criteria and as specified in subsequent clauses of this part. The Bidder shall provide the facilities whatsoever required and also bear the cost for all sampling, testing and quality assurance in the field and in the laboratory. The Bidder shall carry out all sampling and testing in accordance with the relevant Indian standards and / or international standards and this technical specification. Where no specific testing procedure is mentioned, the tests shall be carried out as per the best prevalent engineering practices and to the directions of the Engineer. All sampling shall be done in the presence of the Engineer or his authorised representative. The Bidder shall establish the QA&QC laboratory at site and all field tests shall be
3.1.2
3.1.3
3.1.4
done in the presence of the Engineer and / or his authorised representative. The tests which cannot be carried out in the field laboratory shall be done at a laboratory of repute such as CSMRS, NCBM, IITs, National Test House, Kolkata etc. as agreed by the Engineer. The test samples for such test shall be jointly selected and sealed by the engineer and thereafter these shall be sent to the concerned laboratory through the covering letter signed by FQA representative of the engineer. The cost of transportation and other associative cost including the test charges shall be borne by the Bidder. These cost shall deemed to be included in the respective item of work in the contract. If the Engineer desires to witness such tests at laboratory, Bidder shall arrange to conduct the test in his presence. 3.1.5 The recommendations and suitability of material for concreting and other building materials like brick, cement, aggregates etc., shall be ascertained by Bidder prior to start of work. Preliminary evaluation of aggregate and its evaluation for potential alkali-aggregate reactivity as per following scope of work shall be done: Evaluation of Aggregates: o To carry out different tests on coarse aggregate sample i.e. specific gravity, water absorption, sieve analysis, deleterious material; soundness, crushing value, impact value, abrasion value, elongation index and flakiness index, as per IS: 2386 To carry out different tests on fine aggregate sample i.e. specific gravity, water absorption, sieve analysis soundness, deleterious material, silt content, clay content and organic impurities as per IS: 2386. To prepare evaluation report based on test results of i) and ii) above and to advise regarding suitability of fine and coarse aggregates.
Evaluation of Aggregates for Potential Alkali-Aggregate Reactivity: o Evaluation for Potential Alkali-Aggregate reactivity as per following scope of work: To carry out petrographic analysis and accelerated Mortar bar Test on aggregate samples (1N NaOH at 80 deg. Centigrade for 14 days as per ASTM 1260, or the method established/ developed by CSMRS for 22days test. To prepare a report based on test results of i) above and to advise regarding suitability of aggregates and further testing required if any. The Bidder shall initiate the action with regard to the above mentioned evaluation of aggregates and other building material, so as to ensure timely completion of these tests thereby not affecting any project work. All records shall be submitted, unless specified otherwise, as per the format developed by the Bidder and approved by the Engineer.
3.1.6
The Bidder shall enclose a comprehensive list of bought out items (BOIs) envisaged in the contract for carrying out fabrication/ manufacturing/ erection/ construction/ commissioning activities, procurement of forged, cast, semi-finished and finished components/equipment etc and shall indicate the names of reputed manufacturers for each of them in their bid proposal. The items envisaged by the Bidder to be procured from these manufacturers shall meet the specification requirement. Some of these bought out items (not exhaustive) is listed below for which the Bidder shall submit the requisite details / lists of manufacturers in their bid proposal. Cement Reinforcement and Structural Steel
Construction chemicals: such as admixtures, admixtures, accelerators, plasticizers, Waterproofing, Grouts and resin capsule etc Vibration Isolation System Paint and Painting System PVC Water Stops, Sealing compounds Electro Forged Gratings Profilers for Decking and Cladding sheets Bitumen, Bitumen Impregnated Fiber Board Joint Filler PTFE slide bearings, fixed bearings, Insulating materials Glass and Glazing Fireproof Doors, Particle Boards Floor Tiles Sanitary Items Aluminum Sections Plastic pipes, Hume pipes Any other specific high value and critical bought out item required, meeting the specification requirements.
3.1.7
The list of manufacturers / sub-vendors of each of the BOIs identified / indicated by the Bidder shall be discussed / reviewed by the Owner during post bid discussions and the list of proposed manufacturers / sub-vendors for each of the BOI shall be agreed/ approved. The list of manufacturers for all the BOIs envisaged in contract shall be included in the bid proposal and the same shall be discussed for finalization during the post bid discussions before placement of award. Where the manufacturers are placed in DR (Details required) category, the details of the manufacturers / sub-vendors placed in the DR category shall be submitted to the OWNER/CONSULTANT for approval within the period agreed at the time of post bid discussions. The Bidder s proposal shall include vendors site facilities, expertise, facilities established at the respective works, the process capability, process stabilization, QC systems followed, experience list, etc. along with his own technical evaluation for identified sub-Bidder s proposed. Structural Steel and Reinforcement steel shall be procured from main steel producers like SAIL, TISCO, IISCO, RINL, Essar Steel, Ispat Industries, JSW Steel, Lloyds Steel, Jindal Steel & Power. Bidder shall procure the Cement from main cement manufacturers like ACC, CCI, Ultratech, Gujarat Ambuja, Laxmi, Jaypee, Grasim.
3.1.8 3.1.9
3.1.10 The Field Quality Plans shall detail out all the equipment, the quality practices and procedures etc. to be followed by the Bidders "Site Quality Control Organisation", during various stages of site activities starting from receipt of materials/equipment at site. The Bidder shall furnish complete QA & QC programme (QAP) for the work envisaged which may include the following: The organisation structure for the management and implementation of the proposed Quality Assurance Programme. Documentation Control System The procedure for procurement of materials and source inspection. System for site controls including process controls.
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Control of non-conforming items and systems for corrective action Inspection and test procedures for site activities System for indication and appraisal of inspection status System for maintenance of records System for handling, storage and delivery. Quality Plan detailing out quality practices and procedures, relevant standards and acceptance levels for all types of work under the scope of this contract.
The Bidder shall appoint a dedicated, experienced and competent quality management representative on site, preferably directly reporting to the Project Manager, supported by experienced personnel, to ensure the effective implementation of the approved quality assurance programme. The onsite quality management representative shall have the organisational freedom and authority to implement the requirements of these quality assurance arrangements, free from commercial and programme restraints. The QA & QC setup of the Bidder shall consist of qualified and experienced engineers, with their supporting staff. The QA&QC set up in addition to requisite mechanical & electrical engineers shall consist sufficient graduate civil engineers & supervisors to take care of quality assurance activities of both site & laboratory The deployment of man power for QA & QC set up shall be affected on the basis of agreed manpower deployment schedule, which shall be prepared by the Bidder based on the L-2 network and the same shall be submitted to the Engineer-in-charge for acceptance. Based on the schedule of work agreed with the Engineer-in-charge and the approved FQP, the Bidder shall prepare a schedule of tests and submit them to the Engineer-in-charge and organise to carry out the tests as scheduled/ agreed. All these testing equipment shall be provided by the Bidder at his own cost. The Bidder shall maintain the equipment in good working condition along with valid calibration certificates, for the duration of the contract. Any other equipment though required for testing but not listed in the equipment list shall be provided / arranged by the Bidder at his own cost. 3.1.11 The Bidder shall prepare and obtain approval of the Owner of the Field Quality Plan (FQP) well before the start of the work. This FQP shall cover for all the items / activities covered in the contract/schedule of items and required for completion of the work. 3.1.12 All materials / components and equipment covered under the scope of work which are to be manufactured at shop/ factory of the vendor/subvendor shall be covered under a comprehensive quality assurance programme. The detailed quality plan for manufacturing shall be drawn up by the Bidder and will be submitted to the owner for approval in the prescribed format for manufacturing quality plan. Manufacturing Quality Plan (MQP) shall detail out all the components and equipment, various test/inspection, to be carried out as per the requirements of this specification and standards mentioned therein. The quality practices and procedures followed by Bidders/Sub-Bidders/ subsuppliers Quality Control Organization shall include, the relevant reference documents and standards, acceptance norms, inspection documents raised etc., during all stages of material procurement, manufacture, assembly and final testing / performance testing . The quality plan shall be submitted in electronic media e.g. CD or E-mail in addition to hard copy, for review and approval. After approval the same shall be finally submitted in compiled form on CD. 3.1.13 The Bidder shall store and handle the materials as per the requirements of the relevant standards at his own cost.
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3.1.14 All the equipment shall be duly calibrated by NABL/ NPL accredited laboratories/accreditation agencies. 3.1.15 The Bidder shall associate themselves with the reputed specialized blasting agency such as CMRI, NIRM for trials blasts, design blasts, blasting pattern, monitoring of blast during the blasting operations at site. The blasting operation shall remain in charge of a responsible, competent, authorized and experienced supervisor (Man-In-Charge) and thoroughly acquainted workmen. All blasting work shall be done as per approved blasting scheme/ design/ pattern in line with the technical specification requirements and all statutory laws, rules, regulations, relevant standards pertaining to the acquisition, transport, storage, handling along with use of explosives shall be strictly followed by the Bidder. The Bidder shall install and operate equipments (such as tri-axial seismograph) for continuous monitoring and control of blast induced vibrations, noise level/ air pressure, dust, silica and noxious gases during all blasting operations in line with the Technical Specification requirements in association with the specialized blasting agency. The Bidder shall submit the un-priced copy of the award on the specialized blasting agencies to Owner, highlighting the scope of services/ work awarded to them by Bidder. The services of such specialized blasting agency shall be available through out the period in which the blasting work is undertaken at site. 3.2 3.2.1 GENERAL QA REQUIREMENTS QA REQUIREMENTS FOR PROPERTIES, STORAGE AND HANDLING OF COMMON BUILDING MATERIALS All the materials brought to site for incorporation in the work like Bricks, Stones, Concrete Blocks, Cement, Water, Aggregates, Sand, Reinforcement Steel, Structural Steel shall conform to the relevant IS Codes/ Technical Specification requirements. All materials shall be stacked and stored by the Bidder as per IS-4082 and as per the requirements specified in Technical Specification. All material shall be stacked separately. Cement shall be stored on a raised platform in Weather Proof, Dry & Leak Proof Conditions stores. Different consignment of different types of cement shall be stored separately with clear identification mark. Cement stored for more than 60 days in Bidders godown shall be retested to check their suitability for use. Cement shall be consumed on first in first out basis. Steel shall be stacked and stored consignment wise, on raised wooden battens size wise and grade wise with identification mark. For properties, storage and handling of all materials used shall comply to the requirements of Technical Specification. The sheets/ packets shall be stacked neatly clear off the ground at an angle to the ground, over a base pallet to provide drainage. The packets/ sheets must be covered with water proof covering to protect from moisture rain and foreign particles. Water / moisture should not be allowed to stagnate on surface, or in between layers. This can damage the coating, and cause corrosion.
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3.2.2
QA REQUIREMENTS FOR RCC PILES LOAD TEST ON RCC PILES Pile load testing shall conform to IS-2911 (Part IV) and the Technical Specification. Check all the equipment and instruments used are properly calibrated. Initial load test shall be conducted to assess the safe load carrying capacity of pile before start of work. Cyclic vertical (compression) load test to assess safe vertical load capacity. Lateral load test to assess safe horizontal load capacity. Pull out (Tension) load test to assess safe pull out load capacity. Routine Load Test shall be conducted on Working Piles, to verify their load carrying capacity. Direct Vertical (Compression) load test for vertical load capacity. Lateral load test for horizontal load capacity All other tests on piles shall be carried out as specified in Technical Specification. Pile load-testing procedure and the test setup/scheme to be submitted for approval from Owner/Consultant. The Bidder shall use the test setup having arrangement for reaction piles for both vertical compression and uplift (tension) Load test (initial) on piles. The cost of reaction system/ piles shall deem to be included in the cost of test piles All the gauges (pressure etc.) and the instruments shall be calibrated before the start of the tests on test piles and working piles and the calibration record shall be verified before start of execution of the test. FOR CONCRETING INCLUDING CONCRETING OF MAJOR
3.2.3
QA REQUIREMENTS FOUNDATIONS
All records of concreting, reinforcement, testing of materials, as-built dimensions, the details of the rectification, etc, shall be maintained as given below. Four copies of such record in a bound form shall be submitted to owner for their record and future reference. Testing data / report of aggregates Mix design details. Testing records of admixture including dosage, workability and setting time. Approved scheme for concreting. Hourly records of concreting including pour card. Protocol indicating the dimensional tolerance and details of inserts. Records giving the details of rectification giving the location of grouting, the quantity of grout used at each location, type of grout used. Bar bending schedule. Location and details of mechanical anchoring used for reinforcement. Protocol giving the details of checking of reinforcements before concreting and conformance to the reinforcement details as shown in the construction drawings. Photographs showing the areas where rectification works have been carried out. Photographs should be taken before and after rectification. Report on petrographic examination & potential reactivity of aggregate and the repeated temperature cycle tests. All tests/checks shall be carried out as per FQP.
Check temperature control of fresh concrete temperature of fresh concrete should not exceed 25 degree C at the time of placement. Plasticizer cum Retarder type mixture to be added in the concrete shall be tested as per IS9103. Reinforcement: o o o Check conformity of material to relevant IS codes. Check lapping/spacing of Reinforcement staggered as under no circumstances more than 50% of bars at cross section shall be lapped. Sample test for mechanical bars grips shall be carried out upto the yield strength of reinforcement of bars. The no. of tests to be carried out shall be 3% of the no. of bar grips used subject to a minimum of three.
Batching Plant shall be calibrated regularly at least once in a 3 months and computerized output shall be taken for each batch of production of concrete. The calibration if the batching plant shall be done by NABL accredited laboratories/weights of NPL traceability. All precautions and control as specified in Technical Specification shall be taken care of during concreting. IS 456-2000 shall be applicable for acceptance of execution of concrete works & test results.
3.2.4
QA REQUIREMENTS FOR STRUCTURAL STEEL WORK Physical and chemical properties of material as per relevant codes. Review of correlated Mill Test Certificates or check testing in absence of MTC. Ultrasonic test on plates above 40mm as per ASTM A435. Welding Procedure & Welders Qualification Test as per ASME Section IX/AWS D1.1 Fillet Welds: o o o o Check for size and visual examination. Micro tech examination on production test coupons for main fillet with minimum one joint per built up beams, columns and crane girder etc. 25% weld length of tension member of crane girder shall be subjected to dye Penetration Test. On all other fillet welds, DPT on 5% of weld length with minimum 300mm at each location shall be carried out.
Butt Welds: o o DPT on all butt welds after back gouging Mechanical testing of production test coupons with minimum one joint per built up beam, column and crane girder. 100% radiography test on butt welds of tension flange (bottom flange) of crane girder. All other butt welds shall be subjected to Radiography test on 10% weld length of each welder. Wherever RT is not feasible, UT shall be carried out. Full penetration welds (other than butt welds) shall be subjected to Ultrasonic Testing in following quantum :
100% UT on web to flange joint of crane girder. ii)10% UT on other full penetration joints.
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Ash Bunker/Bins o o 10% DPT after back gouging. 5% spot radiography test on butt welds where access not available. UT shall be carried out with prior approval of Engineer in charge.
Every 1st and further every 10th set of identical structure shall be checked for control assembly in shop before erection. All structure components /members shall be checked for dimensional tolerances during fabrication and erection as per IS-7215 and IS-12843 respectively. Check for Surface Preparation and Paint thickness. In case of failure of any welds in SPOT RT/UT, the %age for retesting shall be doubled at that particular location. Acceptance criteria of NDT on welds shall be as per AWS D1.1. Low hydrogen electrode (AWS E-7018) for welding of High/Medium tensile steel, for M.S (IS 2062 Gr. A/Gr. B, IS 8500) sections thickness above 20mm shall be used. Preheating and Post weld heat treatment requirements shall be complied as specified in the technical specs. /approved WPS.
3.2.5
QA REQUIREMENTS FOR SHEETING WORKS. Colour coated sheet o o o o o o o o Chemical & physical properties of raw material sheet as per relevant codes. Base Metal Thickness Thickness of coatings Type of coating/paint Hardness of painted surface (2H pencil Hardness) (ASTM-D-3363) Flexibility Test Bend test as per ASTMD-328 at 180 degree bends (twice the thickness of sheet). There should not be any crack. Dimensional check after profiling of sheets Weathering Resistance Test: Salt spray test as per ASTM B-117 for minimum 1000 hrs. One sample per batch at random. (For true representative sampling, three samples shall be taken from each batch out of which one sample shall be sent for salt spray test. The batches shall be chosen at the beginning of supply, another at the middle of supply and the third towards the end of the supply) Cross hatch test
Bonded Mineral Wool Insulation a) Thickness o o o Density Thermal Conductivity All other tests as per IS-8183.
Sheeting Installation o o Workmanship including alignment Level, Slope
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o o o
Side and End Laps Proper Installation of Flashing Fixing including opening, (No gas cut opening shall be allowed at the site , whenever opening is specified these shall be properly cut in the factory and shall be filled with lipping/ flashing for true shape/ dimension etc.) Location, Installation of Lining & Installation.
All bought out items shall be procured from the manufacturers approved by Engineer-in - charge and tested as per relevant IS Codes/ Specification. 3.2.6 ARCHITECTURAL & MISC. WORKS Material used for floor finishes and allied work shall conform and tested as per the requirements of relevant IS Codes specified in Technical Specification. Finishes shall be checked for the following: o o o o o o o o o Level, Slope, Plumb Pattern & Symmetry Alignment of joints, dividing strips etc. Colour, Texture Surface Finish Thickness of Paint Details of edges, junction etc. Performance Precautions specified for durability.
For fabricated item like metal doors, windows, ventilators, louvers, rolling shutters and grills etc. The following checks shall be carried out. o o o o o o o o o o o Overall Dimensions Mullions Transoms Doors & Windows shall operate without jamming Doors, windows & frames etc. shall be on a true plane, free from wrap or buckle. All welds shall be dressed flush on exposed and contact surfaces. Correctness of locations and smoothness of operation of all shop installed hardware and fixtures. Provision of hardware & fixtures to be installed at site. Glazing beads shall be cut with mitered corners. Glazing clips, fixing devices etc. shall be supplied in adequate nos. Shop coats shall be properly applied. Exposed aluminium surface shall be free from scratches, stains and discoloration.
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3.2.7
ROLLING SHUTTERS/GRILLS After installing the shutters, the Bidder shall test the performance of the shutter in the presence of the engineer. The shutter shall be smoothly operable under all ambient conditions. All controls and locking devices shall give fault free performance.
3.2.8
FIRE PROOF DOORS Fire Proof doors shall be tested for the requirements mentioned in IS-3614 Part- I&II and The Technical Specification. The doors shall conform to TAC norms and shall have minimum 2 hours fire rating. DFT of paint of Fire Proof Doors shall be checked. The doors shall be finished with suitable fire retardant painting system. Materials used in glass and glazing shall conform to the requirements of the Technical Specification and IS Codes specified in the Technical Specification. All installation shall be free from cracked, broken or damaged glass, edges of large panes of thicker glass and heat insulating glass be inspected carefully for chipped, cracked or underground edges. Glazing shall be carefully done to avoid direct contact with metal frames. All glasses shall be embedded in mastic for steel works and fixed by neoprene gasket for aluminium works to give a leak proof installation. On completion, the panes shall be free from dirt, stains, excess putty etc. to the complete satisfaction of the engineer.
3.2.9
GLASS AND GLAZING
3.2.10 WATER PROOFING Water proofing shall be tested for water tightness by creating a pond of water minimum 25 mm height on area of 6 m x 6 m, for the period of 48 hrs on fully dried elastomeric membrane surfaces. Minimum 5% area of the roof shall be subjected to water tightness test. Such test necessarily be conducted on vulnerable areas like drain channel/ drain head. No dampness shall be visible on the underneath side of roof (i.e. ceiling), parapet and well junctions etc. which have been subjected for testing. The above testing shall be carried out prior to application of wearing course. 3.2.11 PAINTING & ALLIED WORKS. Various materials used shall conform and be tested for the requirements of Indian/International Codes specified in the Technical Specification. All painted surfaces shall be uniform and pleasing in appearance. Dry film thickness of each coat shall be checked and measured by using echo- meter. The thickness as measured shall not be less than the minimum thickness specified for the coat of paint under relevant clauses of the technical specification. Colour, texture shall match exactly with the approved sample
3.3 3.3.1
CONSTRUCTION TOLERANCE AND ACCEPTANCE CRITERIA Excavation and Filling Tolerance Finished surface level shall be within 20mm of the level shown in the drawing. Acceptance Criteria
Following acceptance criteria shall be followed. o o o o When only one set of sample is tested, then all individual samples collected and tested should pass without any deviation For retest of any sample two additional samples shall be collected and tested, and both should pass without any deviation. Where a large number of samples are tested for a particular test then 9 samples out of every 10 consecutive samples tested shall meet the specification requirement. Tolerance on finished levels for important filling areas at approved interval shall be + 20mm. However, for an unimportant area, tolerance upto +75mm shall be acceptable at the discretion of the Engineer. However, these tolerances shall be applicable for localised areas only.
3.3.2
Cast-in-situ concrete and Allied works Tolerances o Cast-in-situ concrete Unless otherwise specified, the tolerance in construction shall be as follows: The dimensions of concrete as cast when compared with those on the drawings shall be within the tolerance given below:
Description of Item/ Structural Element Faces of concrete in foundations and structural members against which back fill is placed Eccentricity of footing
Max +25
Min -10
2% of footing width in the direction of placement but limited to 50mm +5 +5 +5 +12 +1.5 +5 +10 +5 +1.5 +5 +10 -5 -5 -5 -6 -1.5 -5 -10 -5 0 -5 -10
Top surfaces of slabs and of concrete to receive base plates to 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). Level of embedment for equipment support Level of embedment for other embedded parts Centers of pockets or holes with greatest lateral
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Description of Item/ Structural Element dimension not exceeding 150mm Variation in steps Reinforcement Riser Tread
Max
Min
+1.5 +3.0
-1.5 -3.0
Tolerance on placing of reinforcement and for cover shall be as per clause 12.3 of IS: 456. Reinforcement shall be placed within the following tolerances: o o For effective depth 200 mm or less For effective depth more than 200 mm Tolerance for cover Actual concrete cover should not deviate from the required nominal cover by + 10 mm Formwork and staging o Staging shall be checked for its soundness as a whole and for adequacy of the joints and its foundations. Formwork joints shall be inspected for soundness of connections. All joints shall be either vertical or horizontal and shall be such as to avoid loss of liquid through the formwork. Dimensional tolerance for formwork shall be as per Clause 9.6 of IS : 14687 and 11.1 of IS : 456, which is reproduced as given below: Deviation from specified dimensions of : cross section of columns and beams Deviation from dimensions of footings Dimensions in plan: + 50mm : : - 12 mm +12mm - 6 mm 10mm 15mm
Eccentricity : 0.02 times the width of the footing in the direction of deviation but not more than 50 mm Thickness 0.05 times the specified thickness
The above tolerances apply to concrete dimensions only, and not to positioning of vertical reinforcing steel or dowels. o Checklist for formwork shall be as per Clause 9.9 of IS : 14687. Format as per Annexure-C of IS : 14687 shall necessarily be made for all important structures including all machine foundations.
3.3.3
Acceptance Criteria The acceptance criteria of concrete shall be in accordance with clause no.16 of IS: 456. However in exceptional circumstances, and that too in non-critical areas, the Engineer may accept concrete work which is marginally unacceptable as per the criteria laid down in IS: 456. For such accepted work, payment shall be made at a reduced rate pro rate to the concrete cube strength obtained, against that stipulated.
Unacceptable concrete work shall be dismantled by the Bidder and replaced by fresh work, meeting the specification requirements. In the course of dismantling, if any damage is done to the embedded items or adjacent structures, the same shall be made good, by the Bidder, to the satisfaction of the Engineer, at no extra cost to the Owner. Test shall be conducted for the water tightness of the liquid retaining structures as per IS: 3370 and IS: 6494. Tolerances o Fabrication tolerances All tolerances for below shall be as per approved drawings/ IS : 7215 maximum permissible gap in built up members maximum permissible deviation in depth and/or width of girder at the joints maximum permissible out-of-square of flanges in built-up girders (d)tolerances on length of beams and girders and their components (e)permissible deviation in column heights Erection tolerances All tolerances for below shall be as per approved drawings / IS : 12843 permissible tolerances in erected steel columns permissible tolerances in erected steel trusses permissible tolerances in crane girder and rails
3.3.4
Fabrication and Erection of Structural Steel Work
3.3.5
Acceptance Criteria The acceptance criteria of Non Destructive Testing (NDTs) on welds shall be as per AWS D1.1 (Dynamically Loaded Structures - tension welds). In case of failure of any of the tests, the Bidder at his own cost shall also carry out rectification of such defective welds. Retesting of the rectified joint, shall also be carried out by the Bidder at his own cost. Every 1st and further every 10th set of identical structure shall be checked for control assembly in shop before erection. Embedded part - The tolerances for embedded parts shall be as specified under concrete works. Tolerances o All masonry shall be built true and plumb within the tolerances prescribed as below. Care shall be taken to keep the perpends properly aligned. Unless specified otherwise the tolerances in construction of masonry works shall be as below: Deviation in verticality in total height of any 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 3m height. Deviation from the position shown on the plan of any brickwork more than one storey in height shall not exceed 12.5mm.
3.3.6
Brick Masonry & Allied works
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Relative displacement between load bearing walls in adjacent storeys intended to be in vertical alignment shall not exceed 6mm. Deviation of bed joint from horizontal in any length upto 12m shall not exceed 6mm, and in any length over 12m it shall not exceed 12.5mm total. Deviation from the specified thickness of bed-joints, cross-joints or perpends shall not exceed 3mm.
The plastered surface shall be checked for o Blistering, bond failure or loss of adhesion, cracking, crazing, efflorescence, grinning, irregularity of surface texture, popping or blowing, recurrent surface dampness, softness or chalkiness defects and the remedial measures for the same shall be adopted as per IS: 1661. 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 rounding of the corners at junctions of wall or in plastering of masonry cornices etc. shall be ignored.
o o
3.3.7
Acceptance Criteria Following acceptance criteria shall be followed: General workmanship is being good and as recommended by the manufacturer and approved by the Engineer. Tolerances are within the specified limit. Material test certificate is in compliance with the applicable codes/standards. Bought out material is from the approved manufacturer / vendor. Bought out material is matching with the approved sample.
3.3.8
Finishing & Allied works Tolerances o The floor finish shall be checked specially for the following: Level, slope, plumb as the case may be Pattern and symmetry Alignment of joints, dividing strips etc. Colour, texture Surface finish Thickness of joints Details of edges, junction etc. Performance Precautions specified for durability
Local depressions on account of faulty workmanship shall not be acceptable. Tiles /

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natural stones with cracked or broken/chipped edges shall not be acceptable. o The door, window, ventilator, partition during and after fitting and fixing etc shall be checked for the following: Installation shall be at correct locations, elevations and in general on a true vertical plane. Fixing details shall be strictly as shown on drawings. Assembly of composite units shall be strictly as per drawing, with mastic caulking at transoms and mullions, gaskets, weather strips etc. complete. All frames on external wall shall be mastic caulked to prevent leakage through joint between frames and masonry. All openable sections shall operate smoothly without jamming. Lock, fasteners, etc, shall engage positively. Keys shall be non-interchangeable. Cutting to concrete or masonry shall be made good and all abrasions to shop paint shall be touched up with paint or same quality as shop paint. Aluminium doors, windows, ventilators, partitions etc., shall be free from scratches, stains or discoloration. Door and window shutters shall operate without jamming. The clearance at head and jamb for door shutters shall not exceed 1.5 mm. For double leaf doors, the gap at the meeting stiles shall not be more than 2.5 mm.
3.3.9
FOR FALSE CEILING SYSTEM:Following shall be checked: As installed shall be true to shape, level. Correctness for the opening for the fixtures, colour and shade. All joints shall be in the same line and cross joints shall be securely fixed to walls. There shall not be any sagging and/ or unevenness in the surface
3.3.10 Acceptance criteria Ceiling panels shall be best quality material in thickness and properties called for in the specification /schedule of items. Material Test Certificate to be submitted before bulk supply. Finished ceiling shall be at the correct plane and prevent an aesthetically pleasing and uniform appearance, free from sags and warps. Joints and exposed grids shall be in true lines and symmetrically placed in manner as shown in drawings. Cut outs for light fixtures, diffusers and other relevant services shall be of exact dimensions and in exact locations.
3.4 3.4.1
WATER SUPPLY, DRAINAGE Tolerances All soil pipes, waste pipes, ventilating pipes and all other pipes, when above ground, shall be gas tight. All sewers and drain laid below ground shall be watertight.
Section 9
Page : 19 of 27
Obstruction / Straightness Test The obstructions shall be checked by inserting a smooth ball, of diameter 13 mm less than the pipe bore at the high end of the sewer or drain. If absence of any obstructions, such as yarn or mortar projecting through the joints, ball shall roll down the invert of the pipe and emerge at the lower end. The straightness shall be checked by means of a mirror at one end of the line and lamp at the other. If the pipeline is straight, the full circle of the light may be observed. The mirror will also indicate obstruction in the barrel, if the pipeline is not straight.
Service pipes testing with water The service pipes shall be slowly and carefully charged with water, allowing all air to escape avoiding all shock or water hammer. The service pipe shall then be inspected under working condition of pressure and flow, when all draw off taps are closed. The service pipes shall be checked for satisfactorily support and protection from damage corrosion and frost. Fixtures & fittings All fixtures and fittings shall be connected by watertight joints. No dripping of water.
3.4.2
Acceptance Criteria Following acceptance criteria shall be followed: General workmanship is being good and is recommend by the manufacturer and approved by the engineer. Tolerances are within the specified limit. Material test certificate is in compliance with the applicable IS Codes. Bought out material is from the approved manufacturer / vendor. Bought out material is matching with the approved sample.
3.5 3.5.1
SPECIAL ITEMS Vibration Isolation System (V. I. S.) Stiffness values shall be checked. The permissible deviations shall be as per DIN 2096. For accepting, following acceptance criteria shall be followed: General workmanship is being good and as recommended by the manufacturer and approved by the Engineer. Tolerances are within the specified limit. Material test certificate (M. T. C.) is in compliance with the applicable codes / standards. Bought out material is from the approved manufacturer / vendor. Bought out material is matching with the approved sample.
4.0
QA & I CO ORDINATION PROCEDURE It will be discussed between owner and bidder and finalized during Pre- award discussion.
Section 9
Page : 20 of 27
5.0 5.1
PUMPS, PIPES & VALVES Pumps All materials should be of tested quality and test certificates to be provided. DPT of machined shaft and impeller shall be done. Shaft forgings to be also subjected to ultrasonic testing. Impellers to be dynamically balanced to ISO 1940 Gr.6.3 All pressure parts shall be hydraulically tested at 150% of the shut-off head or 200% of rated head, whichever is higher for 30 minutes. No leakage is allowed. All pumps to be performance tested as per Hydraulic Institute Standard/Indian Standard. Performance test to include check for noise, vibration level and temperature rise.
5.2
Valves (a) Valves shall be tested as per relevant standards / codes. (b) Seat Leakage and hydraulic test to be carried out as per relevant standards / codes.
5.3
Pipes and Fittings Pipes and fittings shall be tested as per relevant standards / codes.
5.4
Structural Fabrication All raw materials shall conform to desired material grade as per requirement specified in Technical Specification and drawing. Only material which has been identified against mill sheet or test certificates shall be used for construction. All plate materials and various section used for fabrication shall be procured from well known steel makers. Bidder is not authorized to procure any material from SAIL authorized re-rollers without prior approval of owner. All sections procured shall have proper embossing of manufacturers monogram. Any sections which does not bear manufacturers monogram shall not be acceptable to Employer. The bidder shall produce necessary evidence like original challan and copy of Test Certificate duly authenticated and stamped by stock yard in support of the source of procurement of materials. Bidder shall produce either original Test Certificate or authenticated copy of Test Certificate for all plates material for verification. In absence of proper test certificate for plate material, sample will be selected as per guide lines indicated in the applicable Indian Standard. Ultrasonic test shall be carried out on all plates above 25mm thickness as per ASTM A 435 WPS and welders qualified as per ASME Sec IX shall be used for fabrication. Bidder shall established suitable facilities for storage, preservation, baking and holding of electrodes as per electrodes manufacturers guide lines. All welders employed for welding work shall be provided with suitable electrode holders with thermostat controlled heating arrangement so that temp of electrodes can be maintained above ambient condition to avoid moisture pick up.
Section 9
Page : 21 of 27
All electrodes and welding wires of approved make shall be used for fabrication and stored as per manufacturers recommendations All NDT tests shall be performed by operators qualified as per ASNT OR ISNT. To view the radiographic films at site, the Bidder shall install a film viewer at site. Edge preparation for welding Suitable edge as per weld joint details shall be prepared either by machines or by automatic gas cutting process. All edges cut by flame shall be ground before they are welded. Cleaning prior to welding All surfaces to be welded shall be free from oxide, paint, grease, and moisture. Oiled surface shall be degreased either chemically or with suitable solvent. Degreasing shall be followed by with wire brushing. In multi-run welds brushing shall be carried out after each layer of weld run. MS wire brush for mild steel welds and Stainless steel wire brushes for SS Welds shall be used. Pre-heating of plate thicker than 20 mm shall be carried out. However, requirement of pre-heating and post weld heat treatment of welded structure as required by approved WPS shall be followed. If PWHT any weld joint is specified in the manufacturing drawing /approved Gen. Assembly Drawing, the same shall be performed and WPS shall be qualified accordingly to meet the requirement of drawing. Assembly and Fit-up ALL assembly work shall be carried out using jig and fixture. Where jigging is not possible, Edges shall be kept in alignment by tack welds spaced at regular intervals. All tack welds shall be removed before final welding. When welding is carried out at site, additional precautions shall be taken by the Bidder to ensure that the welding environment is protected from wind and rain. NDT test on welds shall be carried out as per scope identified in the manufacturing drawing subject to a minimum check as specified below ;Fillet WeldCheck for size of welds. Visual inspection of all welds shall be performed in accordance with AWS D.1.1. Also filet welds for built up plate girders shall be inspected 100% by magnetic particle examination. Micro etch examination on production test coupons for main fillet welds with minimum one joint per built up beams, columns and crane girder etc. per welder shall be carried out.. 25% weld length of fillet weld of critical load bearing members shall be subjected to Dye Penetration Test. On all other fillet welds, Dye Penetration Test (DPT) on 5% of weld length with minimum 300mm at each location shall be carried out. Butt Welds: Visual inspection of all welds shall be performed in accordance with AWS D.1.1. Also butt welds for built up plate girders shall be inspected 100% by magnetic particle examination. DPT on all butt welds after back gouging Mechanical testing of production test coupons with minimum one joint per built up beam, column and crane girder etc per welder shall be carried out.
Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II Detailed Technical Specification Section 9 Page : 22 of 27
Radiographic examination shall be performed on butt welds. In case of failure of any welds in RT/UT, the %age for retesting shall be doubled at that particular location. If any further defect is observed in RT/UT in the repaired area and additional area being rechecked, then 100% of weld shall be examined by RT/UT. Acceptance criteria of NDT on welds shall be as per AWS D1.1. Edge preparations for field welding shall be examined by MT and Ultrasonic examination for 100mm depth All structure components/members shall be checked for dimensional tolerances during fabrication and erection as per IS-7215 and IS-12843 respectively. Surface preparation and painting Bidder shall submit their surface preparation and painting procedure for structure to owner for approval. DFT of paint and shade shall be as per specification and drawing. Motor Routine test of all motors as per applicable standard shall be carried out on all motors and type test Shall be carried out on one of each rating MCC Panel i) ii) iii) iv) v) vi) Short time withstand test.- Short circuit withstand test Temperature rise test without any diversity factors. Degree of protection test. Interchangeability of similar draw out type modules Functional tests HV and IR
Switchgear Panels i) ii) iii) iv) v) vi) vii) viii) Short time withstand test.- Short circuit withstand test Temperature rise test without any diversity factors. Degree of protection test. Functional tests Interchangeability for breaker panels of same rating in case of draw out type. HV and IR routine testing of breakers as per relevant BIS Verification of test certificates for meters, relays CTs, PTS etc
Power and Control Cables: - All type and sizes of cables shall be subjected to acceptance and routine tests as per relevant BS. Type test report carried out within the last 1 year shall be made available from a recognized test and subject to approval by the owner.
Section 9
Page : 23 of 27
ANNEXURE-9.1-MANUFACTURING QUALITY PLAN

MANUFACTURERS ADDRESS ITEM: SUB-SYSTEM: MANUFACTURING QUALITY PLAN QP NO: REV.NO. DATE: PAGE:.OF.
REFERENCE DOCUMENT 7 ACCEPTANCE NORMS 8
PROJECT : PACKAGE : CONTRACT NO.: MAIN-SUPPLIER:

INSPECTION AGENCY REMARKS M S **10 O 11
SL NO 1
COMPONENT / OPERATION 2
CATEGORY OF CHARACTERISTICS CHECK 3 4
CLASS OF CHECK 5
QUANTUM OF CHECK M S 6 O
FORMAT OF RECORD 9 D*
LEGEND:D* RECORDS IDENTIFIED WITH TICK () SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION. MANUFACTURER /SUB-SUPPLIER MAIN SUPPLIER Use the following term as appropriate in columns 10 above:- M, S & O ** M: MANUFACTURER / SUB-SUPPLIER S: MAIN SUPPLIER, O: OWNER P: PERFORM, V: VERIFICATION and CHP: Customer Hold Point to be witnessed and work shall not proceeded till it is witnessed and cleared. Ref: Legend Appendix-1 SIGN NAME
For Owners Use
SIGN NAME APPROVED BY SEAL
SIGNATURE, NAME, SEAL
REVIEWED BY
Section 9
Page : 24 of 27
JHABUA POWER LIMITED 1X600 MW+1x660MW JPL SEONI Project Specification for River Water Intake System
APPENDIX- 1 LEGEND FOR MANUFACTURING QUALITY PLAN (MQP) Manufacturers works name and address: In the column of Manufacturers works name and address Manufacturers works name and full address shall be indicated in QP". Item: In the column of Item /Sub System: a) Full name of the item for which QP is being prepared should be indicated along with the complete material, type, class, rating, range, size etc. or complete designation / description of the item or as recommended in the product specification. b) Sub system: Full name of Sub-system to be given with details. Column 2: Component and Operation should be indicated in sufficient detail including exact area and stage of processing, testing, delivery etc. Column 3: Following Characteristics of Check should be indicated, as applicable, visual, dimensional, hydraulic, chemical, mechanical, performance, ultrasonic, magnetic particle, dye penetrant, radiographic, polarization, index, high voltage, insulation resistance, etc. Column 4:
Under 'CLASS' each Check shall be classified as A, B & C.
Column 5: Type of Check shall indicate nature of check i.e. verification, strength, chemical analysis, NDT etc.
visual, measurement,
Column 6: 100% Check or sample basis specifying percentage sample to be checked. However the column "6" 'Quantum of Check' can be sub-divided into 2 or 3 columns to facilitate clarity for a particular set of Bidder / Sub-Bidder / Manufacturer. The quantum of Checks by manufacturer, Bidder and Owner shall be clearly indicated. Column 7: Plant standard, IS, DIN, BS, ASME, IEC or other national/international standards, statutory codes, drawings etc. as per which checks/tests shall be carried out shall be indicated. Column 8: Plant standard, design data, national/international standard or other acceptance norms shall be indicated. Column 9: Appropriate format/certificate on which test/inspection results recorded shall be indicated. Column 9 'D': Records shall be identified by OWNER with Tick [] marks shall be essentially included by Bidder in QA documentation. Column 10: Inspection Agency performing, reviewing or witnessing of tests/checks shall be indicated. Sub column M S O stand for Manufacturer / Sub-supplier, Main Supplier and Owner respectively. Under these sub columns P, V and CHP shall be indicated for Perform, Verification and Customer Hold Points respectively. Column 11: Remarks: Any specific remark shall be written here. (Attach additional Sheets, where required.)
Section 9
Page : 25 of 27
JHABUA POWER LIMITED 1x600 MW +1x660MW JPL SEONI Project Specification for River Water Intake System
ANNEXURE 9.2 FIELD QUALITY PLAN

SUB-BIDDERS NAME AND ADDRESS ITEM: SUB-SYSTEM:
SL NO ACTIVITY / OPERATION CHARACTERISTICS CLASS OF CHECK # TYPE OF CHECK QUANTUM OF CHECK
FIELD QUALITY PLAN QP NO: REV.NO. DATE: PAGE.of

REFERENCE DOCUMENT
PROJECT : PACKAGE : CONTRACT NO.: MAIN-BIDDER:

ACCEPTANC E NORMS FORMAT OF RECORD REMARKS
D*
10
MANUFACTU RER / SUBSUPPLIER Signature
MAIN SUPPLIER
Signature
Seal
Seal
LEGEND :1. D* RECORDS, IDENTIFIED WITH TICK() SHALL ESSENTIALLY BE INCLUDED BY SUPPLIER IN QA DOCUMENTATION 2. LEGEND TO BE USED FOR CLASS OF CHECK #: A, B & C A shall be witnessed by Owner FQA and Executing Dept, Surveillance by Head (FQA) B shall be witnessed by Owner Executing Dept and Surveillance by FQA C shall be witnessed by Bidder FQA and OWNER Executing Dept and Surveillance by OWNERs Authorized Engineer. A,B &C shall be Owner CHP stage CHP: Customer Hold Point to be witnessed and work shall not proceeded till it is witnessed and cleared. ABBREVIATION used for format of record: - FQA=Field Quality Assurance, OWNER=JPL Group, SR=Site Register, TR=Test Report, TC=Manufacturers Test Certificate, LR=Lab Report, LB=Long Box. Ref: Legend Appendix -2
Signature Name
For Owners use Signature Name Approved by Name Seal
Reviewed by Sign
Section 9
Page : 26 of 27
JHABUA POWER LIMITED 1X600 MW+1x660 MW JPL SEONI Project Specification for River Water Intake System
APPENDIX- 2 - LEGEND FOR FIELD QUALITY PLAN - FQP Bidder name and address: Name and full address of Bidder shall be indicated in FQP" a) Item: In the column of Item(title):Full name of the item for which FQP is being prepared should be indicated along with the complete material, type, class, rating, range, size etc. or complete designation / description of the item or as recommended in the product specification. b) Sub-system name of Sub-system with required details. Column 2: ACTIVITY: - Name of components/ equipment / system and operations like Site Receipts Inspection, Storage, Handling, pre-Erection and Erection shall be indicated. However the column '2' & '3" can be merged or divided to facilitate clarity for a particular set of Bidder / Sub-Bidder /Manufacturer. Column 3: Characteristics: Following characteristics of activity should be indicated, as applicable, visual, dimensional, leveling, alignment, hydraulic, chemical, mechanical, performance, ultrasonic, magnetic, particle, dye penetrant, radiographic, polarization index, high voltage, insulation resistance, etc. along with the item on which the these are performed and Instruments used for checking shall be indicated . Column 4: Each Check shall be classified as A, B or C depending upon its criticality in over all integrity of the equipment Surveillance By Owner Head, FQA (Nominated FQA Agency) FQA Engineer (Nominated FQA Agency) Any other Engineer authorized by Head of the Project / Station (VP)
Classification / Categorization Category A
Witnessing & Accepting Authority FQA Engineer (or Nominated FQA Agency), in association with Engineer of Executing Department (nominated by HOD at Site) Engineer of Executing Department (nominated by HOD at Site) Bidders Field Quality Engineer and Engineer of Executing Department (nominated by HOD at Site)
Category B Category C
Checks clarified as: A, B & C shall be Owner CHP stage. Column 5: Type of Check shall indicate nature of check i.e. visual, measurement, verification, strength, chemical analysis, NDT etc. Column 6: 100% Check or sample basis specifying percentage sample to be checked. In case check has to be performed periodically frequency of testing to be indicated. However the column "6" 'Quantum of Check' can be sub-divided into 2 or 3 columns to facilitate clarity for a particular set of Bidder / Sub-Bidder /Manufacturer. Column 7: Plant standard, IS, DIN, BS, ASME, IEC or other national/ international standards, statutory codes, drawings etc. as per which checks/tests shall be carried out and their acceptance norms shall be indicated. Column 8: Plant standard, design data, national/international standard or other acceptance norm shall be indicated. Column 9: Appropriate format/certificate on which test/inspection results recorded shall be indicated. Column 9 'D': Records shall be identified by Owner with Tick marks (3) shall be essentially included by Bidder in QA documentation. Column 10: in case of witness by Owner term "AHP" shall be used against the specified tests/stage by Owner in remark column. Any specific remark shall be written here.
Section 9
Page : 27 of 27
SECTION - 10 LIST OF MANDATORY SPARES
Section - 10 List of Mandatory Spares
Page : 1 of 6
SECTION 10 LIST OF MANDATORY SPARES A. MECHANICAL Sr. No. 1.0 a) b) c) d) e) f) g) h) i) j) k) l) m) n) 2.0 a) b) c) d) 3.0 Description Pumps (Each type of pumps) Impeller (with nuts & other accessories) Impeller shaft Shaft Sleeve Suction Bell Bowl Assembly (including impeller, pump shaft & bearings) Gland Assembly Fasteners Wearing rings (impeller, casing) Shaft bearing (line, head, impeller) Thrust bearing Line shaft and head shaft coupling Other couplings Expansion joint complete with fittings, fasteners etc. Gaskets, O rings for pump & motor assembly Valves Set of gland packings as applicable Set of bearings Set of rubber seals Set of complete motor operator & complete actuator assembly for electrical actuators EOT CRANE AND HOIST The Bidder shall include and quote for following mandatory spares. Bidder to note that one set refers to 100 % requirement of each crane and hoist (spares as applicable). Spares for Long Travel Unit Set of Axle Bearings Set of Gearbox bearings with sleeves Long Travel end shaft bearings Coupling Seals for Travel Gear box Long Travel Brake shoes lining Spares for Cross Travel Unit Axle Bearings Set of Gearbox bearings with sleeves Set of seals for Gearbox Cross travel end shaft bearing Coupling Cross travel brake shoes lining Spares for Main Hoist Main Hoist Pulley Bearings Set of Bearings for Gear box Set of seals for Main Hoist Main Hoist Brake Shoes Quantity 1 Set 1 set 2 sets 1 set 1 set 2 sets 2 sets 2 sets 2 sets 2 sets 1 set 1 set 1 set 2 sets 4 sets 1 set 2 sets 1 no. for each size
3.1 a b c d e f 3.2 a b c d e f 3.3 a b c d
1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set
Section - 10 List of Mandatory Spares Page : 2 of 6
Sr. No. e f B. Sl. No. 1.
Description Main Hoist Brake Springs Main Hoist Brake shoe liners
Quantity 1 set 1 set
ELECTRICAL Description 11 kV Switchgear a) Spring charging motor b) Power contact set c) Aux. Contact set d) Limit switches e) Charging spring f) Closing coil Unit Nos Set Set Nos Nos Nos Nos Nos Nos Quantity 2 2 2 2 2 2 2 2 3 of each rating
g) Tripping coil h) Aux. relay i) 2. Fuses
415V MCC a. 415V breaker a. b. c. d. e. f. g. h. i. Spring charging motor Power contact set Aux. Contact set Limit switches Charging spring Closing coil Tripping coil Aux. relay Fuses Nos Set Set Nos Nos Nos Nos Nos Nos Nos. Nos. 5 5 5 2 2 2 2 2 2 2 2 3 of each rating 2 Nos. of each rating
b. Bi-metal thermal overload relays with single phase preventor of each rating c. Fuses of each rating - Power - Control d. Push button 3. HT Motor of each rating a) Bearings 4. LT Motor of each rating a) Bearings 5. Battery Chargers a) Contactors of each type
Nos.
Set
Set
Nos.
Page : 3 of 6
Sl. No. b) c) d) e) f) 6.
Description Fuses of each type & rating Filter chokes Filter Capacitors Filter condenser Auxiliary relay
Unit Nos. Set Set Sets Nos.
Quantity 2 1 1 2 2 Nos. of each type
UPS System a) b) c) d) e) f) Contactors of each type Fuses of each type & rating Filter chokes Filter Capacitors Filter condenser Auxiliary relay Nos. Nos. Set Set Sets Nos. 2 2 1 1 2 2 Nos. of each type
7.
EOT Crane: Control Panels a) Power contactors of each rating b) Time delay relays c) Auxiliary relays of each type d) Over load relays e) Power Fuses of each rating f) Control fuses Set Nos. Nos. Set Set Set Two 2 Nos. 2 Nos. Two Two Two As required
g) Spares for VVVF Control for each rating
Page : 4 of 6
C. Sl.No. 1 a. b. c. d. e. 2 a. b. c. d. e. f. g. h. i. j. k. 3 a. b.
CONTROL & INSTRUMENTATION Description Field Instruments Ultrasonic Level Transmitter with sensor Electronic Transmitter for Electromagnetic Flowmeter Bearing and Winding RTDs (NDE and DE) Pressure Transmitter Level Switches and other field instruments Control System Control Processors Electronic modules including all I/O cards used in the control system Power supply modules, power packs Network Components including switches, repeaters, hubs, bus couplers and other interface equipment Pre fabricated cable and cable connectors of each type. Ventilation/Cooling fans for control system cabinets Internal wiring and other cables Indicating Lamp Push Buttons (ILPBs) Hardwired Annunciator Windows Relays Fuses & MCBs Accessories Ribbon Head Nos. Nos. 1 No. 1 No. Unit Nos. Nos. No. Nos. % Data 1 No. 1 No. 1 No. of each type and range 1 No. 10% or 1 Nos. (min.) of each type and range.
Nos. Nos. Nos. Nos. % Nos. % Nos. Nos. Nos. %
1 No. 2 nos. of each type and model 2 nos. of each type and model 1 Nos of each type and model. 20% of each type and length 2 nos. of each type and model. 5% of each type, pair and size of actual installed quantity. 2 nos. of each rating. 3 Nos. 2 Nos. of each type and model. 20 % of each type and rating.
4. a. b. c. 4 a. b. c. d.
Cables Instrumentation cables Cable glands Pre fabricated cable and cable connectors of each type. Vibration Monitoring System Vibration Transducer/sensor with Transmitter All electronic modules, PCBs and other signal conditioning equipment Signal cables, pre fabricated cable and special cables Pre Fabricated cable and cable connectors of each type Nos. Nos. % % 2 No. of Each type and Length. 2 No. of each type and model 20% of each type and length 20% of each type and length
Section - 10 List of Mandatory Spares Page : 5 of 6
10% of each type whichever is higher 10% of each type and size whichever is higher % 10% quantity of each type and length
Sl.No. e. f. g. h.
Description Internal wiring and other cables Power Supply modules Fuses MCBs
Unit % Nos. % %
Data 5% of each type, pair and size of actual installed quantity. 2 no. of each type 25% of each type and rating. 20% of each type and rating
5.
Reverse Rotation Sensor including probes and cables
No.
1 No. of Each type
Page : 6 of 6

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JHABUA POWER LIMITED 1 X 600+1 x 660MW JPL SEONI Project Specification for River Water Intake System

Doc.No.3109142MESPC108-001-Rev 0 Volume II Technical Specification

Page 1 of 1 Separator Sheet

QUALITY ASSURANCE PROGRAMME ... 27 LIST OF MANDATORY SPARES ............................................... 5

Doc.No.3109142MESPC108-001 Rev 0 Volume IITechnical Specification Table of Contents

VOLUME II SECTION - 1 GENERAL TECHNICAL SPECIFICATION

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

Electrical Works comprising the following shall be provided

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

General Technical Specification

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

Erection & Commissioning Spares

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

9.0.0 9.1.0 9.1.1

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

10.0.0 10.1.0 10.1.1

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

10.2.0 10.2.1 10.2.2 10.2.3 10.2.4

10.2.5 10.2.6 10.2.7 10.2.8 10.3.0 10.3.1 10.3.2 10.3.3

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

11.9.15 11.9.16 11.9.17

11.9.19 11.9.20 11.9.21

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

11.9.22 11.9.23 11.9.25

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II - Technical Specification

General Technical Specification

VOLUME II SECTION - 2 DETAILED TECHNICAL SPECIFICATION CIVIL WORKS

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II Detailed Technical Specification Civil works

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II Detailed Technical Specification Civil works

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II Detailed Technical Specification

Scope of Work & Design Requirements

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II Detailed Technical Specification

Scope of Work & Design Requirements

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II Detailed Technical Specification

Scope of Work & Design Requirements

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II Detailed Technical Specification

IS:3067 SP:6 SP:7 SP:16 SP:20 SP:22

Doc. No. 3109142-ME-SPC-108-001-Rev 0 Volume II Detailed Technical Specification