Chimney Bid Document

7/25/2019 Chimney Bid Document

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OWNER :M/s. NIRMA LIMITED

Subject Doc. No. Rev.

TENDER SPECIFICATION FOR RCC MULTI FLUE

CHIMNEY 4150954000725 0

PROJECT:70

MW

COGENERATION

POWER

PLANT

VILLAGE : KALATALAV,BHAVNAGARDISTRICT,GUJARAT

OWNER : M/s.NIRMALIMITED

TENDERDOCUMENT

FOR

DESIGNANDCONSTRUCTIONOFRCCCHIMNEY

121MHEIGHTWITHTHREEBRICKFLUES

CONTROLLEDCOPY UN-CONTROLLEDCOPY

AVANTGARDE ENGINEERS

AND CONSULTANTS (P) LTD.

68A, PORUR KUNDRATHUR HIGH ROAD,

PORUR, CHENNAI 810 116.

PHONE : 24828717, 18, 19, 20,

24827843,24828532,

FAX : 91 44 24828531

EMAIL : [email protected];

WEBSITE : www.avantgardeindia.com

PREPARED CHECKED APPROVED

R.C.S S.V S.V

DOC. No. 4150954000725No. OF

SHEETS

222REV. NO.

00DATE

24.12.2015


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CONTENTS

SECTION DESCRIPTION

A1

A2

A3

TENDER NOTICE

NOTICE INVITING TENDER

TENDER FORM

B INSTRUCTIONS TO THE BIDDER

C ARTICLES OF AGREEMENT

D SPECIAL CONDITIONS OF CONTRACT

E SCOPE OF WORK

F PROJECT INFORMATION

G1

G2

G3

G4

RCC CHIMNEY TECHNICAL SPECIFICATION

RCC CHIMNEY ELECTRICAL AND INSTRUMENTATION SPECIFICATION

PILE SPECIFICATION

GENERAL SPECIFICATION FOR CIVIL WORKS

H1

H2

H3

H4

GENERAL NOTES FOR PRICE SCHEDULE

LUMPSUM BIDDING SCHEDULE

PAYMENT TERMS

MISCELLANEOUS UNIT PRICE SCHEDULE

I

J1

J2

J3

J4

J5

J6

BID DRAWINGS

SCHEDULE OF DEVIATION FROM TECHNICAL SPECIFICATION.

SCHEDULE OF DEVIATION FROM SPECIAL CONDITIONS

SCHEDULE OF PRICE IMPLICATIONS ON ACCOUNT OF DEVIATION

SCHEDULE OF CEMENT

SCHEDULE OF REINFORCEMENT

SCHEDULE OF TECHNICAL STAFFS


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J7

J8

J9

SCHEDULE OF EQUIPMENTS

SCHEDULE OF RATES FOR LABOUR

SCHEDULE OF BIDDERS EXPERIENCE

K SOIL INVESTIGATION REPORT


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SECTIONA1

TENDER NOTICE

1.0Sealed offers are invited by M/s. Avant Garde Engineers and Consultants (P) Limited for theproposed design and construction of RCC Chimney 121 M Height with three brick flues for

M/s.NirmaLimited

a)Location of Site : M/s. Nirma Limited, Chemical Complex,Village : Kalatalav, Tal : Bhavnagar,Dist. Bhavnagar 364 313.

b)Time of Completion : 13 months

c) Tender Document :

Attached

d)Last Date forSubmission

: 5.01.2016

e)Validity Time :

Tender shall be valid for acceptance till

60 days from the date of opening.

2.0 One original copy of the un-priced technical bid shall be addressed to Mr. Ajay Kalani ofthe PURCHASER at the Head Office address as below. Also the soft copy of the un-

priced offer shall be sent to the E-Mail ids : [email protected] [email protected]

3.0 One copy of the un-priced technical bid shall be addressed Mr. D. G. Jakhade of thePURCHASER at the Site Office address given below. Also the soft copy of the un-pricedtechnical bid offer shall be sent by E-Mail to Mr. Hirenbhai Patel, Mr. G. J. Adroja, Mr. L.M. Mavani & Mr. D. R. Patel of Nirma Limited in the E-Mail ids as follows:[email protected], [email protected], [email protected] &[email protected].

4.0 One original copy of the price bid with price details shall be addressed only toMr.Hirenbhai Patel, MD of the PURCHASER at the Head Office address given in theProject Information. Also the soft copy of the price bid with price details shall be sent by

E-Mail, only to Mr. Hirenbhai Patel in the e-mail id [email protected]. If anyBIDDER sends the commercial price bid to any other address / e-mail id, other than toMr. Hirenbhai Patel, their bid will be rejected without seeking any clarifications.

OWNER / PURCHASER : M/s. Nirma Limited

CONSULTANT : M/s. Avant-Garde Engineers andConsultant (P) Ltd.,

PROJECT : 70 MW Cogeneration Power Plant


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Owner address

a. Mr. Ajay Kalani, Sr. Manager - ProjectM/s. Nirma Limited,Nirma house, Ashram Road, Ahmedabad -380 009.Mobile no. +91 9978984151, Tel : 079-27549217E-Mail : [email protected] & [email protected]

b. Shri. Hirenbhai Patel, MDM/s. Nirma Limited,E-Mail : [email protected]

c. Mr. G. J. Adroja, Vice presidentM/s. Saurastra chemicals (Division of Nirma ltd),Birlasagar, Porbandar - 360576

Tel: 0286-2242479-80-81Email: [email protected]

d. Mr. D. G. Jakhade,M/s. Nirma Limited, Kalatalav, Bhavnagar.Tel : 0278-2885314, 2885301-2-3-4.E-Mail : [email protected]

e. Mr. L. M. Mavani,M/s. Nirma Limited, Kalatalav, Bhavnagar.Tel : 0278-2885314, 2885301-2-3-4.E-Mail : [email protected]

f. Mr. D. R. Patel, Technical Services,M/s. Nirma Limited, Chemical Complex,Village : Kalatalav, Tal : Bhavnagar,Dist. Bhavnagar 364 313.Tel : 0278-2885314, 2885301-2-3-4.E-Mail : [email protected]

One copy of only the un-priced technical bid shall be addressed to CONSULTANTat the address given below. Also the soft copy of the un-priced offer shall be sent byE- Mail.

Consultant address

Mr. S. Sivakumar / Mr. N. Thilagar lingam,M/s. Avant-Garde Engineers and Consultants (P) Limited,68-A, Porur - Kundrathur High Road, Porur, Chennai 600 116.Tel : 044-24828717 22, fax : 044-24828531E-mails : [email protected] Mobile No.: 0 98400 40600

[email protected] Mobile No.: 0 99403 65555


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SECTIONA2

NOTICEINVITING

TENDER

1.0 Tenders in the prescribed form are hereby invited on behalf of M/s. Nirma Limited for

design and construction of RCC chimney 121 M Height with three brick flues for their

Cogenerationplant.

2.0 Documents Comprising the Bid

2.1 The bid shall comprise of the following:

a) Completed Bid Form and with Complete technical details in accordance with

the requirements of this tender document.

b) Documentary evidence established to the requirements of the relevant Clause

that you are qualified to perform the contract if the Bid is accepted.

2.2 The prepared Bid shall be in two (2) parts.

Part I Technical & Unpriced Commercial Bid

Part II Price Bid

2.3 PART I TECHNICAL & UNPRICED COMMERCIAL BID

2.3.1 Technical Bid shall include / indicate the following to the extent applicable:

a) Confirmation that the goods and ancillary services to be supplied by youconform to the Bidding Documents.

b) Complete scope of supply supported by documents, brochures, standards,

catalogue etc. as applicable.

c) Layout drawings and sketches with dimensions of equipment and indication

of limits of supply

d) BIDDER shall obtain prior approval for the manufacturers proposed for every

equipment / item and materials, which is not of his own manufacture and

establish that the BIDDERis duly authorised by the manufacturer to supply such

goods in India. The subvendor's written confirmation that he will supply the

spares for the items of his manufacture direct to site,if and when such a request

is made shall be enclosed.

e) Nature of maintenance assistance available / offered.

f) Planning for Construction.

g) Delivery Schedule and Place of manufacture / delivery.


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h) Manufacturing schedule with brief statements of the activities and time

estimation leading to quoted delivery separately for each category of

material.

i) Reference list of customers using similar equipment and materials.

j) Information on shipping weights and cubage (length, width and height) with

special attention to heavy and oversize packages.

k) Statement regarding expiry date of labour contracts at the BIDDER's

manufacturing works.

l) Current certified financial statements and organization chart.

m) Deviation from the specifications (technical conditions), if any.

n) Confirmation on acceptance of part order;

o) Country of origin of goods and services.

For the purpose of this clause origin" means the place where the goods were

produced, or from which the services are supplied. Goods are produced when,

through manufacturing, processing or substantial and major assembling of the

components, a commercially recognized new product results that is substantially

different in basic characteristics or in purpose or utility from its components.

The origin of goods and services is different from the nationality of the supplier.

2.4 PART II PRICE BID

Should cover the Bid price and other related costs


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SECTION-A3

TENDERFORM

TO

Shri. Hirenbhai Patel, MDM/s. Nirma Limited,

Nirma House, Ashram Road,

Ahmedabad, Gujarat 380 009E-Mail : [email protected]

I/We have read and examined the following documents relating to the design and construction

of RCC chimney 121 M Height with three brick flues to M/s. Nirma Limited for their

Cogeneration Plant.

A1

A2

A3

TENDER NOTICE

NOTICE INVITING TENDER

TENDER FORM

B INSTRUCTIONS TO THE BIDDER

C ARTICLES OF AGREEMENT

D SPECIAL CONDITIONS OF CONTRACT

E SCOPE OF WORK

F PROJECT INFORMATION

G1

G2

G3

G4

RCC CHIMNEY TECHNICAL SPECIFICATION

RCC CHIMNEY ELECTRICAL AND INSTRUMENTATION SPECIFICATION

PILE SPECIFICATION

GENERAL SPECIFICATION FOR CIVIL WORKS

H1

H2

H3

H4

GENERAL NOTES FOR PRICE SCHEDULE

LUMPSUM BIDDING SCHEDULE

PAYMENT TERMS

MISCELLANEOUS UNIT PRICE SCHEDULE


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I

J1

J2

J3

J4

J5

J6

J7

J8

J9

BID DRAWINGS

SCHEDULE OF DEVIATION FROM TECHNICAL SPECIFICATION.

SCHEDULE OF DEVIATION FROM SPECIAL CONDITIONS

SCHEDULE OF PRICE IMPLICATIONS ON ACCOUNT OF DEVIATION

SCHEDULE OF CEMENT

SCHEDULE OF REINFORCEMENT

SCHEDULE OF TECHNICAL STAFFS

SCHEDULE OF EQUIPMENTS

SCHEDULE OF RATES FOR LABOUR

SCHEDULE OF BIDDERS EXPERIENCE

K SOIL INVESTIGATION REPORT

I / We have inspected, examined the site and its surroundings and have satisfied

myself / ourselves before submitting the tender as to the nature of ground and

subsoil, the form, nature and means of access to the site.

I / We hereby tender for the execution of the works referred to in the aforesaid

documents upon the terms and conditions contained or referred to therein and in

accordance in all respects with the specifications, and within the period of

completion as stipulated in the SectionA1.

In consideration of I / We being invited to tender, I / We agree to keep the tender

upon for acceptance for a period of 60daysfrom the due date of submission thereof

and not to make any modifications in its terms and conditions which are not

acceptable to the employer.

If, after the tender is accepted, I / We fail to commence the execution of the works as

provided in the conditions, I / We agree that the Employer shall without prejudice to

any of their right or remedy, be at liberty to forfeit the contract.


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Signature...................

In the capacity of...........

Witness................ Duly authorised to sign

the Tender on behalf of:

Date ...........................

..................................................

Address...................(In Block Letters)

Date..........................

Postal Address...........................

Telephone No.................


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SECTION B

INSTRUCTIONS TO THE BIDDER

1.0 INFORMATION FURNISHED

1.1 This specification is intended as a general description of quality envisaged formaterial, workmanship and of the finished work apart from the basic guideline forthe design. It is not intended to cover minute details. The work shall be executedin accordance with the best modern practice and to the complete satisfaction ofOwner .Special techniques approved by Engineer shall be used if and where foundnecessary.

1.2 The information given in this specification is in good faith and meant to serve as aguide to the Bidder. It is, therefore, imperative that Bidder shall obtain and examine

for himself all the data, information and particulars required for the satisfactoryexecution of the work under this enquiry. The submission of a bid by Bidder impliesthat he has fully read the specifications, bid drawing, and general conditions ofcontract. Bidder shall make himself aware of the scope and the specifications for thework to be performed and local conditions and other features which have abearing on the cost and execution of the work. Extra charges for any reasonwhatsoever will not be entertained by Owner

.1.3 General Notes (given in Section-H1) shall also be noted before quoting rates

against various items in Section H4 or for the Lumpsum price in Section -H2

1.4 In case of any conflict among clauses of different technical specifications givenunder Section-G, the decision of the Owner/Engineer shall be final and binding on theContractor.

2.0 INSPECTION OF SITE BY BIDDER

2.1 Bidder shall inspect the site, examine and obtain all information required andsatisfy himself regarding matters such as access to site, communication,transport, right of way, the type and number of equipment and facilities required forthe satisfactory completion of work, the quantity of various items of the work, theavailability of local labour, availability and rates of material, local working conditions,uncertainties of weather, obstructions and hindrances that may arise, etc., which mayaffect the work or cost thereof, before submission of his Bid. Ignorance of siteconditions shall not be accepted by the Owner as basis for any claim for

compensation. The submission of a bid by the Bidder will be construed as evidencethat such an examination was made and any later claims/ disputes in regard to ratesquoted shall not be entertained or considered by the Owner.

2.2 The rates quoted by Bidder shall be based on his own knowledge and judgement ofthe conditions and hazards involved and shall not be based on any representations ofthe Engineer.


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3.0 VALIDITY OF BID

The Bid shall remain valid for acceptance for 60 daysfrom the due date of receipt ofthe Bids and during this period no bidder shall be allowed to withdraw the bid.

4.0 ACKNOWLEDGEMENT

On receipt of bidding document, bidder shall acknowledge the receipt andconfirm his intention to bid for the work. Any addendum issued by Owner/Consultant shall become part of bidding document and bidder shall submitOriginal addendum duly signed and stamped as a token of his acceptance.

5.0 MATERIAL SUPPLY AND FACILITIES BY THE OWNER

5.1 The Owner will provide the following facilities to the Contractor free of cost.

(a) Provision of one permanent benchmark and base line for laying out.

(b) Construction water at one point.

5.2 Construction power at one point will be provided by owner on chargeable basis.

6.0 INFORMATION TO BE SUBMITTED ALONG WITH TENDER

a. Types and details of formwork for wind shield construction proposed to be used.

b. Type of plant and equipment and instruments proposed to be used including theone for brick laying purpose- for construction, quality check etc.,

c. Proposal for lifting of men and material to various levels of the chimney duringconstruction.

d. General arrangement drawing of chimney as per contractors design with keydimensions, with volume of concrete& reinforcement steel.

e. The total number of specialist formwork and lifts available with the contractorpresently, where they are being deployed currently and when he expects to shiftthem to the site.

f. Bidder shall submit the complete particulars of similar jobs executed by him.

g. Within 10 days of the award of the Contract, the Contractor will submit a masterprogramme for completion of the work giving month wise requirement ofmaterials, particularly mentioning in details the materials which are to be suppliedby the Owner and for the procurement of which the help of the Owner is requiredas per the terms and conditions of the Contract.

h. Detailed day-to-day programme may have to be reviewed and updated by theContractor before the commencement of the work.


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7.0 BID DOCUMENTS

7.1 Under Section-I, list of the bid drawings enclosed is indicated. The drawings areintended to give the Bidder general idea of the type and extent of work involved. Assuch, they are indicative and for bid purpose only. Engineering design andconstruction drawings will be prepared by the contractor. Work shall proceed onlyafter approval of construction drawing by the Consultant/ Owner.

7.2 No alteration or mutilation, other than filling in particulars wherever called for, shallbe made in the bid documents. Any changes/modifications made by the Bidder onthe bid documents itself shall not be taken into consideration.

7.3 In case of conflict regarding interpretation of the intent or meaning of thespecification or drawing, the Engineer shall interpret such intent or meaning,which will be final and binding on the Contractor.

8.0 SUBMISSION OF BID

8.1 Procedure for Submission

The completed bids shall be submitted on or before the last date of submission5.1.2016

8.2 Bid shall be sealed and cover shall be super scribed

NIRMA LIMITED- K A L A T A L A V B H A V N A G A R70MW COGENERATION POWER PLANT

1 2 1 m H i g h M u l t i f l u e R C C C h i m n e y

8.5 Each page of the bid document including the bid drawings shall be signed anddated in ink by the Bidder as a token of having examined the same. English languageand metric units shall only be used. Any corrections in the rates entered in theSchedule of Quantities shall also be signed and dated by the Bidder in ink, beforesubmitting the bid. Non-compliance with these conditions will make the bid liable forrejection.

8.6 The bid prices and rates must be filled only in the Schedule of Quantities. Bidder shallalso fill in the schedule of deviations from technical specifications and specialconditions of contract. If these schedules of deviations are not filled up, it shall bedeemed that the bidder abides by the stipulations as in the bid documents.

8.7 Bid shall be accompanied by a covering letter, in which Bidder may furnish anyinformation, which he wishes to be considered along with the bid.

8.8 All accompaniments of the bid shall be in duplicate.

8.9 Bidder shall submit along with his bid an attested copy of Income Tax and Sales TaxClearance Certificates, audited balance sheet for the last three financial yearsand latest solvency certificate from the competent authorities.


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8.10 Details of concurrent commitments of bidder along with list of similar works

executed in last five years and list of Manpower and equipment to be deployed onthis project and schedule of execution to be furnished along with the bid.


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SECTIONC

ARTICLESOF

AGREEMENT

Made on this __________________ day of _______________ between M/s. Nirma Limited,

Bhavnagar, Gujarat (hereinafter called "the Owner") of the one part and

M/S._________________________________________ of (or whose registered office is situated

at)________________________________ (hereinafter called "the Contractor") of the other part

WHEREAS the Owner is desirous of DESIGN AND CONSTRUCTION OF RCC CHIMNEY

121 M HEIGHT WITH THREE BRICK FLUES at M/s. Nirma Limited for their

Cogeneration Plant, Gujarat hereinafter called "the Work") and has caused

specification showing and describing the work to be done to be prepared by or under

the direction of ____________________________________________________________

AND WHEREAS the Contractor has supplied the Owner with a fully priced copy of

the said Bills of Quantities (which copy is hereinafter referred to as "the Contract

Bills") in line with his own engineering design and drawings as per the general

guidance of the technical requirements specified by the consultant/owner AND

WHEREAS the said Drawings (hereinafter referred to as "The Contract Drawings")

and the Contract Bills have been signed by or on behalf of the parties hereto with

the consultant/owner for the due performance of this Agreement.

NOW IT IS HEREBY AS FOLLOWS:

1. For the consideration hereinafter mentioned the Contractor will upon and subject to

the Conditions annexed carry out & complete the work shown upon the Contract

Drawings & described by or referred to in the Contract Bills and in the said

Conditions.

2. The Owner will pay the Contractor the sum of Indian

Rupees________________________________________ (Indian Rs ) (hereinafter

referred to as "the Contract Sum") or such other sum as shall become payable

hereunder at the times and in the manner specified in the said Conditions.

3. The term "the Consultant in the said Conditions shall mean the said ________or inthe event of his death or ceasing to be the Consultant for the purpose of this

Contract, such other person as the Owner shall nominate for that purpose, not

being a person to whom the Contractor shall object for reasons considered to be

sufficient by and arbitrator appointed in accordance with the said Conditions.

Provided always that no person subsequently appointed to be the Consultant

under this Contract shall be entitled to disregard or overrule any certificate or

opinion or decision or approval or instruction given or expressed by the

Consultant for the time being.


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4. The said condition and appendix thereto shall be read and constructed asforming part of this Agreement, and the parties hereto shall respectively abide by,

submit themselves to the Conditions and perform the agreements on their parts

respectively in such Conditions contained.

AS WITNESS our hands this day of 2016

Signed by the said

in the presence of Owner

Witness

Name :

Address:

Signed by the saidIn the presence of Contractor

Witness

Name :

Address:


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SECTION D SPECIAL CONDITIONS OF CONTRACT

1.0 PRICES AND RATES

1.1 Prices and rates quoted shall include cost of all materials , labour, supervision,setting out, machinery and equipment, transport charges, wastage of material, allconsumables such as, but not limited to petrol, oil, diesel, lubricants, drill bits,pipes, ropes, etc., construction facilities such as scaffolding, cribbing, tarpaulins, windbreak, etc., taxes, duties, royalties, octroi and any other levies payable on alltransactions, all leads and lifts, etc., overheads/profits of Contractor for dueperformance of the work under this contract. The prices & rates shall also includecost for mobilization/demobilization of equipment.

1.2 Prices and rates quoted shall be deemed to include everything necessary tosatisfactorily complete the work as determined by the Engineer though they may not

have been specifically referred to in these documents.

1.3 Prices and rates quoted shall be firm for the entire duration of the contract and anyagreed extensions thereafter.

1.4 The p r i c e s a n d rates quoted by bidder shall remain unaltered for the use ofany type of cement such as pozzolana, ordinary Portland, sulphate resisting, etc.

1.5 No price escalation on any account shall be allowed during the entire period ofContract.

1.6 The contract is on Lump sum turnkey basis and this lump sum price shall be filled upagainst section H2 Bidding schedule.

1.7 The payment terms suggested by owner are as per section H3.

1.8 Bidder shall also fill up the unit rate price schedule against section H4 taken now forany future addition/deletion of works. This unit rate should be reasonable and shall notbe considered by owner for bid analysis

2.0 PAYMENT

The mode of submission of bills and payment shall be as indicated below:

Contractor shall submit each of his running Account bills upon successful completionof respective milestone activities stipulated under section H3.

Payment for such RA bills will be released within 30 days from the date ofsubmission of bills. Certification of RA Bills will be done by the ConsultantsRepresentative /Owner representative in presence of Contractors Engineer. On thebasis of this certified bills payment will be released.

Final bill certificate along with work completion certificate will be issued within onemonth of completion of whole work on the project provided no defects are noticed in


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the work completed and the contractor had reconciliated when applicable to thesatisfaction of the Companys representative the cement, reinforcement steel and

structural steel and all such owner issued materials / facilities.

Income Tax at applicable rates will be deducted at source from all the payments andnecessary certificate will be issued as per prevailing Income Tax Act.

3.0 MOBILIZATION ADVANCE

A non-recoverable mobilization advance of 5% (Five percent) of the contract value willbe paid to the successful bidder on submission of an unconditional BankGuarantee for equivalent amount in the standard format given by the owner froma Nationalized bank. Mobilization advance will be paid only on completion ofmobilization at site and after the submission of Security deposit.

4.0 RETENTION MONEY

10% of the gross value of each RA bill shall be retained as retention money. Theretention money will be released only after satisfactory completion of all theworks and against a bank guarantee (from a Nationalized bank) of equivalentamount. This bank guarantee towards retention money shall be valid till completion ofdefects liability period of 18 months from date of commissioning of chimney.

5.0 TIME OF COMPLETION AND WORK SCHEDULE

5.1 Time is the essence of this contract. An ant ic ipat ed work sch edul e wit h tim eof completion is attached under Section E. The Contractor shall, within ten

days of receipt of the Letter of Intent submit to the Owner for his approval, adetailed work schedule showing how he proposes to carry out the work. Itshall specifically mention time period as well as dates of commencement andcompletion of each activity. Contractor must strictly adhere to the approved schedule.The Owner reserves the right to revise the schedule at his discretion in order to keepup to the completion date and to suit the project requirement and such alterationsshall not entitle the Contractor to any extra payment.

5.2 The whole works must be proceeded with, within such sections and at such times andin such order and manner as described in these specifications and as directed bythe Engineer. No extra payment or relaxation in the rates will be permitted on accountof this.

5.3 Contractor shall make all necessary arrangement at site to mobilize and maintain,machinery, equipment, labour, material and operators to guarantee suchminimum / peak rate of progress of the work as is required by the agreedschedule for the timely completion of the work,

5.4 The contractor shall make all arrangements for carrying out all possible constructionactivities to be taken up simultaneously. Costs for any special arrangement that hemakes towards this shall be included in his quoted price.


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5.5 Time is the strict essence of this Contract.So contractor to suggest and adopt after

approval by Avant Garde any means of expediting construction process , (like precast

RCC floors , working simultaneously for all flues construction in 2/3 levels by providingtemporary cut off platforms) but in any case keeping basic parameter of 3 nos Brick

flues unchanged. Quoted price will be inclusive of all costs towards such means.

5.6 The Contractor shall make his own arrangements for providing accommodation forall their staff and storage space for equipment and consumables such as but notlimited to petrol, diesel, lubricants, oxygen, acetylene, welding rods, etc., togetherwith sufficient quantity of spare parts for efficient and uninterrupted execution of thework. The Contractor shall furnish the engineer monthly report describing thesummary of the progress / milestones achieved on each of the major frontsduring the month accompanied with Photographs. Apart from it weekly work chartsshall be submitted.

5.7 Extension of contract period will not be granted by the owner except only underforce majeure conditions equal to the time, force majeure conditions were inexistence. Monsoon or inclement weather shall not be considered as a reason forextension of time.

5.8 Idle time charges for any reason whatsoever shall not be entertained by theowner.

6.0 NIGHT WORK

6.1 The time of completion as defined in clause herein above, shall be deemed toexclude working during night shifts. However, Engineer may consider grantingpermission for working during night shifts, if he considers it essential in order tocomplete the work in the stipulated time, on specific request by the Contractor.Where night work is in progress, the Contractor, at his cost, to safeguard theworkmen and the public shall provide sufficient lights, shall take suitable precautionsto prevent accidents. Accident-prone areas shall be barricaded and provided with redlights as caution to prevent accidental falls. Contractor shall take all necessaryprecaution to ensure the quality of work.

7.0 EQUIPMENT

7.1 Contractor shall provide and maintain at the site necessary number and type ofmachinery and equipment including survey instruments in good working condition forproper setting out and timely completion of the various works covered under this

specification. All arrangements for transporting the equipment, men and machinery, toand from the site shall be done by the Contractor at his own expense. No claim shallbe entertained for mobilizing additional equipment and/or personnel to complete thework within the stipulated time.

7.2 The Contractor shall ensure a continuous supply of coarse and fine aggregates andother materials conforming to the specification for the duration of the contract period.

7.3 Contractor shall provide all fuels and lubricants required for the operation andmaintenance of construction machinery and equipment as well as his transport


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vehicles.

7.4 Contractor shall ensure that work shall proceed uninterrupted even in the event ofpower failures. As such, adequate number of diesel operated machinery (such asconcrete mixers, vibrators, welding sets, etc.) shall be provided by the Contractor asan alternative arrangement in case electrically operated machinery are proposed tobe brought to site.

8.0 WORK EXECUTION AND SUPERVISION

8.1 Contractor shall have at the site adequate number of qualified engineers andsupervisors with experience in execution of similar type of works and also sufficientnumber of foremen and operators for machinery and equipment, for satisfactoryprogress and timely completion of the works. If Owner/Owner representative finds thecaliber /quantum of such deployed men lacking & insists on the contractor for

replacement / Replenishment, Contractor shall do it immediately at no extra cost toowner.

8.2 In the event of occurrence of any accident at/near the site of work or inconnection with execution of the work, a report shall be made immediately to theEngineer, giving full details of the accident. He shall also report such accidents to allthe competent authorities.

8.3 The Engineer reserves the right to order in writing from time to time duringprogress of the work, removal and re-execution of any work which is not, in theopinion of the Engineer, in accordance with the specification.

8.4 During inclement weather, rains, Contractor shall suspend grouting/ concreting for

such time as the Engineer may direct and shall protect from damage all works alreadyin progress or completed just then. All such temporary protective measures shall beat Contractor's cost and any damage to works shall be made good by the Contractorat his own expense.

8.5 Should the works be suspended by reason of strike/riots by Contractor's ownemployees or any other cause whatsoever, save and except the force majeurecondition, Contractor shall take all precautions necessary for the protection of workand make good, at his expense, any damage arising from any of these causes.

8.6 Owner reserves the right to split up the work mentioned in the scope of enquiryamong more than one Contractor at the stage of initial award of contract or duringprogress of work due to unsatisfactory progress of work at site by the Contractor.

Bidders quoted rates shall remain unaltered even if the work is split up. Owner willnot entertain any claim from the Contractor as a result of such splitting up.

9.0 SURVEYING AND LAYOUT

9.1 Only a base line and one permanent benchmark would be furnished to theContractor on site. Surveying and laying out of all works shall be done by theContractor at his cost. Contractor shall maintain without disturbance during thecourse of execution of the work the reference line and the benchmark. The


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Contractor shall also check the accuracy of positioning of the footings and anchorbolts for the structural to be erected by him. Any discrepancy shall immediately be

reported to the Owner.

10.0 CONTRACTOR'S RESPONSIBILITIES

10.1 The Contractor will be required to provide at his own cost all facilities for hisoffice, warehouse, tool room, change room or any other building/structurerequired to execute his work.

10.2 Each Contractor shall establish his own office / shed at specified place inside theplant. The office/shed shall have proper ventilation lighting and sanitary facilities. TheContractor shall obtain clearance from the Owner before construction of theoffice/shed.

10.3 All royalties shall be paid by the Contractor as also all tolls, local and other taxes, etc.at no extra cost to Owner.

10.4 All materials supplied by the Contractor shall be of the best quality and shallconform to this specification. Approval in writing shall be obtained from Ownerbefore any alternative or equivalent material is proposed to be used by theContractor.

10.5 Contractor shall furnish manufacturer's test certificates for the materials supplied byhim. Where such certificates are not available, the specimen of the material shall begot tested at a recognized testing laboratory (approved by Owner) at Contractor'scost.

10.6 Contractor shall obtain all necessary permits and licenses before commencement ofwork at no extra cost to Owner.

10.7 Contractor shall take all necessary insurance coverage as per the statutoryrequirement at no extra cost to Owner.

11.0 DEMOBILISATION

On completion of work, the Contractor shall promptly demobilise from the site andleave the place in a manner as directed by the Owner/Engineer, includingcleaning of the area. Contractor shall start demobilization only after thesuccessful completion of the contract with the permission of Owner.

12.0 OTHER WORKS

During the course of contractors works, other works either by the Owner or by otherContractors or by both simultaneously will be in progress within the project area.Contractor shall make his best effort to work in harmony with others in the best overallinterest of the project and towards its speedy completion.

13.0 SECURITY & SAFETY RULES OF OWNER


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13.1 All persons employed or allowed at the site shall at all times conform to allregulations laid down by the Owner.

13.2 Contractor shall strictly abide by the rules and regulations of security and safetyenforced by the Owner. Contractor shall provide proper identity cards, badges, etc.,to his employees whenever directed by the Owner.

13.3 Contractor shall be solely responsible for the security and safety of hispersonnel and equipment.

13.4 Contractor, his employees and agents shall not disclose any information ordrawing furnished to them by the Owner / Engineer. All drawings, reports or anyother information prepared by the Owner / Engineer / Contractor, either individuallyor jointly for the execution of the contract shall not be disclosed without priorwritten approval of the Owner. No photographs of the work or plant within the project

site shall be taken without prior written approval of the Owner.

13.5 Contractor shal l adopt all safety measures/provide necessary protection toalready constructed foundation/structures irrespective of the sequence ofconstruction.

14.0 PENALTY (Liquidated damages):

If the Contractor fails to maintain the stipulated time of completion specifiedunder clause 5.0 in this section, he shall be liable to pay penalty at the rate of 0.5 %per week of delay subject to a maximum of 5% of contract value. It shall be clearlyunderstood that failure to meet interim completion dates shall also attract penalty.

15.0 DRAWINGS AND DETAILS

15.1 The Contractor shall prepare fabrication drawings for structural steel works based onhis design drawings approved for construction by the Consultant / Owner.

16.0 OWNER RESERVES RIGHT

16.1 The Owner reserves the right to accept any bid irrespective of whether it is thelowest or otherwise or reject any or all bids without assigning any reasonswhatsoever. Owner reserves the right to split the work and/ or delete or addsome works from the scope of this contract


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SECTION- E

SCOPEOFWORK

1.0 SCOPE

1.1 Scope of Work covered under this specification comprises of

a) Analysis, Design, preparation of Construction drawings and Construction of onenumber 121M high multi flue Reinforced Concrete Chimney with all accessories asper specification.

b) The scope also includes, supply of all materials ( i n c l u d in g c em en t a nds t e e l ) and labor along with necessary tools and tackles etc. When there areowner issued materials, if any, it also includes collection of materials from theOwners stockyard either at site or from other places, transporting the same to

the site, unloading, storing them in the Contractors own covered storage area.Storing shall be done in a neat & systematic manner and also providing necessaryfencing and security to ensure proper utilization of such material exclusively for theproject.

1.2 It is not the intent to completely specify herein all details of design, manufacture andconstruction. Nevertheless, the structure/equipment shall conform in all respects tohigh standards of engineering, design and workmanship, complying with the technicalspecifications and shall be capable of performing in continuous commercial operation,up to VENDORs guarantee, in a manner acceptable to OWNER, who will interpretthe meaning of drawings and specifications and shall have the power to reject anywork or materials which, in his judgment, are not in full accordance therewith.

1.3 The scope of work includes, but is not limited to the following. The VENDOR shallfurnish everything necessary and as required by OWNER although not listed herein,for the successful operation of the equipment supplied by him as specified above:

i) Design of Chimney its foundation & related civil works

ii) Supply at site of all required materials for the entire scope of work.

iii) Construction of Reinforced Cement Concrete foundation including pile & pile capand conducting routine pile load test, supporting the wind shield as well asstaircases, duct support foundation on pile cap etc including excavation,dewatering, chloride protection layer below ground level, backfilling, etc complete.

iv) Construction of R.C.C wind shield using s lip form including provision of openingsof various sizes in the windshield at various levels. If required the wind shield canbe tapered for bottom 35 meters based on design requirement.

v) Construction of internal RCC corbels / leaving openings in the wind shield atvarious levels to support Pre cast / c as t a t s i te RCC beams including theirbearing supports.

vi) Construction of RCC roof slab w i t h w e a t h e r i n g c o u r s e w i t hw a t e r p r o o f i n g a d m i x t u r e s o v e r wind shield including acid resistant


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tile protection of the roof and drainage arrangement of roof including down pipes tillbottom.

vii)Providing inside RCC connection platforms ( RCC: Cast at site orp recast type including their bearing and proper connections) comprising of roofsupporting platform, flue support platform at various levels ( 10m Maximumintervals) , with openings for flues, flooring of RCC slab, GI hand rail for safety asadequate etc .

viii) Providing brick flues ( Fire bricks and Acid Resistant(AR) bricks ) supported on theRCC platforms.

ix) Structural steel flue gas ducting of rectangular configuration from terminalpoints of supply for steam generator vendor, of structural steel up to circular brickflue including structural steel stiffening arrangement for the ducting.

x) Providing restraint and support arrangement for ducts on the windshield.

xi) Providing lined and insulated RCC ash hoppers and insulated mini shell outside thebrick liners from hopper level to the next floor level for all three flues with minimumthickness of 150 mm.

xii)Providing GI band ing , insulation on the outside of all the brick flues andducts including protective aluminium sheet with all leak proof arrangements

xiii)Providing above roof slab Mini shells of as many numbers as there are flues withinsulated lining and stainless steel caps ,access ladder etc all complete.

xiv)Providing structural steel work for supporting ducting if any inside windshield.

xv)Provision of G I structural steel stair case inside wind shield from ground floorlevel to top platform with interconnection to various platforms and GI cage ladderfrom top platform to roof of chimney. Opening latch in the roof to access fromladder, GI access doors in shell at bottom, GI insulated clean out doors in shell andflues at appropriate levels

xvi)Inside and outside painting of RCC windshield and structural steel works whererequired

xvii)Aviation warning lighting, general lighting inside the chimney and obstructionlighting and all connected electrical works including embedding conduits, junction

boxes, pull boxes, cabling etc. All reinforcement steel work to be connected toearthing system during construction.

xviii)Earthing and lightning protection system including all connected works fromtop of chimney to terminal point outside chimney at ground level.

xix) Provision of inserts/pipe sleeves for mounting instruments for monitoring airquality, including conduits, junction, pull boxes, cabling etc.


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xx)Provision of discrete strakes of galvanized structural steel, if required.

xxi) Supply and Use of KP 200(Krishna conchenm) integral admixture or approvedequivalent in all concrete works including piling and FOSROC conplast 430 orapproved equivalent to improve workability of concrete.

2.0 TIME OF COMPLETION

2.1 Time of Completion of Works shall be as follows

Work covered under this tender shall be completed within 13 (thirteen) calendarmonths from the date of issue of Letter of Intent or Work Order whichever isearlier.

SL.

NO. DESCRIPTION

PERIODOF

COMPLETIONIN

MONTHSFROMTHE

DATEOFLOI

1.Completion of shell and foundation design and getting the

same approved by Consultant / Owner1 Month

2.All foundation works including Piling ,Routine pile load test

and Pile cap below ground level including back filling etc.,2.5 Months

3Completion of remaining design and Getting the same

approved by Consultant / Owner3 Months

4. a) Slip form Construction of Straight / Tapered Shell 5 Months

b) Construction of all RCC internal platforms 9 Months

c) Completion of lining, insulation, hopper, duct & duct

connections complete in all respects, for first Unit11.5 Months

d) Completion of lining, insulation, hopper, duct & duct

connections complete in all respects, for second Unit11.5 Months

e) Completion of lining, insulation, hopper, duct & duct

connections complete in all respects, for third Unit11.5 Months

5.

All other accessories such as GI staircase, GI ladders, lighting

including aviation obstruction lights and lightning system,

port holes including access platform / staircase, doors,

pulley brackets, wire mesh screen.

13 Months

2.2 Bidder shall submit a construction bar chart including all activities keeping in mindthe period of completion time.


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3.0 SOIL CHARACTERISTICS

A detailed report on geotechnical investigation and foundation recommendation forthe plant site is available and enclosed with this specification for reference.The BIDDER should contact Consultant for any clarifications and apprise himself ofthe details of the report before submitting his bid. The BIDDER, before submission ofhis bid, may conduct soil investigation test as required by him to ascertain the actualsoil condition at site. No claim for extra payment will be entertained if the actual soilconditions are at variance with the data given in the investigation report or with thebore log data enclosed as a bid drawing. However, in case the BIDDER by hisinvestigation, arrives at a higher pile load capacity or more favorable values of soilparameters, he shall adopt the bearing capacity and parameters as specified and asgiven in the bore logs enclosed with this specification.


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SECTION - FPROJECT INFORMATION

1.0 DIMENSIONS OF CHIMNEY

1.1 (a) Clear inside flue path diameter for : 4000 mmFlue 1 & 2

(b) Clear inside flue path diameter for : 3200 mmThird flue

(c) Maximum Top exit diameter for flue 1 & 2 : 3400 mm

(d) Maximum Top exit diameter for third flue : 2550 mm

(e) Clear inside diameter of concrete shell : 14000 mmWind shield (Minimum)

(f) Minimum thickness of shell at the top : 250 mm

(g) Minimum thickness of mini shell : 200 mm

1.2 (a) Top elevation of concrete shell from FFL (0.0m) : EL +114.5.000M(Wind shield)

(b) Mini shell above platform From FFL : EL+114.500M toEL+121.00M

(c) Top Elevation of Chimney from FFL : EL + 121.000M

1.3 Batter of concrete surfaceInternal : As per Bidder DesignExternal : As per Bidder Design

1.4 External Diameter of Shellover Foundation top : As per Bidder Design

1.5 Graded level of ground : EL (-) 0.850m

1.6 Chimney grade slab level : EL (+) 0.00 m

1.7 Number of flue duct openings : Three

2.0 FLUE GAS DATA


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2.1 Maximum volume of flue gas : 215 m3/sec for flue 1 &2.120 m3/sec for 3rdflue.

2.2 Maximum flue gas temperature at entry : 150 0COf chimney

2.3 Maximum flue gas quantity for flue 1 & 2 : 636194 kg/h

2.4 Maximum flue gas quantity for 3rdflue : 325521 kg/h

2.5 Quantity of SO2 : 662 kg/h for flue 1& 2

356 kg/h for 3rdflue

3.0 DESIGN TEMPERATURES

3.1 Ambient temperature : 30 0C

3.2 Maximum Temperature : 45 0C

3.3 Minimum Temperature : 5 0C

3.4 Relative Humidity : 60%

4.0 ANALYSIS

(a) Wind Load Analysis

CD = Drag coefficient : 0.8

(For strakeportion additional dragCoefficient shall be consi dered as perCl.A.7.1 of IS: 4998 (Par-I)).

Consider aerodynamic Interference Effect(Proximity effect) due to presence ofOther tall structures and stacks in the vicinity

Vb = Basic Wind Speed : 50 m/sec.

Terrain category : 2

Class of structure : C

Topography factor k3 : 1.00

(b) For Seismic Analysis

Seismic Zone = III

5.0 DESIGN DATA


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5.1 Modular Ratio for stress computation As per IS:4998(Part-1)-

1975

5.2 Increase in concrete stress permissible : Nildue to ageing

5.3 Density of ash in hopper : 1.12 t/m3

5.4 Maximum coefficient of thermal : 0.06 kCal/m/hr/0Cconductivity of glass / mineral

wool insulation at 1500C mean temperature

5.5 For computation of temperature stress,the modulus of Elasticity of Concrete to be

used shall be obtained as Es/m wheremodular ratio m shall be as per Clause 5.1

above, and Es taken as 210000 N/mm2.

5.6 Coefficient of linear thermal expansion of : 11x10 6/0Cconcrete and reinforcement

6.0 GENERAL REQUIREMENTS

6.1 Method of shell construction : Slip form a b o v e h o p p e rring beam and slip/jump form belowhopper level.

6.2 Provision of strakes : If required it shall be provided asPer the Sti pul ati on of IS4998 - (Part I)

6.3 Provision for separate hoist : YesMaterial and passengerduring construction

6.4 Provisions for instrumentation : Provisions shall includeembedment plates, conduits for allI&C cables and purge air, junctionboxes, etc. complete as perSpecification. The number of conduitsand size of conduits shall be asrequired during detail engineering.Suitable opening, pipe sleeve, flange,access platform for working onanalyser etc. shall be provided asrequired for purchasers analysers.

7.0 DEFLECTION ON WIND SHIELD


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7.1 The permissible deflection at top of windshield shall not exceed H/500, whereH is the total height of the windshield above top of foundation.

7.2 The amplitude of cross wind oscillation shall also be restricted to 80% of the limits laiddown as above.

8.0 FLOODING OF CHIMNEY AREA

CONTRACTOR shall be responsible for taking all safety measures necessary forprotecting all materials stored by him against damage by rainwater or flooding fromany other source. If any material is damaged, the CONTRACTOR shall replace thesame at no cost to the OWNER. The OWNER will not entertain any claim of theCONTRACTOR on this account.

9.0 The bidder shall assume subsoil water table at ground level for chimney

foundation design.

10.0 TESTS

All materials and workmanship shall be of respective kinds described in theContract and in accordance with the Engineer instructions and shall be subjectedfrom time to time to such tests as the Engineer may direct at the place ofmanufacture or fabrication or on site or at all or any of such places. For otherstructural components like pre-cast slabs bought out materials like bitumen, waterbar, tar felt, acid resistant tiles bricks, fire clay bricks and mortar, aggregates orany other material whose conformity to requirement of specifications cannot be

authenticated by CONTRACTOR by ISI certificate etc., these materials will be gottested at approved laboratories. The cost of samples and conducting all such tests asstated above shall be borne by the CONTRACTOR.


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SECTIONG1

REINFORCEDCONCRETE

CHIMNEY

TEC

HNICAL

SPECIFICATION

1.0 SCOPE

1.1 This specification covers the specific requirements for design and construction ofa reinforced concrete chimney including foundations, RCC shell, brick lining,accessories that includes fixtures, fittings, conduit and embedment , lift onlywhere specified, etc., all complete. It is not the intent to specify completelyherein all the details of design and construction of the works involved underthis specification. However, the works shall conform, in all respects, to highstandards of engineering, design and workmanship.

1.2 In case drawings submitted by the BIDDER with his bid do not show some of

the work called for in this specification and the attached bid drawings exceptwhen mutually agreed to in writing before contract award the scope of workshall not be deemed to have changed from what has been defined in this biddocuments. Also the CONTRACTOR shall not be entitled for any extra claimon account of his having wrongly interpreted or overlooked any aspect called forin this specification.

2.0 APPLICABLE CODES, SPECIFICATIONS & REFERENCES

2.1 Unlessspecificallymentionedotherwise,allapplicablecodesandstandards intheir

latestadditionsaspublishedbyBureauofIndianStandardsandallothersuchasmay

be directed published by them during currency of the contract, shall govern in

respectofdesign,workmanship,qualityandpropertiesofmaterialsandmethodof

testing. In case of discrepancy between this specification and those standards

referred to herein, the former shall governSomeoftherelevantavailablecodesare

listedhereunder::

IS:6 Moderate heat duty fire clay refractories,Group-A.

IS:158 Ready mixed paint, brushing, bituminous, black, lead free; acid,alkali and heat resisting.

IS: 195 Fireclay Mortar for laying fireclay refractory bricks-specification.

IS:456 Code of Practice for plain and reinforced concrete.

IS:732 Code of Practice for electrical wiring installations.

IS:800 Code of Practice for general construction in steel.

IS:875 Code of practice for design loads (other than earthquake) forbuildings and structures: Part 1 to 3.


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IS:1526 Sizes and shapes for fire bricks.

IS:1528 Methods of sampling and physical tests for refractory material.

IS:1893 Criteria for earthquake resistant design of structures.

IS:1904 Code of Practice for design and construction of foundations insoils: General requirements.

IS:2042 Insulating bricks.

IS:2062 Steel for general structural purposes. IS:2750 Steel scaffoldings.

IS:2932 Enamel, synthetic, exterior (a) under coating, (b) finishing. IS:2933Enamel, exterior (a) under coating, (b) finishing.

IS:3346 Method for the determination of thermal conductivity of thermalinsulation materials (two slab guarded hot-plate method)

IS:3696 Safety code for scaffolds and ladders. (Parts 1 & 2)

IS:4014 Code of practice for steel tubular scaffolding. (Parts 1 & 2)

IS:4289 Flexible cables for lifts and other flexible connections : Part 1Elastomer insulated cables.

IS:4456 Methods of test for chemical resistant mortars: Part 1 Silicatetype and Resin type.

IS:4687 Gaskets and packings - Gland packing asbestos.

IS:4832 Specification for chemical resistant mortars: Part- 1 silicate type.

IS:4860 Acid resistant bricks.

IS:4998 Criteria for design of reinforced concrete chimneys: Part 1 -Design criteria - 1975

IS:4998 Criteria for design of reinforced concrete: Part 1 Assessmentof loads-1992

IS:8112 OPC Cement Grade 43

IS:8183 Bonded Mineral wool.

IS:8500 Structural steel - micro alloyed (Medium and high

strength qualities).

IS:13947 Low voltage switchgear and control gear : Part 1 General rules


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ICAO Annex-14 International Standards and Recommended Practices Aerodromes- International Civil Aviation Organization.

2.2 The following is the list of publications referred to in this specification.

Manohar,S.N Tall Chimneys-Design and Construction", Tata McGraw HillPublishing Co.Ltd., New Delhi, 1985.

Pinfold,G.M "Reinforced Concrete Chimneys and Towers", View Point Publication,Cement and Concrete Association, U.K., 1975.

ACI 307 88 Standard Practice for the Design and Construction of Cast-in-placereinforced concrete chimneys

2.3 SI units shall be adopted for all design and drawing work.

3.0 DESIGN REQUIREMENTS

3.1 The basic design parameters to be considered in design of this chimney are indicated inproject information.

3.2 The design and construction of the all components in the chimney including the windshield and foundations shall conform to the requirements of all statutory rules andregulations of local and national authorities and where such requirements are lessconservative than the corresponding requirements of this specification, the lattershall govern.

It may be noted that only the Working stress method of design shall be followed in the

design of all the components of the chimney including wind shield foundations andinternal platforms.

3.3 The chimney and its foundation shall be designed to resist stresses due to themost critical combination of any of the following:

(a) Self Weight of the chimneyi) With lining, platforms, accessories and all other dead loads. ii) Without the above when deemed critical for the design/stability

(b) Wind l o a d s ( both along-wind and across wind) or earthquake forceswhichever is governing.

(c) Eccentric loads from corbels/platforms supporting the lining, ash hopper ring

beams etc.

(d) Live loads on i n t e rna l platforms

(e) weight of equipment and materials and other live loads during constructionincluding reaction from heavy lifting jacks, brick layers platforms , lifting hoistsetc. Construction loads such as those due to plant and equipment,stacked materials, live loads due to movement of plant, materials and men.


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(f) Temperature gradient calculated across the liner insulation and then chimney shell.

(g) For t h e shell below grade level as well as foundations, appropriate buoyantforce due to water table / hydro- static forces, earth pressures, , surcharge etc.,all as applicable.

(h) Local moments due to ovalling.

(i) Loads from flue duct supports, staircase, etc

(j). When applicable as per scope -forces from the lift and operating equipment.

3.5 Design of any cross section shall include all the design stresses d u e t o a l lsecondary effects, namely secondary moments due to p-effect, eccentric loading

due to platforms, corbel effect when corbels are provided etc.

3.6 Stresses in the shell shall be shown to be within permissible limits at 10 metreintervals along the height of the shell or at every corbel level whichever distance isless and in addition at the critical locations across openings.

3.7 In no case the total design stress shall exceed the permissible stresses as in clause7.0 of IS:4998 (Part-1) 1975, H o w e v e r for (DL+WL) case, the permissiblestress 0.275fcu shall be if the circumferential tensile stress in concrete due to windinduced ring moment exceeds the value specified in clause 7.1.1 (g) of IS : 4998 Part I, additional reinforcement shall be provided in 2 layers limiting the stress inreinforcement steel to value specified in clause 7.1.2 (g).

3.8 Under worst combination of loads the Factor of Safety against over-turning, shall notbe less than 1.5 in any direction during construction and 2.0 after construction iscomplete.

3 . 9 Only 90% of the dead loads as calculated from dimensions and densities ofmaterials, shall be taken into account for the purpose of calculating safety factoragainst overturning.

3 .10 For the purposes of analysis/design, Shell shall be assumed fixed to foundation In thefoundation, diagonal tensile stresses and bending stresses about two orthogonal axisshall be checked at critical sections.

3.11 The modulus of elasticity of concrete shall be as per the mean value specified in clause

A-3.1 of IS:4998 (Part-1) for estimating the deflections of the chimney in lined andunlined conditions

3.12 Air inlet and Outlets :

Air inlets shall be provided near the base as indicated in tender drawings. , So asto prevent pests or heavy airborne dusts entering the access void through theopening the openings shall be provided with a GI wire mesh on the outside mountedon a GI frame These openings also will have an Aluminium louver behind the mesh


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,sloping downward .Calculation of air inlet opening area shall be as per IS:4998(Part-1)-1975.

Similarly air outlets shall be provided near the top as indicated in the tenderdrawings with proper stainless steel wire mesh mounted on stainless steel frame atthe outside, apart from Aluminium framed lovers sloping upwards Area of air outletopening shall be same as area for air inlet opening.

3.13 At the base or anywhere along the height of the shell Temporary openings, if any,required by the CONTRACTOR, for the purpose of placement of concrete, access ofmaterial and personnel, to provide support platforms for material, etc., shall beindicated during bid stage and finalised before the award of the contract. Only theseopenings finalised and shown in the released for construction drawingsapproved by the OWNER/ CONSULATANT shall be allowed to be providedduring construction. These openings up after use shall be closed by providing extra

reinforcement and with the grade of concrete same as that of the shell around theopening and as appropriately with approval by CONSULTANT for the design andmethodology , at no extra cost to the OWNER by the contractor

3.14 The maximum width of the openings shall be limited to less than 60 anglesubtended at the centre of the concrete shell. When the extent of shell left betweentwo openings is limited with the subtended angle less than 45, that part of shellshall be designed as column.

3.15 Corbels, if required, shall be designed to take the load of platforms, lining,insulation, hopper, etc., supported on them

3.16 The analysis of the windshield for wind and earthquake forces shall be done as per the

requirements of clause 13 and 14 of this specification.

3.17 The foundation shall be designed as a rigid member. Stiffness of shell shall notbe considered for design of the foundation The thickness of the foundation belowthe shell shall not be less than 0.40 times the overhang of the foundation beyond theshell, or 0.09 times the foundation diameter whichever is more.Foundation designshall be based on the foundation criteria as indicated in Project information. Forfoundation design, no increase in permissible material stresses will bepermitted for wind load combination. Permissible increase in material stressesshall be 33-1/3 % under seismic load condition However the Permissible increase insafe bearing capacity of soil shall be 25% under seismic load condition. Suchincrease shall be only on the net bearing pressure of soil. No such increase in safebearing capacity of soil will be permitted for wind load combination.

4.0 SPECIALREQUIREMENTS FOR CHIMNEY CONCRETE

4.1 The minimum thickness of the concrete shell shall be 250 mm.

4.2 Degree of envi ronmenta l exposure of concrete as per Table 3 of IS 456 shall betaken as very severe for foundation ( being concrete in contact with or buriedunder aggressive sub-soil / ground water) and severe for all superstructure


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including wind shield and all other concrete elements in the chimney ( being concreteexposed to coastal environment) Based on which the clear concrete cover (over all

reinforcements including the circumferential steel ) in the shell shall not be less than 50mm. In foundations, the clear concrete cover over all reinforcements including ties shallbe 75 mm.

4.3 Maximum grade of concrete shall be M40 for all the concrete works.

Minimum grade of concrete f or foundation including piles and pile raft shall be M35

For chimney w i n d s h i e l d shell including mini shell, p l a t f o r m s , slab, beams,corbels when provided, hopper, ring beams and other structural work minimum gradeof concrete shall b e M30.

Minimum grade of Plain cement concrete used shall be M20.

All concrete work shall be carried out strictly in accordance with the specification,except as otherwise specified hereunder.

4.4 Cement, aggregates, water and approved admixtures, if any, shall have unchangedsource and type throughout the construction of the chimney.

4.5 The maximum size of coarse aggregates, unless specified otherwise, shall not belarger than 1/8th the narrowest dimension between forms nor larger than one-half theminimum clear distance between reinforcing bars nor more than 20 mm.

4.6 Natural gravel and rounded aggregates of acceptable quality shall be preferred tobroken stone with sharp angular corners for slipform work, in particular

4.7 When slip forming is adopted, the slump shall be between 100 mm and 150 mm atthe point of placement. However, precise requirements in this regard shall beestablished from field tests and shall be subject to ENGINEERS approval.

4.8 Where necessary, to maintain the workability only approved admixtures such asretarders/ plasticizers identified after preliminary tests to prove their satisfactoryperformance and compatibility with the particular type of cement envisaged to beused shall be used a n d t h a t t o o with the prior consent of theENGINEER. Based on dosage over all weather conditions, the total quantity ofadmixture for the complete work shall be estimated and procured . The procurementhowever shall be in batches to ensure that the same is utilized before expiry of itsshelf life. No additional payment shall be made to CONTRACTOR for

providing and using retarders/plasticizers.

4.9 The minimum cement content and maximum water cement ratio shall be as given inTable 5 of IS:456-2000 corresponding to very severe exposure condition forfoundations including piles and severe exposure condition for the superstructure.Maximum cement content shall be limited to 450 kg/cum.

4.10 While concreting shell at corbels( when provided) and platform levels, care shall betaken to ensure that the dowels for corbels and platforms when cast at site are


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initially bent within the wall thickness and concrete of specified grade for shell at thatlevel is placed and well compacted. The dowels may be later exposed by chipping the

shell surface only after the concrete is well set. On no account will the method bypacking the area with sand or any other material be allowed for the purpose ofexposing dowels at a later date.

5.0 SPECIAL REQUIREMENTS FOR CHIMENY REINFORCEMENT

5.1 The minimum vertical reinforcement on each face with deformed bars a n d M i l ds t e e l b a r s shall be 0.125% and 0.15% respec ti ve ly of the concrete area ofthe section under consideration.

5.2 The minimum diameter of vertical reinforcing bars shall be 12 mm and they shall notbe spaced at more than 300 mm centres.

5.3 Laps for the vertical reinforcement shall be staggered with not more than one-third ofthe bars being lapped at any one level. Which again should be distributed around theperimeter and not concentrated in only one part of the perimeter of the shell.

5.4 Above openings where vertical reinforcement is required to be lapped, lap shall beallowed only after a height of B/2 above the opening for the whole section, where B =width of opening.While curtailing reinforcement above openings, care shall betaken to ensure proper transfer of tensile forces if present in the section to thesubsequent section by provision of adequate reinforcement. The bars shall not becurtailed abruptly and an adequate development length shall be provided.

5.5 The circumferential reinforcement on each face of shell, for deformed bars and mildsteel bars respectively shall not be less than 0.1% and 0.125 % of the concrete area

of the section.

5.6 The minimum diameter of the circumferential reinforcing bars shall be 10 mm andthey shall be spaced at a centre to centre distance not exceeding 300 mm or theshell thickness whichever is less.

5.7 Circumferential reinforcement shall be placed around the exterior of and securelywired or welded to the vertical bars at an interval of not more than 600 mm.

5.8 Circumferential reinforcement shall be evaluated so as to satisfy the minimumrequirements as mentioned above and to safely withstand the circumferentialforces and moments. However, for a height from the top equal to half the shellouter diameter or 3 metres whichever is more, the quantity of circumferential

reinforcement shall be twice that arrived at as stated above. This is applicable for minishell also.

5.9 Particular attention shall be paid to placing and securing the circumferentialreinforcement so that it cannot bulge or get displaced during the placing and workingof the concrete.

5.10 The reinforcement for corbels when p rov ided and dowels for platformreinforcement shall be of mild steel and of size not larger than 12 mm diameter.


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5.11 In general dowels, wherever provided, shall extend on either side of the construction

joint by alength equal to the full development length of the bars in tension.

5.12 Extra reinforcement shall be provided around and at corners of openings. In additionto the reinforcement determined from structural considerations as well as to meettemperature and other stresses,

5.13 The extra reinforcement shall be placed near the outside surface of the chimney shellas close to the opening as proper detailing of reinforcement will permit. Unlessotherwise specified, all such extra reinforcement shall extend past the openingto a length equal to its development length in tension.

5.14 At each side of the openings, the extra vertical reinforcement shall have a totalarea equal to the design reinforcement for one-half of the width of the opening.

This steel shall be placed on each side of the opening within a distance notexceeding 1.5 times the shell thickness wherever column design procedure specifiedabove is not applicable. The extra reinforcement shall extend past the opening by alength equal to 1/2 the width of opening plus its development length in tension.

5.15 Extra horizontal reinforcement shall be placed at both top and bottom of eachopening, These shall be having an area at least equal to one-half of the designcircumferential reinforcement interrupted by the openings but the area 'As' of thisextra reinforcement shall not be less than that given by the following :

As (mm2) = fck.t.s/c

Where,

fck = characteristic strength of concrete in N/mm2,t = shell thickness at opening in mm,s = width of opening in mm,c = 16000 and 13000 for high yield strength deformed bars

and mild steel bars, respectively.

5.16 One half of this extra reinforcement as stipulated above, shall extend completelyaround the circumference of the chimney and the other half shall extend beyondthe opening to a length equal to the development length of the bars in tension. Thissteel shall be placed within a height not exceeding the thickness of the shell.

5.17 For shell thickness greater than 250mm, diagonal reinforcement with a total cross

sectional area in sq.mm of not less than 5 times the shell thickness (in mm) shall beplaced at each corner of an opening. These bars shall also extend on either sideof the corner a distance equal to the development length of the bars in tension.

5.18 For the shell of thickness less than 250 mm additional steel of a total crosssectional area in sq. mm of not less than 3.5 times the shell thickness (in mm) shall beplaced horizontally/vertically. These bars which shall extend to a distance equal to thedevelopment length in tension on either side shall be in addition to the entire steelalready provided as per clauses above.


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5.19 Foundation of chimney shall be provided with a minimum layer of reinforcement at

top and same shall not be less than 12 mm deformed bars at 250 mm centresplaced orthogonally.

5.20 Temporary openings, if any, required by the CONTRACTOR along the height ofshell, for the purposes of access to material and personnel, placement of concrete, forsupporting temporary platforms while laying of bricks, etc. shall be allowed only on theapproval of the ENGINEER.

5.21 These openings shall be designed as permanent openings with provision of extrareinforcement as per the requirements of clauses above. The edges of openingsshall be provided with suitable MS rods as dowels which shall be bent and exposed.Additional bars if required, shall be tied to the dowels to form a reinforcementmesh work within the opening and the opening later filled with concrete of same

grade as of the surrounding shell.

6.0 BRICK LINING

6.1 Fluesoffirebricks/acidresistantbricksasspecifiedhereundershallbeinstalledinthechimney as flue gas exhaust system .Unless otherwise specified the flues shall beconstructedwithfirebricks,exceptintop/hopperportions,whereitshallbeofacidresistantbricks

The lining distribution as Fire brick / AR brick shall be as specified in the bid drawing.The locations where Fire bricks and Acid resistant bricks are to be used are givenonly as guidance in the Bid Drawings and it is the sole responsibility of the EPCcontractor to tune the locations of such distribution between fire bricks and acid

resistant bricks in line with the flue gas composition g iv en in th is b id do cu me nt .

6.2 The liningshall be supported on concrete platforms at intervals of not more than 10metres unless otherwise shown in the tender drawing and shall be of material suitableto withstand the service conditions. Lining bricks shall be uniformly well burnt, strong,, uniform in colour, of correct shape and size, homogenous in texture and free fromcracks, voids and other flaws All bricks shall be clearly marked with theMANUFACTURERS name and trade mark

In case where the inner diameter of the lining is less than 4500 millimetres, shapedbricks shall be used to maintain the thickness of joints

Broken bricks shall not be allowed to be used except for closing the course..

6.3 The sizes and shapes of fire clay bricks shall conform to IS :1526 and shall be ofGroup-A Type 1 conforming to IS:6. The mortar for laying fireclay refractory bricksshall be of grade-2 conforming to IS:195.These bricks shall be laid in these airsetting mortar and cured as per MANUFACTURERS specification.

Prior to dispatch of mortar material from MANUFACTURER, at least five (5)samples of the lot to be dispatched shall be tested for bond strength as specified


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in relevant standards and the test reports submitted to OWNER/CONSULTANT forapproval and permission for dispatch of material. Similarly, five (5) samples of the lot

to be dispatched shall also be tested for chemical resistance as per IS:4456(Part-1) and loss in weight and loss in compressive strength of the test specimenshall not exceed 5 %. The test reports on chemical resistance shall be reported asper clauses 10.11.2 and 10.11.3 of IS:4456 (Part-1).

6.4 The acid resistant bricks shall conform to Class I of IS:4860 and the mortar for acidresistant brickwork shall conform to IS:4832 (Part 1) - Silica type with potassiumsilicate liquid binder.

6.5 The mortar joints for all the Acid resistant Brick lining, shall be cured with 25% diluteHCl for a minimum period of 3 days and as per MANUFACTURERS specificationafter which exposed face shall be thoroughly cleaned with water.

Prior to dispatch of bricks from MANUFACTURER at least five (5) samples of the lotto be dispatched shall be tested for K-value at an approved laboratory and testreports submitted to ENGINEER for approval and permission for dispatch of material.While testing, the hot-face temperature of the bricks shall be 300C. Similarly, testcertificates for acid resisting properties shall also be furnished for acid resistingbricks.

6.6. Thebricksshallalsosatisfythefollowingrequirements.

a. Firebricks

Thermalconductivity : 1to1.25kcal/m/hr/OC

(Itshall be considered as K =1.25 Kcal/m/hr/C for the purpose of

design of shell for temperature effects)

Bulkdensity : 18002000kg/m3

Crushingstrength(min) : 140kg/m3

Waterabsorption(max) : 15%

Coefficientofexpansion : 11X106/OC

b. Acidresistantbricks

ThermalConductivity : 1to1.25kcal/m/hr/OC

(It shall be considered as K =1.25 Kcal/m/hr/C for the purpose ofdesign of shell for temperature effects)

Bulkdensity : 2000kg/m3

Compressivestrength : 500kg/cm2(min)


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FlexuralStrength(min) : 70kg/cm2

Waterabsorption(max) : 4%

Resistancetoacid : Lossofweightshallnot

exceed4%

6.7 Provision shall be made for differential vertical expansion at the lining support

6.8 The thickness of lining shall be as shown on the bid drawings. TheEPCcontractorshall also submit adesign calculationjustifying the thicknessof thebrickwall andinsulationused includingtheirgrades/densitiestosuitthetemperaturedropacross

theliner

system

according

to

the

maximum

flue

gas

temperature

and

minimum

ambienttemperature.

The radial joints shall be broken in each course. Lining shall be strapped withcircumferential and vertical galvanised mild steel bands

These circumferential and vertical steel bands shall be having a minimum dimensionof 75x6 mm and 50x6 mm respectively, both spaced at one metre centres, on theexterior of the brickwork throughout the full height of the lining.

6.8.1 The circumferential bands shall be laid immediately touching the brickwork to take upthe hoop stress and the vertical bands shall be laid outside.The vertical andhorizontal bands shall be joined together by either suitable spot welding in which

case all weld joints shall be painted with 2 coats of zinc rich aluminium paint over acoat of compatible primer as per the requirement of the MANUFACTURER, or theyshall be fixed by bolting arrangement, with counter sunk GI bolts with slotted holes.

6.9 Special care shall be taken to ensure proper laying of bricks to cover the RCCinside platforms so as to protect the platforms from the action of gases.Glass/mineral wool insulation of 25 mm thick shall be provided between the face ofthe platform and brick lining with a sealing by 2 Nos. 25 mm dia asbestos chordsconforming to Grade 3 of IS: 4687. Bricks shall be laid on corbels wh e n u s e don 12 mm thick asbestos sheet.

6.10 Mortar for lining shall be used within the initial setting time and no re-temperingshall be permitted. Joints shall be properly filled and at a given cross section, the

thickness of the joint shall not be more than 2 mm along the inner periphery of thelining and not more than 12mm along the outer periphery.

7.0 INSULATION & CLADDING

7.1 All insulation shall be of dimensions specified in the drawing.


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7.2 The materials for insulation and packing shall be mineral/glass wool, asbestosrope, asbestos mill boards, insulation bricks, etc., of approved quality.

7.3 The mineral/glass wool shall be of resin bonded type conforming to IS:8183 orequivalent with a minimum density of 0.80 kN/m3..

7.4 The maximum coefficient of thermal conductivity of mi ne ra l wool /g la sswool sh al l be 0.060 Kcal/m/hr/C at a mean temperature of 150C.

7.5 1.0mm thick aluminium foil shall be provided all around the insulation asc l a d d in g , wrapping around the lining of flues and ducts. The sheeting shall be inthree segments with all necessary fixing arrangements with GI bolts/pins includingoverlapping and work shall be executed as per drawings and as directed by theENGINEER

7.6 The diameter of the asbestos rope conforming to Grade 3 of IS:4687 shall be 25mm unless otherwise specified on the drawing. The rope of approved quality shallalone be used and shall be firmly packed so as to prevent gas leakage at all locationswhere the lining overlaps.

7.7 The strands of asbestos rope shall be long, well twisted They shall be stranded wellwith no torn fiber sticking out.

7.8 Asbestos mill board w h e r e p r o v i d e d shall be 12 mm thick, unlessotherwise specified on the drawing.

Such boards shall be without cracks, flaws or any other manufacturing defect andshall be plain, dense and have a homogenous texture,. They shall be laid directly

over the concrete after removing all loose materials but without any mortar/plasterbedding

7.9 The base for acid resistant brick lining in hopper portion shall be either cellularconcrete or insulating bricks of Grade 'C' conforming to IS:2042 or equivalentunless otherwise specified on the drawing.

8.0 CHIMNEYACCESSORIES

8.1 STAINLESS STEEL CAP

To prevent the chimney top from chemical attack of flue gases and to prevent gas-

entrained matter from falling into the annular space between the liner and the minishell a sectional stainless steel cap of minimum 12 mm thickness shall be providedThis shall be provided over 25 mm thick asbestos board, unless otherwise specifiedon the drawing. The cap shall cover the concrete shell, brick lining and annular airspace or insulation between them. The cap shall slope towards the inside of thechimney at approximately 30 to the horizontal. All sections of the cap shall beanchored in place with bronze bolts and bronze rag bolts respectively.

8.3 CAGED GI LADDER