Co-gen bid

7/23/2019 Co-gen bid

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Doc No. : GDP/EPC-BID/09-10/030, R1

Date : June 8, 2009

Assign No. : GPD/SDE/HPCL/08-09/045Date : September 12, 2008

ENGINEERING, PROCUREMENT & CONSTRUCTION(EPC) BID DOCUMENT

20 MW Cogeneration Power Plant

Village Lauriya, District West Champaran, Bihar

Technical Basis And Specifications

Prepared For

Hindustan Petroleum Corporation Ltd. (HPCL)(A Govt. of India Enterprise)

Petroleum House, 17, Jamshedji Tata Road,

Mumbai 400 022

Prepared By

MITCON Consultancy Services Ltd. (MITCON)Kubera Chambers, Shivajinagar

Pune - 411 005

June, 2009


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Doc No. : GDP/EPC-BID/09-10/030, R1

Date : June 8, 2009

Assign No. : GPD/SDE/HPCL/08-09/045Date : September 12, 2008

EPC BID DOCUMENT

20 MW Cogeneration Power Plant

Village Lauriya, District West Champaran, Bihar

TTAABBLLEEOOFFCCOONNTTEENNTTSS

ChapterNo.

Chapter No. PageNo.

1 DESIGN BASIS, SCOPE OF WORK, TERMINAL POINTS,PERFORMANCE GUARANTEE

1 - 175

1.1 Design Basis 11.2 Scope Of Work 1721.3 Terminal Points 1741.4 Building Dimensions 175

2 TECHNICAL SPECIFICATIONS FOR MECHANICAL &ELECTRICAL EQUIPMENTS, INSTRUMENTATION &CONTROL AND ERECTION AND COMMISSIONING

176 -463

2.1 Steam Generator &Auxiliaries 1762.2 Steam Turbine Generator & Auxiliaries 2212.3 EOT Crane & Hoists 2812.4 Water Treatment Plant 2922.5 Air Compressor & Air Dryer 3002.6 Fuel And Ash Handling System 3032.7 Cooling Tower & Auxiliaries 3142.8 Fire Fighting System 3222.9 Piping & Fittings 3262.10 Painting 333

2.11 Electrical Evacuation System 3352.12 Cabling 3852.13 DCS Based Instrumentation And Control 3972.14 Uninterrupted Power Supply 4372.15 Erection & Commissioning 444


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TTAABBLLEEOOFFCCOONNTTEENNTTSS((ccoonnttdd....))

ChapterNo.

Chapter No. Page No.

3 CIVIL WORKS 464 - 486

3.1 Major Civil Works 4643.2 Design Data 4653.3 System Description & Specifications 4653.4 Design Criteria 4663.5 Foundations 4673.6 Machine Foundations 4673.7 General Design Considerations 4713.8 Design Of Miscellaneous Items 475

3.9 Architectural Concepts And Design 4773.10 Construction 480

4 APPROVED LIST OF VENDORS, LIST OF SPARES ANDLIST OF DRAWINGS / DOCUMENTS

487 - 512

4.1 Approved List Of Vendors 4874.2 List Of Spares 4934.3 List Of Drawings & Documents 501

5 DATA SHEETS 513 - 552

5.1 Steam Generator & Auxiliaries 5135.2 Steam Turbine Generator & Auxiliaries 5165.3 Water Treatment Plant 5195.4 Cooling Tower 5225.5 Fuel & Ash Handling 5235.6 EOT Crane 5315.7 Electrical Evacuation 5335.8 DCS 5495.9 Building Dimensions 5505.10 Performance Guarantee Data Sheet 550

5.11 Technical Deviations 552


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TTAABBLLEEOOFFCCOONNTTEENNTTSS((ccoonnttdd....))

LIST OF APPENDICES

APPENDIX

NO.APPENDICES

I SITE LOCATION MAP

II PROXIMATE & ULTIMATE ANALYSIS OF BIOMASS FUELS

III TYPICAL TG HALL LAYOUT

IV PROPOSED MASTER PLAN DEMARCATING COGEN

AREA AND PROVIDING SCHEMATIC OF FUEL

HANDLING SYSTEMV TYPICAL SCHEMATIC PLANT STEAM SYSTEM

VI TYPICAL SCHEMATIC FOR HP HEATER

VII TYPICAL SCHEMATICS COOLING WATER SYSTEM

VIII TYPICAL SCHEMATICS PLANT WATER SYSTEM

IX TYPICAL BOM, FIRE FIGHTING

X TYPICAL SCHEMATICS SYSTEM CONFIGURATION,PLANT DCS

XI TYPICAL SINGLE LINE DIAGRAM, ELECTRICAL

EVACUATION & DISTRIBUTION SYSTEM

XII PIPING MATERIAL SPECIFICATIONS

XIII CODES & STANDARDS

XIV TYPICAL PAINTING SUMMARY

XV ELECTRICAL SYSTEM REQUIREMENTS FOR MOTOR

SELECTION

XVI RAW WATER ANALYSISXVII HEAT & MASS BALANCE DIAGRAM

XVIII TERMS & CONDITIONS FOR ERECTION &

COMMISSIONING


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Technical EPC Bid Document for Cogen Power Plant at Lauriya, Dist. West Champaran, Bihar 1

CHAPTER 1

DESIGN BASIS, SCOPE OF WORK, TERMINAL POINTSAND PERFORMANCE GUARANTEE

1.1

DESIGN BASIS

1.1.1

General

The cogen power plant will have installed capacity of 20 MW and willEmploy 110 kg/cm2 and 540C configurations. Bagasse generated fromcane crushing, excluding handling losses and bagacillo requirements willbe available for operation of the high-pressure boiler during season of 130days. Saved bagasse, cane trash, rice husk will be used during the off-season period of about 170 days.

The auxiliary steam consumption for the cogen power plant will be forsoot blowing and other auxiliary consumptions like Steam Jet Air Ejector(SJAE) & Gland Steam Condenser (GSC) at high pressure, for twin type

HP heater at medium pressure and for de-aerator at low pressure. Theauxiliary power consumption for the power plant should be about 8.5% ofgeneration during season and 9% of generation during off-season periods.

The process steam required for sugar @ 22% on cane or 32.08 TPH duringseason, 20 TPH for ethanol plant during season & 10.25 TPH during off-season will be provided from the cogen power plant. Also, powerrequirement of 2.92 MW for sugar process during season & 0.15 MWduring off-season, 1 MW during season & 0.9 MW during off-season

periods for ethanol plant & 0.15 MW both during season and off seasonperiods for the colony will be provided from the cogen power plant.


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The brief design parameters for the cogen power plant will be as follows:

Boiler capacity, TPH : 1 x 100

Pressure, kg/cm2 : 110.00

Temperature, C : 540

Turbine capacity, MW : 20.00

Turbine type : Bleed cum doubleextraction cum condensing

Season operation, days : 130

Off season operation, days : 170

Fuels used for season operation : Mill bagasseFuels used for off season operation : Saved bagasse, Cane Trash,

Biomass

Boiler efficiency, %

- On bagasse / bio-mass / canetrash

: 70.00, 2

Feed water temperature, C : 210

Captive power consumption, % of

generation

: 8.5 during season & 9

during off-season

1.1.2

Key performance parameters

The key performance parameters for the cogen power plant are givenbelow:

Sr.No.

Description Value

1 Steam Generator efficiency, % : 702 on bagasse / biomass/ cane trash

2 Steam to Fuel Ratio, kgbagasse / kg

: 2.65

3 Average Steam to Power


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Ratio, kg / kWSeason

Off-Season

:

:

5.08

3.804 Auxiliary Powerconsumption, MW (%)SeasonOff-Season

:: 1.70 (8.5)

1.80 (9)

Note: The estimated HMBD is provided inAppendix XVII. However, theTenderer can optimise the same to maximise power generation atthe required steam flows to process.

1.1.3

Ambient Conditions

Plant Elevation above Mean Sea Level (MSL) : 71 meters

Temperatures:(a)

Maximum Temperature : 46 Deg. C(b) Minimum Temperature : 5 Deg. C(c) Plant Design Temperature : 36 Deg. C

(Performance design)(d) Plant Design Wet Bulb Temperature : 27.0 Deg. C

(e)

Plant Design Temperature for Electrical : 50 Deg. CEquipment

Precipitation:

(a) Average Annual Rainfall : 1422 mm

Wind:

(a) Wind Direction : South - West (May Sept)North - East (Oct - Apr)

(b) Design Wind Velocity : As per IS 875

Seismic Coefficient : As per IS: 1893-2002

Seismic Zone :Zone 4


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Soil Bearing Capacity* : 20 ton/m at 2 mfrom NGL

* Tenderer will need to carry out required trial pits and other tests toaffirm the SBC and other required soil characteristics

1.1.4

Fuels

a) Design & Guarantee Fuels

During sugar season, the principle fuel will be bagasse and thesteam generator will be designed for 100% MCR on bagasse.During sugar off-season, the boiler will operate on stored /procured bagasse and other biomass.

The estimated fuel balance will be as follows :

ValueSr.

No.

Item

Season Off

season

1. Crushing rate, TCH 146 -2. Bagasse generation at 34% on cane,

TPH49.58 -

3. Bagacillo / handling loss at 1.0% oncane, TPH 1.46 -

4. Bagasse available as fuel at 33% oncane, TPH

48.13 -

5. Biogas available from distillery(equivalent to bagasse), TPH

2.08 2.08

6. Total equivalent bagasse available,TPH (MT)

50.21(156655)

0.00

6. Bagasse consumed by cogen boiler,TPH (MT)

37.74(117748)

26.60

7. Bagasse saved / available for offseason operation, TPH (MT)

12.47(38904)

9.54(38904)

8. Biomass requirement, equivalentbagasse, TPH (MT)

- 17.43(71114)


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The following will be the analysis and the Gross Calorific Value(GCV) of the design fuel (Bagasse).

Ultimate Analysis:Carbon : 23.5%Hydrogen : 3.25%Oxygen : 21.75%Moisture : 50%Ash : 1.5%GCV with 50% moisture : 2270 Kcal/Kg

The Following gives the Ash Analysis for Bagasse:SiO2 : 50-60%

Al2O3 : 10-13%Fe2O3 : 10-12%CaO : 3-5%MgO : 3-4%TiO2 : 2-4%P2O5 : 1-2%Na2O : 0.5-1.5%K2O : 4.5-6.0%SO3 : Nil

b) Other Fuels

The Cogeneration plant will also be designed to operate with otherfuels like sugarcane trash, rice husk and maize cobs in combinationwith bagasse. The operation of the plant during the seasonaloperation will be basically with bagasse and during off season withsaved bagasse and biomass. However during off season bio-massfuel sugarcane trash, rice husk and maize cobs are envisaged to beused depending upon the availability.

Ultimate and Proximate analysis of the other fuels like sugarcanetrash, , rice husk and maize cobs are given inAppendix II


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1.1.5

Plant Design Criteria

The estimated cogen plant design criteria is as follows :

Sr. No. Item Value

1. Cane crushing, TCH 1462. Bagasse generation, % cane (TPH) 34.00

(49.58)3. Bagacillo / handling loss,% cane (TPH) 1.0

(1.46)4. Bagasse available for boiler, % cane (TPH) 48.13

(98.60)5. Bio-gas available from distillery as fuel

(equivalent bagasse)2.08

6. Total equivalent bagasse available for boiler,TPH

50.21

7. Steam generation, TPH (@ 2.65kg steam / kgbagasse

100.00

8. Steam consumption, TPH8.1 HP steam @ 110 & 25 kg/cm2

- Gland Steam Condenser & Steam Jet AirEjector (SJAE)

1.00

- HP heater I 7.008.2 MP steam @ 8 kg/cm2

- Ethanol process 20.00- HP heater II 8.00- De-superheating water addition (0.56)- Total MP steam 27.44

8.3 LP steam @ 2.5 kg/cm2- Sugar process @ 22% on cane 32.08- De-aerator 4.60- De-superheating water addition (0.73)- Total LP steam 35.95

8.4 Condensing steam @ 0.1 kg/cm2 28.618.5 Total steam consumption 100.009. Power generation, MW (@ 5.08 kg/kW avg.) 19.6910. Power consumption, MW

- Sugar process @ 20 kWh/TCH 2.92


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Sr. No. Item Value

- Ethanol 1.00

- Cogen auxiliaries 1.70- Colony 0.15- Total 5.77

11. Power export, MW (14-15) 13.9212. Power export, MUs 43.43

Off Season Operation

13. Steam generation, TPH 76.0014. Steam consumption, TPH14.1 HP steam @ 110 kg/cm2 for GSC 0.76

HP steam @ 25 kg/cm2 for HP Heater I 5.32

14.2 MP steam @ 8 kg/cm2- HP heater II 6.08- Ethanol Plant 10.25- De-superheating water addition (0.33)- Net MP steam 16.00

14.3 LP steam @ 2.5 kg/cm2- De-aerator 5.70- De-superheating water addition (0.11)- Total LP steam 5.59

14.4 Condensing steam @ 0.1 kg/cm2 48.33

14.5 Total steam consumption 76.0015. Power generation, MW (@ 3.80 kg/KW avg.) 20.0016. Power consumption, MW

- Colony & Sugar Complex 0.30- Ethanol Plant 0.90- Cogen auxiliaries 1.80- Total 3.00

17. Power export, MW 17.0018. Power export, MUs 69.3619. Total power export, MUs 112.79

20 Boiler size & configuration 1x110TPH110kg/cm2,5400C

21 Turbine size & configuration 1x20 MW105kg/ cm2,5350C


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1.1.6

Main Plant And Equipments

1.1.6.1

Steam Generator & Auxiliaries

The steam generating system for the Cogeneration plant willconsist of one bagasse and biomass fired boiler with a MaximumContinuous Rating (MCR) of 110 TPH. The outlet steam parametersof the boiler shall be 110 kg/cm2 and 540 deg C. The tolerance onthe super-heater outlet temperature shall be a + 5 Deg. C. Thecombustion system of the boiler shall be travelling grate withspreader stoker. The boiler efficiency, firing 100 % bagasse, shall

be a minimum of 70 % on the GCV basis. The flue gastemperature leaving the boiler to stack shall be chosen such thatmaximum economically possible efficiency is achieved but thetemperature shall be sufficiently higher than the dew pointconsidering the fuel characteristics. However, at 100% MCR thesame shall not be higher than 140 deg C. An ESP is envisaged tocontrol outlet emission to 100 mg/Nm3.

1.1.6.2

Turbo-generator & Auxiliaries

Triple extraction cum condensing steam turbine generator &auxiliaries is envisaged. The high pressure bleed will be at about25 kg/cm, medium pressure bleed at 8 kg/cm and low pressurecontrolled extraction at 2.5 kg/cm will cater to the sugar millprocess needs and cogeneration power plant auxiliaries. Balance ofsteam will be passed through condenser to generate the ratedcapacity. Feed water will be de-aerated in a pressurized de-aeratorand further heated in HP heaters.

The Turbo - Generator and the Auxiliary Equipment covered under

this specification shall be designed to achieve maximum powergeneration as per normal steam flow rates from the triple extractioncum condensing set.


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Part of the generated power will be supplied to the sugar factorycomplex and the rest will be exported to the grid, after stepping upthe voltage to EHV and transporting the power throughtransmission lines to the nearby sub-station of the BSEB. Theextractions from the turbine provide the sources for the mediumand low pressure steam for the use in the sugar complex & powerplant auxiliaries.

The turbo alternator shall be designed taking into consideration allpossible electrical parameters affecting the choice of the machine,assuring stable and reliable operation in a rural network. Tenderershall offer his standard micro-processor based controls andinstrumentation system with panels etc, for the start up, shut down

and operation with all standard features.

Basic Design Parameters for the design:

Water Cooled CondenserOperating Pressure (ata)

0.1 (in off-season)

Temperature rise for coolingwater (Deg. C)

8

Power Factor (lagging) 0.8Generation Voltage (kV) 11.0, 3 phase

Ambient Temperature forElectrical Equipment Design(Deg. C)

50

Parallel operation with grid Required with BSEB gridGrid Voltage 132 kV, 3 phaseDuty Requirements Continuous 8000 hoursSystem Frequency 50 + 5%Turbine Type Triple Extraction cum

CondensingInlet Steam Parameters- Pressure (Kg/Sq. Cm(a)) 105- Temperature (C) 535- Flow (Kg/Hr) 99000 in season & 75250 in

off-season


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Extraction parameters, No ofExtractions, Steam Flow

3 extractions at 25 kg/cm,8 kg/cm and at 2.5

kg/cm. Bleed at about 25kg/cm is only for HPheater no. 2. Bleed at 8kg/cm is for HP heaterno.1 and to supply 20 TPHto ethanol in season.Extraction at 2.5 kg/cm isfor deaerator and supply of32 TPH steam to sugarprocess in season.Appendix XVII providesthe HBD

The turbo-generator system should be designed in such a way thatthe TG set does not trip during the Grid load- throw off condition,when the plant is operating at 100% rated capacity.

The prime mover control system shall be selected and programmedto satisfy the following conditions under parallel mode of operationwith the grid:

a. Load set point shall remain unaffected for the variationof frequency between 47.5 Hz and 52.5 Hz.

b. The turbine inlet steam pressure shall be maintained atthe set value by controlling the power export to the grid.

The Turbine extraction which provides the Medium PressureProcess Steam shall be selected such that the pressure at thebattery limit will be maintained between the turbine inlet steamflows of 60% to 100% of the MCR flow. This is required mainly

from the point of view of energy efficiency, where in even underless than the capacity crushing of the sugar plant, the MP processsteam is taken through the turbine instead of taking the steamthrough the PRDS.


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1.1.6.3

Fuel & Ash Handling

The project will have common bagasse and biomass handlingsystems. The bagasse handling system will take-off the millbagasse from the take-off point in the sugar mill to the boiler,return the excess bagasse to the yard and supply bagasse from theyard to the boiler. Other biomass will be mixed in the bagassestorage yard.

All ash will be mechanically handled and conveyed to ash silos andwill be transported from the site by trucks / trolleys.

The fuel & ash handling system covered under this specificationshall be designed to achieve the following objectives.

Bagasse from sugar mill elevator & yard,biomass from the yardAsh from Boiler bed, Economiser, ESP Hoppersof Boiler & Bagasse from yard & mill

1 MaterialHandled

Ash from furnace through submerged ashconveyor will be normally wet when it isdischarged on to the belt.

Bagasse : 150 Kg/ Cu M2 Bulk DensityBagasse Ash: 180 Kg/ Cu. M

3 MaterialTemperature

180 Deg. C for the fly ash and40 Deg .C for the bagasse

4 Nature of AshMaterial

The ash collected will Contain un-burnt carbonParticles & also occasionally un-burnt Bagasse

5 Bagasse Ash analysis (% )SiO2 50 - 60Al2O3 10 - 13Fe2O3 10 - 12

CaO 3 - 5MgO 3 - 4TiO2 2 - 4P2 O5 1 - 2Na2O 0.5 -1.5K2O 4.5 - 6.0


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1.1.6.4

Cooling Tower & Pumps

A closed circuit cooling water system to provide cooling water forcondenser and power plant auxiliaries will be constructed. Pumpsand piping circuits will be provided for auxiliary cooling.

The cooling tower to be designed for continuous duty. The designof the tower shall be as per the enclosed specification and DataSheet.

The equipment offered shall be capable of cooling the ratedcapacity of water through the specified range at the design wetbulb temperature.

The specified design wet bulb temperature of 27.50C includes thenecessary recirculation allowance. Hence, Tenderer shall design hiscooling tower based on this design wet bulb temperature withoutconsidering further recirculation allowance.

While arriving at the air flow through the tower, due considerationshall be given to heat carried away by evaporation and enthalpycorrection of altitudes. Tenderer shall furnish detailed heat balancecalculation in support of the air flow through the tower. Tenderer

shall also furnish the basis of the enthalpy values indicated.

The motor rating of the cooling tower fans shall be at least 125% ofthe fan power requirement at the motor output shaft to take care ofany changes in tower loading or fan performance at a later date,Tenderer shall furnish calculations for arriving at the motor rating.

1.1.6.5

Water Treatment System

Raw water will be drawn by the Tenderer from the delivery header

of the raw water transfer pumps at the ground water reservoir.Appendix IVprovides the plant layout. Tenderer will also provideborewells at locations provided by the Owner / Consultant andconnect the same to the day reservoir before the water treatmentplant. The total capacity of the borewells should be 3000 m3/day

Schematic of plant water system is given inAppendix VIII


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Primary package consists of the treatment plant consisting of alum,polyelectrolyte, sodium hypo chlorite, and lime dosing systems,clarifloculator with bridge or tube settler, flash mixer, raw waterpumps, auxiliary equipments for clarifier / tube settler, clarifiersludge pipes, related sludge discharge pumps, clarified waterpumps etc., sampling devices, plant instrumentation, metering /measuring devices, pressure gauges, basket strainers, all piping etc.

Secondary system comprises of Multi grade Filters, ActivatedCarbon Filters, Filter Water pumps, Chlorine dosing and aciddosing, anti-scalant dosing systems, SMBS system related tanks andpumps, ultra-filtration unit, DM plant, Degasser, Degasser Tank,

Blowers, degassed water pumps, mixed bed units, related acid andalkali dosing tanks, ejectors, morpholine dosing systems, allauxiliaries, including pumps and piping. Plant instrumentationincluding pH, conductivity meters, flow metering devices andtotalliser.

Basis for Design

Source of water Sikharana River. In case of exigencies,borewell water will be required to be used

for process and boiler. Hence the watertreatment plant should be designedaccordingly.

Total outflow ofwater

DM plant : 1000 m/day, OBRPre-treatment plant : 1250 m/day. OBR

No. of Regenerationper day

One per stream

1.1.6.6

Compressed Air System

Two (2) instrument air compressors will supply the requirement ofcompressed air for instruments and the control systems of theproposed cogeneration plant with one (1) working and the otherstandby. Each of the compressors shall be of 7 kg/cm pressure.The air compressor shall be provided with accessories likeIntercooler, after cooler, Moisture separators, Air driers, Airreceivers and control panel.


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The air compressor shall be oil free two (2) stage reciprocating non-lubricating type with belt drive. The design of the reciprocatingcompressor will be opposed piston dynamically balancedaccording to the standard.

The heat exchangers (inter and after coolers) shall be designed asper TEMA-C and coolers shall be mounted horizontally. Thecooling water flow shall be through tubes and the tubes shall be ofcopper. The internal surfaces of the cooler shall be galvanized. Thecoolers shall be fitted with moisture separators and all necessaryaccessories.

The air drier unit shall comprise of 2 x 100% absorber towers withone of the towers in operation and the other one in regenerationmode. The towers shall be fabricated from SA 515Gr. 70 or IS:2002material and filled with alumina. The air drier shall be providedwith sequence timer for automatic change over valves. He entiredrying system shall be skid mounted.

The air receiver capacity shall be fabricated from SA 515 Gr. 70 orIS:2002 material. The internal surface shall be galvanized. The airreceiver shall be fitted with all accessories including safety valves,

moisture separators etc.

The control system of pressure switches, solenoid valves, regulatorsfor automatic loading of compressors shall be mounted on a localcontrol panel.

All air piping shall be internally galvanized.

The service air requirement of the Cogeneration plant, being verylow will also be met by the instrument air compressors. However

the service air will be directly tapped off from the air receiver bypassing the dryer units.


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The compressors are to be opposed, belt pulley driven, non-lubricating type reciprocating air compressors complete with driveguards, AC electric motors, LPBS, air receiver, intercooler, aftercooler, moisture separators, air dryer, moisture traps, allinterconnecting pipe work & fittings, control panel, etc. The heatexchangers shall be designed as per TEMA-C and coolers shall bemounted horizontally. The air receiver shall be fabricated from SA515 Gr. 70 or IS : 2002 material. The internal surface shall begalvanised.

Control air will be supplied to boiler and its auxiliaries, turbogenerator and its auxiliaries and common plant auxiliaries like

water treatment plant, fuel handling plant, ash, pump house etc.Compressed air will meet the requirements as stated below :

Capacity : 200 m3/hr or higher as per plantneeds

Nos.: : 2 nos. (1 operating & 1 standby)

Pressure at receiver outlet : 7 kg/cm2(g)

Dew point temperature atAtmospheric conditions : (-) 400C

Particulate material size (max.) : 1 micron

Contaminants : No corrosive, hazardous, toxicOr flammable material

Oil Content : 100% Oil Free

It is proposed to interconnect the service air system with theinstrument air system before the instrument air dryers. A non-return valve and a manual isolating valve will be provided in thisline so that instrument air cannot be supplied to the service airsystem.


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1.1.6.7

Tanks & Vessels

The tanks shall be designed, manufactured and tested inaccordance with the requirements of the ASME Boiler andPressure vessel Code Section VIII. Other equivalent standards arealso acceptable. All vessels for steam application shall be designedfor full vacuum.

The cogeneration plant tanks will have storage capacities asrequired by design of the systems. Tanks will be of the closed toptype. Tanks will be fabricated in accordance with guidelinesestablished by API or AWWA, as determined by the service. A

corrosion allowance of 3 mm shall be provided.

Overflow connections and lines shall be provided where requiredand will be at least one pipe size larger than the largest input lineor combination of inputs that can discharge simultaneously.

Maintenance drain connections shall be provided of an adequatesize to facilitate drainage of tanks is within a reasonable time.Manholes where provided on tanks and pressure vessels shall be ofsize NB 500. The manhole covers shall be provided with davits.

Ladders and cleanout doors will be provided on large tanks. DMwater tank shall be internally lined with natural rubber or paintedwith three coats of Epoxy Coating. DM water and make up watertank shall be provided with interconnection platforms andstaircase.

The saddles and reinforcement pads welded on to the vessels andtanks shall be of the same material as that of the vessel/tank shellor head. Insulated vessels shall be provided with insulation cleatsfor applying the insulation.


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1.1.6.8

Piping

All cogeneration plant piping will be as per applicable IBR / ISstandards. All piping will be aesthetically and neatly laid on piperacks with approved colour coding. The cogeneration plant pipingwill inter-alia include raw water intake, water treatment plant,cooling water circulation, auxiliary cooling water circulation, plantservice water, plant potable water, plant sanitation, compressed airring, drain piping, treated effluent piping, steam piping from boilerto turbine, steam piping from HP line via PRDSH stations to LP &MP headers, HP / MP / LP steam piping to all cogenerationauxiliaries, steam piping from LP & MP headers to sugar plant

headers.

HP piping to be sized for highest safety valve pressure at 110%MCR with maximum pr. drop of 2 kg/cm for the entire piping.The pipeline will be duly approved by IBR by the Tenderer on thebuyers behalf. Standard fittings like expansion loops, stream traps,supports etc. are to be provided. The line should be insulated tosuit weather conditions and preferably of LRB mattress withmultilayer mineral wool and aluminium cladding (22 g), to achieveskin temperature of not higher than 65C. Stress analysis for the HP

piping to be submitted by the Tenderer along with IBR approvedsteam pipe drawing.

All piping required for effectively connecting the steam generatorwith the steam, feed water, and other systems shall be provided.The piping provided shall be complete in all respects includingvalves, fittings, supports etc. as required. Necessary supportingmaterials, towers and trestles to support and anchor the pipelinesat regular intervals shall be supplied. Suitable expansion loops andhangers shall be provided wherever necessary.

Suitable expansion loops restraints and anchors shall be providedso as to ensure compliance with the applicable codes and to limitthe stress and reactions to within the allowable values.


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a)

The flow velocities in pipes shall be limited to the followingvalues:

Super-heated Steam. 30-60m/sec depending on pipe sizeSaturated Steam. 20 to 35 m/secCooling Water. Up to 3 m/sec

b) Drains at all low points and vents at all high point shall beprovided.

c)

Al local instruments shall be located on pipelines so as torender them observable from the nearest available platform.

d)

Oil drains shall be sized to run no more than half full whenflowing at a velocity of 0.3 m / sec, and shall be arranged toensure good drainage.

Material Of Fabrication Of Equipments And Piping WhereverApplicable

01 Clarifloculator Rotating Bridge Type02 Inlet well RCC

03 Alum Dosing Tank HDPE / FRP / MSRL04 NaOCl dosing tank HDPE / FRP / MSRL05 Polymer Dosing Tank HDPE / FRP / MSRL06 Lime Dosing Tank HDPE / FRP / MSRL07 Mixing channels RCC (Through flow pipe)08 Clarifier RCC09 Clarified water storage tank RCC10 Multi grade filter MSEP11 ACF MSEP12 Acid Measuring Tank HDPE / MSRL

13 Caustic Measuring Tank MS / MSRL14 Anti Scalant Tank HDPE15 Fast Flush Tank HDPE16 Backwash Tank HDPE / FRP17 Degasser Tower MSRL18 Degassed Water Tank MSRL


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19 Degassed Blower SS 316 internals20 Degassed water pumps SS 316

21 MB Unit MSRL22 ETP Pump SS 31623 Acid and Caustic Lye Pumps PP24 Neutralisation pit RCC with acid proof tile

lining25 Softener MSEP26 Brine Preparation Tank RCC Bitumen27 Brine Dosing Tank MSEP / Bitumen28 Sludge Sump RCC29 Sludge Pumps SS 304

30 DM water piping MSRL31 Soft water piping MS32 UFRO Unit SS / PVC / MSRR33 Effluent / Sludge Slurry PVC34 DM water tank MSRL35 Soft water tank MSEP36 Filtered water storage tank MSEP37 All dosing pumps SS 316 internals38 Raw water pumps CI39 Filtered water and clarified

water pumps

CI with SS 316 internals

1.1.6.9

Insulation

High grade insulation materials suitable for out door Steamgenerators shall be supplied with LRB mattress with mineral woolof multilayer with aluminium cladding, water proof lagging andprotected from rain water, wind and Dust etc. for the exposedportion of the steam and mud drums, steam generator furnaces,integral pipe work from the feed pumps to the steam generators,steam & exhaust piping, hot air & gas dusting, condensates pipes,valves having high temperature fluids & hot water / condensatesfeed water tank, de-aerated water tanks, and other steam generatoraccessories to be provided.


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Glass wool materials is used should confirm to I.S. 3690 - 1974 type2 mineral wool shall confirm to I.S. 5696 - 1970. The thicknessshould be to suit the diameter and temperature of pipes. The wiremesh should be of galvanized wire and lugs/pins used should begalvanized.

1.1.6.10

Fire Fighting System

Fire fighting scheme meeting TAC recommendations and ensuringplant & personal safety will be constructed.

Pressurized fire hydrant system will consist of a pipe network andhydrants positioned around the station in sufficient numbers and

so located that all buildings and risks are readily protected.Necessary number of loops will be formed around various risks.

The loops will be interconnected for better reliability of the system.To isolate a portion of the ring main because of damage/repair,suitable nos. of valves will be provided.

The hydrant network will be sized and analysed to ensure thatabout 3.5 kg/cm2pressure is available at the hydraulically remotestpoint in the system with the hydrant pump discharging at rated

head and capacity. The velocity in the hydrant main will notexceed 2 m/sec.

The fire alarm system shall consist of smoke detectors, heatdetectors, fire alarm panel, hooter, manual call point etc. Thedetectors shall be located in all the electrical panel rooms, controlroom and battery room. The manual call point and hooters shall belocated throughout the entire TG building. The detectors will sensethe fire automatically and will generate fire alarm through Firealarm panel.

The portable fire extinguishers shall consists of dry chemicalpowder type, carbon-di-oxide type, foam type fire extinguishers.The extinguishers shall be located strategically inside the TGbuilding.


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Raw water will be will be taken from the raw water pumps headerat ground water reservoir to the fire water reservoir in the cogenplant. Raw water will be used for fire fighting. Typical BOM forfire fighting is provided inAppendix IX

1.1.6.11

Crane for the Turbo-generator Building

An Electrically operated overhead travelling (EOT) crane withthe main hook lifting capacity suitable for maintenancerequirement of turbo-generator and an auxiliary hook liftingcapacity of 5 Tons shall be provided to facilitate maintenance of theTurbo-generators and their auxiliaries. The crane travel will coverthe entire length of the Turbo-generator building.

The crane shall be electrically operated, bridge type and shall bedesigned and equipped for indoor operation complete with allaccessories. The crane bridge shall consist of bridge girders eachone carrying a rail on which a wheeled trolley is to run. The bridgetrucks and trolley frames shall be fabricated from structural steel.Access walkways with safe hand railing are required along the fullspan length on either side of the bridge girders.

Bridge and trolley trucks shall be of cast steel or fabricated struc-

tural steel sections. Wheel trucks of cast or welded constructionshall be stress relieved as per accepted standards. Spring buffersshall be provided on the trolley and bridge structural frames atsuitable places to absorb the shock of impact without transferringto the structural frame.

1.1.6.12

Electrical System

The power generated will be evacuated to the sugar mill at thegiven terminal points. All the cogeneration power plant auxiliaries

will operate on the power supplied from the cogeneration powerplant. Balance of power generated after meeting the sugar andauxiliary load will be exported to the grid after stepping up to 132kV. DG set will be provided for emergency power. All other powersources including DC power, UPS, control power, lighting, etc. willbe derived from the cogeneration panels. Required earthing will beprovided to ensure safety.


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Proposed synchronous alternator shall be of 20 MW rating withgeneration at 11 kV. Surplus power, after meeting the cogenerationplant auxiliary requirement and power requirement of the sugarplant, shall be exported to the grid through 11/132 kV,ONAN/ONAF, generator transformer. The generator transformershall be suitable for exporting the maximum power at 132 kV,without any limitation in the plant operation and power export.

All equipment shall be designed to withstand the maximumfault levels provided in this tender document. The successfultenderer shall carry out complete system study for the electricalsystems to ascertain the selection of fault levels of the switchgears

are within limit, power (active and reactive) flow, system lossesand power factor at various MCCs, voltage level in various level ofvoltage, motor starting analysis and stability study of the plantwith BSEB grid.

Power system shall be designed so as to export the entire powerfrom cogeneration plant (total generation less auxiliary powerconsumption), when the sugar plant is not in operation.

Following lighting sources are considered,

Plant areas HPMV Lamp in Industrial type High Bayfixtures or in integrated Well Glassluminaries, Industrial type Fl. Lampfixtures with Vitreous enamelled reflectors

Electrical Room - Mirror Optic Fl. Lamps or CFL

Outdoor Lighting in transformer yard HPMV flood light fittings

Battery operated Critical Lighting provided at strategiclocations such as stair cases, control rooms and escape routes inthe plant area - CFL lamps


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Earthing arrangement in 132 KV switchyards shall be strictly as perthe statutory regulations. The earthing shall include:

a. Provision of earth electrodes for LAs, switchyard equipmentsbody earthing, T.G. set Alternator , D.G. set AlternatorNeutral and Body earthing, Transformer neutral earthing,earthing of structures etc.

b.

Provision of earth mat as per IEEE 80.c. Provision of lightning conductor over 33KV switchyard.d.

Provision of earthing grid conductor as per fault levelconsidered.

e.

Chimney Lightning protection and Lightning protection ofother buildings

The switchgear shall be free floor standing, totally enclosed, dustand vermin proof with draw out type circuit breakers. Verticalunits shall be assembled to form a continuous line Up of uniformheight and depth

The panel structure shall house the components contributing to themajor weight of the equipment such as circuit breaker, main

horizontal bus bars and other components are adequatelysupported without deformation or loss of alignment during transitor during operation.

Each unit of the switchgear shall have necessary internal sheetmetal barrier to form separate compartments for buses,instruments, relays, cable connections etc.

Adequate barriers shall permit personnel work safely within anempty compartment with the bus bars energised. Checking andremoval of components shall be possible without disturbing the

feeder.

All auxiliary equipment shall be easily accessible to facilitate theiroperation and maintenance. It shall be possible to set all relays andmeasuring instruments without de-energising the switchgear.


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All doors and opening shall be fitted with dust excluding neoprenegaskets with fasteners designed to ensure proper compression ofthe gaskets.

When covers are provided in place of doors, generous overlap shallbe assured between sheet steel surfaces with closely spacedfasteners to preclude the entry of dust.

The panels shall have a rear cable chamber housing the cable andconnections. The design shall ensure generous availability of spacefor easy installation and maintenance.

System Fault Level : 40 kA for 1 Sec. for 132kV system

: 40 kA for 1 Sec. for 11kV system: 50 kA for 1 Sec. for 415V System: 9 kA for 1 Sec. for Lighting Circuits

a) Power Supply:

132 kV + 10%, 50Hz + 5 %, 3 Phase for Grid Connection 11 kV + 10%, 50Hz + 5 %, 3 Phase for Generation and Power

Supply to 11KV Eqpts.

415 V + 10% , 50Hz + 5 % , TPN for plant load operating at415V supply

Control Voltage 110V AC, 50Hz for MCCs and PCCs Power Supply for Space Heaters, Plug Sockets, Lighting : 230

V,50 Hz, 1Ph.

Power Supply for Tripping and Closing Circuits of Circuitbreakers : 110 V, D.C.


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b) Power Distribution :

a) Power will be generated at 11KV, 3Ph, 50Hz with SteamTurbine. Power will be

stepped up to 132KV for Grid Connection andEvacuation to BSEB.

b) 11kV Power Supply will be given to Sugar PlantSwitchboard. Further downstream power distribution willbe done in Sugar Plant.

c) 11kV/433V distribution transformers are provided to caterpower to 415V rated equipments in plant.

d) 230 V Single phase power supply shall be derived through

Phase & Neutral for single phase power consumer.

c) Design Criteria In Equipments / Power Distribution :

All Busbars shall be Air insulated and of Aluminium. Busbarsize shall be selected based on Temperature limit of 85 C atBusbar for the rated current.

Power Cables (HV & LV) shall be XLPE armouredALUMINIUM conductors above and including 6 sq. mm.size. Power cables including and less than 4 sq. mm.

shall be copper conductor. Squirrel Cage Motors up to 15 KW shall have automatic

DOL Starter suitable - for operating from MCC, DCSand PB Station near Motors.

Motor rating above 15 KW up to 200KW shall be withAutomatic Star Delta - Starter suitable for operatingfrom MCC, DCS and PB Station near Motors.

Motor rating above 200KW shall be operated with SoftStarter suitable for operating from starter, DCS and PBStation near Motors. Starter Shall have bypass contactor

with AC3 rating.

VFD shall be provided as per the functional requirement.

Following spare feeders shall be considered in PowerDistribution

o In 11KV Switchboard - 1 No. Transformer feeder


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o Panels in other areas including PCC / MCC / DB -1 No. of Each Rating

MCC shall be floor mounted self supporting, dust andvermin proof , fixed type construction. Power Control Center (PCC) shall have Switch Disconnector

Fuse up to 630A and above 800A these shall have Manuallyoperated Draw Out (MDO) type ACB.ON indication shallbe provided on outgoing feeders.

Motor Control Center (MCC) shall have Switch DisconnectorFuse unit, Contactor and Bimetallic Over Load (O/L) relayfor starters. Starters on MCCs shall have ON & TRIPindication. The selection of switchgear components shallbe minimum with one stage higher than Type II coordination as per IS 13947

Motor protection shall be provided in ACVF Drives & SoftStarters, as inbuilt protection functions.

Rating of Switchboard incomer ACB/SDF shall be 1.2 timesthe operating load current.Protection & Indication

Flameproof equipments such as Push Button Stations,junction boxes, Lighting Switches, L lighting Fixtures etcshall be considered with hazardous area classification inEthanol plant.

Push Button Station with Shrouded type actuator for

ON push button, Lockable Mushroom type actuator forOFF Push button with Aluminum die cast enclosureshall be provided. Push Button Station for Motors above15KW rating shall be provided with suppressed scaleAmmeter. Push Button Station for VFD shall have SpeedSetting Potentiometer and speed indicator in addition toPush Buttons and Ammeter


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d)

Power And Distribution Transformer

The following criteria shall be applicable for the sizing ofTransformer1) Total Connected Load shall be calculated based on Motor

List.2) Operating Load shall be calculated excluding Standby Loads

and equipment for maintenance such as Crane.3) Load Factors shall be considered on Operating Loads

according to Load Factor to consider shall be as below:Motor Loads with DOL / S/D Starter / Soft Starters : 0.85Motor Loads with VFDs 0.75Lighting Loads : 1.0Utility Plug Sockets : 0.5Cranes, winches etc. : 0.1

4) Average Power Factor 0.8 shall be considered to arrive atKVA.

5) Equipment Efficiency shall be considered 90% as average.6) On such Calculated load + 20% Margin shall be considered.

7) If necessary percentage impedance shall be increased morethan the impedance indicated in IS to limit 415 V side FaultLevel to 50KA for 1 sec.

e) Power Factor Improvement

01) Plant PF shall be required to improve above 0.9502) This is achieved by providing:

Capacitors across HV Motors as per recommendation ofmanufacturer.

Provide Automatic Power Correction Panel with requiredno. of APP type capacitor banks in 415V PCC in CogenPlant.


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03) To determine number of capacitors following considerationbe givenOperating KW & Average operating P.F.Drive with VFD shall maintain P.F. above 0.95. These loadsshall not to be considered for deciding capacitor rating.

f)

LV Power Control Centre (PCC)

The following points shall be considered while designing andselection of components.I) TYPE OF FEEDERS:

Incomers : D.O. 3-Pole ACB

Emergency Power SupplyFeeder

: D.O. 4-Pole ACB

Outgoing Feeders : SDF up to 630 A: MDO Type ACB Above800A

II) BUSBARS Color Coded SleevedAluminumBus bar Size shall be selectedas per following norms:

Continuous current carryingcapacity as per the RatedCurrent of IncomerTemperature Rise LimitShort Circuit WithstandCapacity


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g) Motor Control Centre (MCC) :

The following points shall be considered while designing &selecting components.

I) Incomer Feeder - MDO ACB above 800 A up to 2000A

Fixed Switch Fuse Disconnector upto 630 A

II) Outgoing StarterFeeder

Feeders shall be comprising of:Switch Fuse Disconnector

ContactorsThermal Overload RelayTimer in case of Star Delta StartersPush ButtonsIndicating Lamps

III) Bus bar Above 125A ratingIV) Control Logic Plant shall be capable of operation

from MCC, DCS located at CentralControl Room or locally from PushButton Station near motor.02) It will be possible to start the Motorlocally through enable command fromPLC.03) P.F. and KW parameter of Incomershall be communicated to PLC.05) ON/ OFF Status of the Motor shallbe communicated to PLC.

V) Provision ofSpare feeders

In MCC total 10% spare feeders shall beprovided, depending on feeder ratings

in MCC following feeders shall beprovided.


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h) LV Bus Ducting

Bus duct up to 3200A shall be CRCA enclosure with color codedsleeved Aluminum bus bar. Short circuit rating shall be 50KA, 1sec.

i) Battery And Battery Charger

01) BATTERY: 1) VRLA Maintenance Free2) Capacity shall be determined by totaloperating load and 20% margin.3) AH shall be determined for 8 hourbackup time.

02) BATTARYCHARGER

1) Float and Float cum Boost with 20%capacity

03) DCDB : Built in with Battery charger panel withIncomer as MCCB & Outgoing as MCB.

j) Grounding / Earthing System) & Lightening Protection

01) Earthing shall be done according to IS 3043 1987.02) Earthing shall be carried out by G.I. Strips & Wires. Earth

Electrodes shall be G.I. Plate type & Pipe type as per requirement.However, Transformer Neutral will be connected to G.I. EarthElectrode through Copper Strip.03) Total Resistance of Earthing system shall be Less than one ohm.04) Plant shall be protected against lightning according to IS 2309-1989.


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k) Cables

The following consideration shall be given for Cable Sizing andSelection on Nominal Current Capacity Ambient Temperature in Air/Ground Continuous Load Current

Short Circuit Withstand Capacity Voltage Drop at the Starting of Motor limited to 15% & 5%

at Steady state up to motor terminals. Deration Factor due to type of Laying & Grouping. Generally Power and Control cables shall be stranded.

XLPE insulated cables upto & including 4 sq.mm shall be

with stranded copper conductors. Cables of 6 sq.mm &above size shall be with Al. conductor

Generally Cable trays shall be prefabricated Hot Dip GalvanizedIron. Cable Trays shall be run in Vertical formation as far aspossible.

HV & LV Power Cables shall have separating distance of 300mm.Separating distance between Power and Control cable shall be300mm. Instrument cables & screened shall run on perforated

cable tray having 300 mm separating distance of 300 mm.

The Lux Level in various indoor areas shall be as per IS. In plantareas, the lighting shall be provided as per functional requirement.

HPMV Well Glass with integral control gear box fittings (IP55)shall be provided in plant areas. Industrial FL. Lamp fittings willbe provided in sub station and other indoor areas. Mirror Opticfixtures shall be provided in CCR. In outdoor areas HPSV Lampfixtures (IP 55) shall be provided.

The lighting shall be catered by Main Lighting DB. LDB & SLDBconnected by Al. conductor cables. The Emergency power supplyfrom 415V DG set will be made available to lighting transformer incase of failure of power


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1.1.6.13

Instrumentation & Control System

The entire plant will be controlled by a centralized DCS with highredundancy level with inputs and controls of all loops, analyzers,control valves, motorized valves, motors, etc.

The integration of all the inputs / signals for continuousmonitoring, operation, data logging, data analysis, alarms, safetyinterlocks, annunciations etc. will be achieved through the DCS.

The DCS will include the DCS control station, related licensed

software & hardware, instrument & control cabling from themarshalling cabinet receiving signals from junction boxes of allcogeneration equipment, all MCCs and software links with Turbo-visory panel, Woodward Governor and turbine temperaturescanner.

The entire cogeneration plant will be smoothly started, normallyoperated, provided with necessary interlocks & emergency trips,monitored, controlled and smooth shut down from the DCS. TheDCS to have required software or compatibility to internet.

Basic Control Design should be as below:a.

Generator, gearbox, turbine bearing temperature monitoringshall be through the temperature scanner.

b. Critical AI/AO/DI/DO signals will be redundant whilenon-critical & DAS points will be non-redundant. Allcontrollers for critical controls will be redundant. The fieldinputs for critical inputs will be1/2 logics. 25% of the I/Osto be considered as critical.

c. Sequence of event recorder will be provided

d.

Required Annunciation windows shall be includede. 25% spare I/Os to be considered.f. TG governing will be by Woodward 505E. However the

critical parameters will be monitored by providing serialModus Interface


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g. All I/Os will be potential free

Plant communication shall be provided with Telephone system,Public Address System and Walkie-talkies

1.1.6.14

In-Plant Communication System

The cogeneration power plant will have an EPBAX system withintercoms at all operating locations, admin building and securitypoints. The EPBAX will have expandability and junction box to beinterconnected to the EPBAX systems of the sugar, ethanol andnon-plant buildings. The system will have minimum 20 extensions.The Tenderer will provide a wireless handheld walkie talkie system

of Motorola / Philips make for intercommunication of all plantpersonnel with minimum of 15 instruments. The required battery,battery charger, centralized transmission system, etc. to beincluded. The system will have a frequency which will not disturbany other public or radio system. The tenderer will be responsiblefor obtaining the in-principle and operating license and thefrequency allocation. Statutory fees, if any, will be paid by theOwner

1.1.6.15

Civil & Structural

a)

Construction Specification For Rough Grading

This specification covers furnishing all labour, materials andequipment, and performing the necessary work to completethe clearing, grubbing and excavating, filling, roughgrading, consolidation and compacting

i

Clearing And Grubbing :-

Within the battery limits, all shrubs, stumps,vegetation and jungle, including roots, shall beremoved and burned except as directed by the Owner/ Architect.


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ii Excavation :-

Excavation will include earth, weathered rock andhard rock. Whenever finishing grade is referred to, itshall mean to elevations indicated on the drawingsplus or minus thirty millimeters. For descriptivepurposes, excavation shall be classified as follows :-

Earth excavation shall be defined asunconsolidated, or consolidated material whichcan be broken with a pick.

Weathered rock shall be defined as consolidatedor cemented material which can be broken with apointed pry bar or pick.

Hard rock shall be defined as competentconsolidated material with few fractures thatcannot be broken with a pointed pry bar and mustbe blasted.

Ditch or channel excavation shall be defined as

that excavation between the invert of the channeland the point at which the channel side slopeintersects natural or finish grade, whichever islower

iii Filling :-

Filling shall consist of performing all operationsnecessary to place the fill to the line and grade. Fillingshall be placed in layers that are not over 150 mm

thick before compaction, then watered andcompacted as hereinafter specified.


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In platforms for structures, roadbeds, the top 150mmshall not contain lumps or rock of 60mm size orlarger. When filling is to be placed against hillsides orexisting fill, the material consists of large rockmaterial or hard lumps which cannot be readilybroken, such material shall be well distributedthroughout the fill, and sufficient earth or other finematerial as it is deposited, so as to fill the intersticesand produce a dense compact fill.

iv Watering :-

Watering for compacting backfill material and water

required for laying dust caused by grading operationsshall be applied as directed by the Owner. The watershall be applied so as to obtain the optimum moisturecontent for compaction. The application of water willbe by a distributor equipped with a spray system thatwill ensure a uniform application of water. At thedirection of the Owner, water may be applied to theexcavation area from which the fill is obtained.

v Compaction :-

All fill shall be compacted by road rollers, tampingrollers, or by tamping, as specified herein.

All areas within the bench area of buildings marked,compaction of all roads, shall be compacted bytamping rollers and / or road rollers. The layerexcluding the top layer shall be compacted by not lessthan four passes with the tamping roller. Before thelast layer is placed the road roller shall make one pass

over the area. The last layer shall then be placed andcompacted with the road roller by making not lessthan four passes. The balance of the fill may becompacted by using air operated or hand rammers, asdirected by the Owner.


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Tamping rollers shall be a metal drum surroundedwith metal studs with tamping feet projecting not lessthan 160mm from the surface of the drum. Thetamper feet shall be arranged in rows spaced not lessthan 150mm, nor more than 300mm on centre. Theload on each foot shall not be less than 250 poundsper square inch (17.58 kg/sq.cm.). The load per footwill be determined by dividing the roller weight bythe cross-sectional area of one row of feet across theroller.

Road roller shall be three wheeled and weight not lessthan 12 tonnes and shall produce a compression on

the rear wheel of not less than 325 pounds per linerinch (60 kg per liner cm) of wheel width.

Rammers shall have a base area of at least 28 squareinches (182 sq. cm.).

vi

Weed Killer :-

All roadway base shall be treated with a commercialweed killer applied according to the manufacturers

recommendations.

vii

Civil Works Requirements

Scope of Work

The scope of permanent works includes theconstruction of all earthworks associated withsite levelling and embankments, mass andreinforced concrete foundations to machinery

and buildings incorporating all holding downbolts and all site roads, hard-standing anddrainage for the structures


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Materials

Materials used in the works shall be new and asper approved list or relevant IS standards. TheOwners Representative shall have the right toreject any material that is damaged or hasdeteriorated and such materials shall beremoved from site immediately.

Branded materials shall be handled, stored andused, and processes shall be carried out strictlyin accordance with the manufacturer's

instructions and recommendations.

The Owners Representative may require theTenderer to obtain at his own expense acertificate in respect of any material stating thatit is in accordance with the relevant IndianStandard Specification.

Elevations and Benchmarks

Except where otherwise specified, all elevationswill be in meters above mean sea level with anaccuracy of two decimals. The data for all levelswill be based on Benchmarks. The Tenderer, onhis own responsibility, shall ensure that theWorks are constructed in relation to this data.Benchmarks and other points of reference in thevicinity of the Site may be indicated on theDrawings.


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viii Demolition And Site Clearance

Removal of Termite Hills

All termite hills shall be demolished and thesurplus material removed to tip. The cavityformed by the removal of the termite hill shallbe treated with the solution specified below in"TERMITE PROOFING" and then filled withapproved material in the specified manner forin-filling trenches.

Termite Proofing

Termite Proofing shall be undertaken over thewhole area of the buildings and aprons and shallconsist of the application of a solution of 5 partspentachlorophenol and 95 parts of furnace oil(by weight) well mixed together and applied bymeans of watering cans with fish tail spouts at arate of 5 liters per m2. Before treatment thesurface must be cleared of all rubbish and in

particular scrap timber. The treatment shall beon the ground after removal of the top soiland/or soft layer before making up levels.

Site Clearance

The site of the works shall be cleared of all trees,bushes and vegetation. Trees and bushes shallbe uprooted and raked into windrows andburnt. Holes left by stumps and roots shall be

filled with suitable material and compacted asspecified.


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Mature trees required to be preserved forlandscaping purposes will be indicated andmarked by the Owners Representative beforesite clearance commences. The Tenderer shalltake all necessary precautions to protect suchtrees from damage during all phases of theworks.

ix Earthworks

The excavation and fillings shall be carried out insuch manner and order as the Owners

Representative may direct.

The following definitions of the earthworks materialsshall apply to this tender in which reference is madeto the defined materials:

'Top Soil' shall mean the top layer of soilcontaining more than 5% by weight of organicmatter.

'Unsuitable material' shall mean other thansuitable material and shall include:

(i) material from swamps, marshes or bogs;

(ii) peat, logs, stumps and perishablematerial;

(iii) material susceptible to spontaneouscombustion;

(iv) clay of liquid limit exceeding 80 and/orplasticity index exceeding 55;


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'Rock' shall mean material which in the opinion ofthe Owners Representative requires the use ofwedges, pneumatic tools or blasting to enable theexcavation to be completed, but specificallyexcludes isolated volumes of rock or other hardmaterial of up to one cubic meter in content.

Rippable soft rock' shall mean material which, inthe opinion of the Owners Representative,requires the use of tractor drawn tines to break upthe material. These rocks will, in general, beweathered sandstones and other sedimentary

rocks.

'Ordinary ground' shall mean material which inthe opinion of the Owners Representative can beexcavated by normal excavation machinery.

b)

Construction Specification For Structural Excavation AndFine Grade

The work covered by this specification includes furnishingall labour, materials, equipment and performing theoperations necessary to complete the excavation and fillingrequired, for all buildings; structures and foundations andthe fine grading.

i Excavation:-

The Tenderer shall perform all excavation requiredfor the various structures and foundations. All

excavation shall be to line and grade required for theproper installation and removal of the forms and tofacilitate the construction. Excavation for allfoundations shall be carried one meter below the floorslab for interior footing or one meter below thefinished grade for wall footings and exterior footings.


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ii Back- Filling :-

After all below grade work has been completed andall debris has been removed, the excavated area shallbe backfilled. The backfilled material shall be theexcavated material and it shall be placed in 150 mmlayers.

iii Compaction :-

All backfill areas shall be well watered and wellcompacted by ramming as directed by the Owner.

iv

Shoring And Bracing:-

The Tenderer shall furnish and install all shoring,bracing and sheeting as required to adequatelysupport the excavation and to provide safety for thepersonnel. This shoring shall be removed as thebackfilling takes place.

v Fine Grade :-

The Tenderer shall furnish and install the sand orgravel sub grade below the floor slabs. This sub gradeshall be levelled and compacted. Exterior fine gradewill include cutting, filling and compacting.

vi Earthworks

Where the excavation reveals a combination ofsuitable and unsuitable materials the Tenderer shall,unless otherwise agreed by the Owners

Representative, carry out the excavation in such amanner that suitable materials are excavatedseparately for use in the Works withoutcontamination by the unsuitable materials.


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The Tenderer shall dispose of excavated materials insuch a manner and, at such time, as instructionsprovided by the Owner

vii Limits Of Excavation

The excavation shall be carried out to the requiredlines, levels, widths and depths.

Before commencing any excavation the Tenderermust satisfy himself as to the accuracy of the levelsshown and bring to the notice of the OwnersRepresentative any discrepancies.

Excavations shall be suitably trimmed and leveledbefore oversite concrete is placed. In locations wherethe material is subject to softening, a bottom layer ofsoil approximately 75 mm thick shall be left in andremoved immediately before the placing of concrete.

In the event of over-excavation, the area shall be filledwith selected excavated material or Grade 10concrete.

viii

Protection Of Excavations

The faces of excavations shall be retained withsheeting, timbering, strutting and shoring asnecessary to protect the workmen and to preventdamage to adjacent services and structures.

If, in the opinion of the Owners Representative,sufficient support of the excavation is not being

provided and the work is dangerous to workmen orproperty or to permanent work, the OwnersRepresentative may suspend operations untilsufficient timbering or sheeting is provided.


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The Tenderer must take every precaution againstslips or falls and should any occur he shall removethe surplus as required by the OwnersRepresentative.

All necessary temporary drains and culverts shall beconstructed to keep the site free of water. Trenchesand excavations shall be kept free of surface water bypumping or other means.

ix Approval Of Bottoms Of Excavation

The Tenderer shall report to the OwnersRepresentative, at least 24 hours before concreting isrequired, when suitable bottoms to the excavationshave been reached. Any further work executedbefore the excavations have been inspected andapproved shall, if required by the OwnersRepresentative, be removed and new worksubstituted after the excavations have been approved,at the Tenderer's expense.

x

Infilling Of Channels, Trenches And Pipes

When no longer required, all temporary channels,trenches or pipes which it may have been necessary toconstruct in or under the permanent work shall befilled with suitable material, approved by theOwners Representative. Infilling shall be performedin layers not exceeding 300 mm thick and each layerthoroughly compacted to the satisfaction of theOwners Representative.


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xi Blasting

The Tenderer shall store explosives, if required, in astore or magazine provided with separatecompartments for detonators. Explosives shall behandled by experienced and competent shot firers.The Tenderer shall ensure that there is nounauthorized issue or improper use of explosivesbrought on the Site.

Explosives shall be used in the quantities and mannerrecommended by manufacturers. The written

permission of the Owners Representative shall beobtained for each location or series of locations wherethe Tenderer wishes to use explosives.

xii Filling By Embankments

Suitable material arising from excavations shall beused where possible for filling on the Site, unlessotherwise specified or required by the OwnersRepresentative.

Where insufficient suitable material is available fromexcavations approved suitable material from borrowareas may be used.

Borrow areas within the Site will be those areasspecifically designated as such by the OwnersRepresentative.

Sand for filling, in making up levels, etc. shall be

naturally occurring sand, or sand prepared bycrushing natural stone.


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The compaction achieved in filling will be measuredby the following tests, carried out in accordance withIndian Standards 'Methods of Testing Soil for CivilEngineering Purposes'.

Density-Moisture Tests

Density Tests

The moisture content of the fill materials shall beadjusted as necessary to achieve the requiredcompaction.

The minimum relative compaction to be achieved inthe compacted areas shall be 100% of maximum drydensity as measured above. Any material which,after repeated compaction, does not achieve thisfigure will be removed.

Filling in areas on which no roads, structures orservices are to be constructed shall be spread in layersnot thicker than 100 mm and subjected to as much

traffic as possible during construction.

At the end of each day, the surface shall not be leftwith areas that can retain water and, if necessary,ditches shall be cut to ensure that this object isattained.

When the state of the weather is such that, in theopinion of the Owners Representative, it wouldadversely affect the placing of compacted fill, all such

work shall be stopped.

All filling material, whether placed and/orcompacted or awaiting placing and/or compactionwhich, in the opinion of the Owners Representative,does not comply with the specification or has beendamaged by weather or in any other way.


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xiii Frequency Of Compaction Test

Each layer shall be compacted satisfactorily beforeproceeding with the next layer, with a maximumthickness of 200 mm per layer.

xiv Surplus Excavated Material

The disposal of excavated material shall be carriedout as required by the Owners Representative.

All surplus excavated material, where so required,

shall be removed and transported to a tip.

The location of such tip will be specifically designatedby the Owners Representative, within the overall Siteor without.

xv Hard Core

Hard core shall be sound approved uniformly gradedstone of maximum size 150 mm.

xvi

Clay For Lining

Clay used for impervious lining shall be excavatedfrom borrow pits on site as required by the OwnersRepresentative. The location of borrow pits will bedetermined by the Owners Representative on siteduring the progress of work. The maximum hauldistance from borrow pits to areas requiring liningshall not exceed 4,000 meters.


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xvii Compaction Of Clay For Lining

Materials for impervious linings shall be deposited inuniform layers, not exceeding 150 mm. The materialshall be compacted so that it is homogeneous and freefrom lenses, pockets, streaks or other imperfections.Each layer shall be compacted using a 'sheepsfoot'roller of sufficient weight for proper compaction, byhand or power tampers or by other means andequipment approved by the Owners Representative.

The dry density of the soil fraction in the compacted

material shall not be less than 95 per cent of thelaboratory standard maximum soil density (dry) asdetermined by Test as specified.

If the water content is less than that required foroptimum compaction, water shall be added either atthe site of excavation or at site of compaction asnecessary.

If the water content is more than that required for

optimum compaction the material shall be rejected foruse or compaction shall be delayed until such time asthe material has dried out to the optimum watercontent.

xviii Stone Pitching

Stone pitching shall be of sound, durable, crushedrock or natural stone as approved by the OwnersRepresentative and shall be uniformly sized between

100 mm minimum dimension to 150 mm maximumdimension.


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The stone shall be hand placed in a single layer andbedded on a uniform surface of approved excavatedmaterial to give a uniform finished surface withmaximum opening between contiguous stones of25 mm.

Stone pitching shall be pointed with a mortar of 3parts sand to 1 part cement.

xix Rip-Rap

Rip-rap shall be of sound, durable, crushed rock or

natural stone as approved by the OwnersRepresentative and shall be uniformly sized at 200mm nominal maximum dimension.

The stone shall be placed and spread to produce theminimum finished thickness with a uniform finishedsurface.

xx Seeding

The ground shall first be rotovated to a depth of 300mm, leveled and raked free of stones. Prior tosowing, the ground shall be well watered and seedthen spread at the rate of 1 kilogram per 20 squaremeters. Seed will be covered by raking and theground consolidated with a light roller.

The area will be watered daily by the Tenderer untilthe site has been accepted by the Owners

Representative.


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c)

Construction Specification For Concrete

The work covered by this specification includes furnishingall labour, materials, equipment and performing theoperations necessary to complete the concrete work. TheTenderer has to prepare the working drawing alongwith thebar bending schedule in detail alongwith the form drawingsfrom the R.C.C. drawing and shall get approved the same,prior taking up the actual work activities at site.

i Applicable Publications :-

All work shall be in accordance with the latestrevision of the Indian Standard except wherespecifically noted otherwise : -

Plain and Reinforced Concrete I.S. 456Cement I.S. 269Aggregates I.S. 383Structural Safety I.S. 875Testing of Concrete I.S. 516Sampling I.S. 1199

Compaction I.S. 2505 I.S. 2506Rapid Hardening Cement I.S. 8041Admixtures I.S. 9103 I.S. 2645

ii Materials :-

Cement

Cement shall be ordinary portland cementconforming to I.S.269. All cement used in exposed

concrete faces of the structure shall be of the samemanufacturer. All cement shall be suitablyprotected from exposure to moisture until used.Special cement, if any, shall be used only after theapproval of the Owner/Architect.


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Coarse Aggregate

Coarse Aggregate shall consist of approved soundcrushed rock or gravel. It shall be free of organicmatter or other deleterious material. Adequatesupplies of coarse aggregate shall be stockpiledsufficiently in advance of construction to permitsampling and testing before use.

Fine Aggregate

Fine Aggregate shall consist of approved natural

sand, or crushed stone screenings combination ofboth;and shall be hard and durable. It shall befree of organic matter or other deleteriousmaterial. Adequate supplies of aggregate shall bestockpiled sufficiently in advance of constructionto permit sampling and testing before use.

Water

Water shall be clean, fresh and free from organic

or deleterious matter in solution or in suspension,and shall be added in such amount that may notimpair the strength of concrete as specified.Water, for mixing concrete, shall be supplied bythe Owner, if available at site, otherwise Tendererhas to make his own arrangement for theconstruction water requirement. For all purpose,the Tenderer shall arrange his own supply, storageand necessary pumping and conveyance system.

FormsForms shall be of wood or metal, approved by theOwner/Architect.


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Admixtures

The use of admixtures is encouraged where asound technical reason justifies it, but with theapproval of the Architect/Owner.

Water stops

Water stops may be either rubber or copper.Copper water stops shall be 24 guage material.

Expansion joint filler

Expansion joint filler material shall consist offormed strips of a durable resilient compound.Where stiffness is lacking in proformedexpansion joint filler, the strips shall be encased insaturated felt, asphalt impregnated cottonwebbing or other satisfactory material. Anymaterial used for encasement shall be firmlysealed to the body of the joint filler and shall notbecome detached there-from after immersion in

water for a period of 48 hours. Expansion jointfiller material shall be manufactured in aworkman-like manner and when 10 percent ormore of any lot or shipment is of non-uniform orimproper construction, the entire lot or shipmentmay be rejected.

iii Concrete Design Mix And Strength:-

Unless otherwise noted on the drawings, all concrete

shall be proportioned so as to obtain a twenty eight(28) days cube compressive design strength of 200kg/cm2 at preliminary test. The grade of concreteshall be M:15 (1:2:4 approximately) / M:20 (1:11/2:3)or as specified. The design mix shall be prepared byan established testing laboratory and submitted by


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the Tenderer to the Architect / Owner for approvalbefore use.

iv

Grading Of Aggregates :-

Aggregate shall be furnished in primary sizesspecified herein and shall be stored in separatebatching. bins and batched as required to confirm tothe combined grading requirements. Theproportioning of the fine and coarse aggregate maybe varied as directed by the Engineer to produce aworkable mixture.

The maximum size of aggregate shall be controlled bythe purpose for which the concrete is intended and inaccordance with the following table.

Location Maximum SizeCoarse Aggregate

Massive Foundations 2 inch (63mm)Typical Foundations 1 inch (38mm)Columns, Beams and Girders 1 inch (25mm)Walls 8 inch (200mm) and thicker 1 inch (38mm)

Walls 6 inch (150mm) and thinner inch (18mm)Slab at grade thicker than 4 inch(100mm)

1 inch (25mm)

Slab at grade 4 inch (100mm) thick inch (18mmStructural slabs inch (18mm)


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The grading of aggregates shall be as follows :

PERCENTAGE PASSING SIEVESSIEVES Primary Aggregate Size Combined Aggregate Sizes

2 Inch 1 Inch Inch Fine 2 max 1 max max3 100 1002 90-100 95-1002 35-100 100 80-85 1001 0-15 95-100 65-85 95-1001 0-10 55-85 100 50-75 50-80 100 0-5 35-70 90-100 45-65 45-75 90-1003/8 10-30 20-55 100 35-55 35-60 60-80

No.4 0-5 0-10 95-100 30-45 30-45 40-60No.8 0-5 80-85 20-35 20-35 30-45No.16 50-85 15-30 15-30 20-35No.30 25-60 10-15 10-15 10-25No.50 10-30 5-10 5-10 5-15No.100 2-10 0-3 0-3 0-5No.200 0-2 0-2 0-2 0-2

v Storage Of Aggregates :-

Aggregates shall be stored or stockpiled in such amanner that separation of coarse and fine particles ofeach size will be avoided and also that various sizeswill not become intermixed before proportioning.Aggregate in storage shall be adequately protectedfrom dust or other foreign matter and all aggregates,which have become coated with dust or foreignmaterial to such an extent as the Engineer maydetermine, has impaired the quality of the aggregates,shall be washed or rejected as the Engineer maydecide

In placing materials in storage or moving them fromstorage to the mixer, any method which may causesegregation, degradation, or combining of materialsof different grading, shall be discontinued and thematerials so handled shall be reprocessed.


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vii Amount Of Water And Slump Tests :-

The amount of water added at the mixer shall be inaccordance with the design mix and shall beregulated in accordance with the free water in theaggregates and the requirements for workabilitywithin the limits of slump test forth. The amount ofwater, including the free-water in the aggregates,shall not exceed 25 litres per sack of Cement. Theequipment for measuring and supplying the water tothe mixer shall be so constructed and arranged thatthe amount of water to be added to the mixture can

be measured positively, and the predeterminedquantity of water required can be discharged rapidlyin one operation. The equipment shall be so designedthat water from the source of supply cannot enter themeasuring tank while the water is being dischargedfrom the measuring tank into the mixer.

Location Of Concrete SlumpHeavy sections & foundations 2-3 inches

(50mm to 75mm)

Thin sections 8" and under. 3 inches (75mm)Slabs at grade 3-4 inches

(75mm to 100mm)Structural slabs. 3 inches (75mm)

All slumps are to be plus or minus 12mm. Slump testshall use the procedure of I.S.- 456. Slump test will bemade by the Tenderer in presence of theEngineer/Architect.


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viii Form :-

The forms shall be smooth, true to line and gradeand of sufficient strength to resist any appreciablespringing out of shape during the placing ofconcrete. All dirt, chips, saw dust, tie wire, orother foreign matter shall be removed from theforms before any concrete is placed therein. Beforeconcrete is deposited in the forms, all insidesurfaces of the forms shall be coated with anapproved form oil. The form oil shall be of highpenetrating quality leaving no film on the surface

of the forms that can be absorbed by the concrete.

All sharp corners above grade shall be chamferedwith 1"x1" (25mm x 25mm) triangular fillets. Thefillets or chamfer strips shall be surfaced on allsides.

Forms shall be of sufficient strength to carry thelean weight of the concrete as a liquid without anydeflection. Forms for beams, girders and slabs

shall be cambered such amount as may bedirected.

Form ties shall be approved form clamps or boltsto fasten the forms. The use of twisted wire-loopsto hold the forms in placing during concreting willnot be allowed. Bolts or clamps shall be positive inaction and shall be of sufficient strength to preventspreading out of the forms. They shall be of suchtype that can be entirely removed or cut back

25mm below the concrete surface. All forms forside of members shall be constructed with stiffwales at right angle to the studs and all formclamps shall extend through and fasten suchwales.


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Plans of false work and centering shall besubmitted to the Owner/Architect two weeks inadvance of the time, the Tenderer beginsconstruction of the false work. All false work andcentering shall be designed and constructed toprovide the necessary rigidity and to support theloads. All false work shall be adequately braced.

The forms and false work shall not be removed orreleased before the concrete has obtainedsufficient strength to support itself, but in no caseless than the following time, shall the formsremain in place:-

---------------------------------------------------------------------LOCATIONS. TIME

---------------------------------------------------------------------Sides of footing 24 hoursMass footings 3 daysColumns 3 daysWalls 5 daysSides of beams or girders 5 daysSoffits of beams or girders 21 daysStructural slabs 14 days

---------------------------------------------------------------------At time of low temperature or other adverseconditions, the Owner may increase the setting timeto 28 days.

Removal of forms shall be in such a manner as to notdamage the concrete. Centering shall be removeduniformly and gradually starting at the middle of aspan and working towards the support.


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ix Concrete Coverage Of Reinforcing :-

The concrete coverage of reinforcing steel shall be asfollows, except, as specifically noted otherwise on thedrawing.

----------------------------------------------------------------------------LOCATION COVERAGE

----------------------------------------------------------------------------Footing poured against earth 3 inches (75mm)Footing poured against forms 2 inches (50mm)Formed concrete against earth 2 inches (50mm)Columns 2 inches (50mm)

Beams and Girders :-Bottom of beams 2 inches (50mm)Sides of beams 2 inches (50mm)Tops of beams 1 inches (38mm)

Structural Slabs :-Bottom 1 inch (25mm)Tops 1 inch (25mm)

------------------------------------------------------------------------------

x Waterstops :-

Waterstops shall be accurately located and securedagainst displacement during the placing of concrete.For rubber water stops, all field splices shall be full-vulcanised, shall be bevelled at 45 degree or flatter.All finished splices shall have a tensile strength of notless than 50 percent of the un-spliced material. Forcopper water stops, all splices be lapped 25 mm and

soldered each side of the joint to form a smoothwatertight joint.


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xi Expansion Joint Filler :-

Expansion joint filler shall be placed true to line andgrade and shall be placed full depth of slab or widthof wall. It shall be securely held in place by cementingto the oldest concrete, at the joint, with a bitumasticcement. The ends will be butted tight.

Expansion Joints In Buildings

Where shown, expansion joints shall be formedbetween the concrete faces, or between c