tender document for design, supply ,installation ... · mbr technology stp( 120 kld ... erection...

TENDER DOCUMENT

FOR

Design, supply ,installation, commissioning and operation of the MBR technology STP( 120 KLD capacity) at BPCL township , Ernakulam

PREPARED FOR

BPCL-KOCHI REFINERY

APRIL 2017

FACT ENGINEERING AND DESIGN ORGANISATION

Specification No./Task Rev. 0/ Date

DESIGN, SUPPLY ,INSTALLATION AND COMMISSIONING THE MBR TECHNOLOGY STP OF 120 KLD CAPACITY)

BPCL-KOCHI REFINERY

SCOPE OF WORK

.

DATA SHEET

SPECIFIC REQUIREMENTS OF WORK 8138 - 12– DA - 009

PAGE 1 OF 25 R0

0 25.10.2016 GS LTA LTA

REV. DATE PRPD. BY CHKD. BY APPRD. BY


12FT026/94

DESIGN, CONSTRUCTION, COMMISSIONING & OPERATION OF STP OF

120 KLD CAPACITY BASED ON MBR TECHNOLOGY AT BPCL

TOWNSHIP ERNAKULAM.

1.0 INTRODUCTION

Bharat Petroleum Corporation Limited, Kochi Refinery (BPCL-KR) is constructing a

residential township in their land near Kerala High Court, Ernakulam. FACT

Engineering and Design Organisation (FEDO) the engineering consultancy division of

the Fertilisers and Chemicals Travancore Limited (FACT), is the Project Management

Consultant for the project. The project aspires to achieve highest rating under

‘GRIHA’, the green rating offered by TERI under MNRE (Ministry of New and

Renewable Energy).

Sewage treatment plant (STP) based on MBR technology (Membrane Bio Reactor) is

proposed for the treatment of waste water generated in the township so as to use the

treated water for flushing system of toilets.

2.0 SCOPE OF WORK

The tender is invited on turnkey basis for Design, Engineering, Supply, Construction,

Erection and Commissioning of 120KLD Sewage Treatment Plant (STP) based on MBR

technology, to provide treated effluent quality as specified under cl. 4.0 of this document

with performance guarantee for three years.

The schematic P&ID attached with this document is preliminary. However, the successful

contractor will be required to submit the Detailed Process, P&ID & Good For

Construction (GFC) drawings incorporating the working details. These detailed drawings

shall be submitted to Consultants for comments & approval. Vendor has to submit all the

technical details for equipments used for operation of plant to the consultant for approval.

DATA SHEET

SPECIFIC REQUIREMENTS OF WORK 8138 - 12 - DA - 009

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12FT026A/94

All the works shall be carried out as per approved "Good for Construction” drawings only.

The project involves Design, Construction, Supply, Erection, Testing &

Commissioning of STP of 120 KLD capacity complete in all respects including all

contingent Civil, Electrical, Mechanical, piping & instrumentation works and

including operation & maintenance of the system for three years at BPCL Township

Ernakulam.

The tender is for turnkey job where it will be the responsibility of the contractor to

hand over a completely functional unit complying with PCB norms and with all

necessary components.

The work shall include but not limited to the following major items:

i. Design and engineering of STP to be operator friendly and for the operator’s

safety, health and hygiene.

ii. Design Calculations and drawings shall be submitted to Client/Consultant for

approval. Construction shall be started only after approval of GFC (Good For

Construction) drawings by consultant.

iii. Design & installation of all civil structures for the system including pile

foundation.

iv. Getting the required approvals, permissions, NOC from the statutory /

government agencies including incurring related expenses. ‘Consent to establish’

STP has already been obtained by BPCL. ‘Consent to operate’ shall be taken by

Contractor.

v. All aspects of quality assurance, including testing of equipment, procurement of

materials from approved agencies/suppliers and other components of the work.

vi. Testing of all equipment at shop. Pre-dispatch inspection of equipment shall be

carried out by Consultant.

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vii. Complete interconnecting piping between various units as per piping details

including supply of all materials like GI pipes, fittings, all valves, gaskets,

flanges, nuts and bolts , necessary pipe supports, etc., complete

vii. Project Management to ensure completion of Project as per timelines.

viii. Submission of Operators’ Manual and training of personnel.

ix. Submission of the completion (‘as-built’) drawings and other related documents

along with a soft copy.

x. Making good any defect during the performance guarantee period of three years.

Spares for the entire equipments and instruments for three years including labour

for replacing all damaged components of STP are also covered under vendor scope

vide the performance guarantee. For MBR membrane, additional two years

guarantee shall be provided by the Contractor.

xi. Operation of the plant for 3 years after the completion including cost of consumables

and labour.

The location of the treatment plant is indicated in the layout plan enclosed.

Battery Limits are defined as follows:

1. Sewage Inlet to pumped manholes inside STP 2. Treated water to final sump in the STP 3. Electrical feeder to LT panel. 4. Fresh water line to STP

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3.0 QUALITY OF INLET EFFLUENT

The inlet sewage from apartments and multipurpose hall will generally have the following characteristics: pH 5.5 – 9.0 BOD (3 days at 200C) mg/l 250-350 mg/l COD 400- 600 mg/l Suspended Solids 250 – 300 mg/l Oil & Grease less than 50 mg/l Boron ,maximum 2 mg/l Total Coli form MPN/ 100 ml, maximum 10000 Faecal Coli form MPN/ 100 ml, maximum 5000 Faecal streptococci MPN/ 100 ml, maximum

5000

4.0 REQUIRED WATER QUALITY

Quality of Treated water

The treated sewage shall have following characteristics suitable for flushing water closet: pH 6.5 – 8.5 BOD (3 days at 270C) mg/l less than 3 mg/l COD Less than 30 mg/l Suspended Solids Less than 10 mg/l Oil & Grease less than 1 mg/l Boron ,maximum Nil Total Coli form MPN/ 100 ml, maximum < 200 Faecal Coli form MPN/ 100 ml, maximum < 200 Faecal streptococci MPN/ 100 ml, maximum

< 200

Any other parameters required by Pollution Control Board shall be complied by the

Contractor at no extra cost.

The contractor shall submit the report confirming the above parameters for the testing

of treated water on quarterly basis from reputed/ Govt. approved Laboratory, failing

which the penalty of Rs. 10,000/- per quarter shall be deducted from the bills of the

contractor & in addition BPCL /Consultant shall test the water sample at the cost of

the contractor. The test report of treated water shall confirming the above parameters

within the permissible limit of (+/-) 5%, the contractor should call MBR expert for

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taking corrective action at his own cost as per direction of Engineer-In-Charge, failing

which BPCL will call the MBR expert & charges incurred by BPCL shall be

recovered from the contractors bills.

Other than above, additional testing of treated water will be done by BPCL for routine

quality checking of treated water.

5.0 TREATMENT SCHEME

The treatment scheme shall be based on Membrane Bioreactor based Biological

Treatment followed by chlorination. The STP will consist of following stages:

Stage 1: Primary Treatment

Pumped manholes with cutter pumps, Screen Chamber, Oil & Grease chamber,

Sewage collection cum equalization tank

Stage 2: Secondary or biological treatment

Aeration tank equipped with PVDF submerged membranes

Stage 3: Tertiary treatment

Activated Carbon Filters, Chlorine Dosing System

Stage 4: Sludge Treatment

Filter Press

5.1 TREATMENT UNITS

Following are the main units involved in above treatment scheme,

1. Pumped manholes with cutter pumps for pumping out sewage

2. Bar screen chamber coarse (an ultrasonic non-contact type open channel flow

measurement meter shall be installed before the bar screen).

3. Oil and Grease separator

4. Fine Screen

5. Coarse bubble diffuser.

6. Equalisation tank

7. Pump Room

8. Anoxic tank/ Aeration tank/ MBR tank.

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9. Chemical cleaning of membranes

10. Activated Carbon Filters

11. Micron filter

12. Chlorine dosing

13. Final tank

14. Filter Press with screw pump

15. Sludge holding tank

16. Piping and cabling

17. Units designed and proposed for LT panel

18. PLC Panel

6.0 BRIEF PROCESS DESCRIPTION

6.1 Pumping

The inlet sewage coming to pumped manholes is pumped to bar screen chamber

using cutter pumps separately for Soil, grey water and kitchen waste water.

6.2 Screening

The Sewage is led into a Bar Screen Chamber provided with MS Bar Screen. Bar

screen shall be provided at inlet point in the bar screen chamber. Screen with

openings generally of uniform size to remove suspended or floating matters in sewage

to be provided. The primary screen has to have size of 10 - 15 mm and secondary

screen has to have size of 4-5 mm. The velocity shall be maintained so as to avoid

settling of grit or organic matter. Bar screen shall be so designed that it can be cleaned

manually from outside of tank.

6.3 Oil & Grease Chamber

The raw sewage after passing through Bar Screen shall be taken into an oil & grease

trap for removal of oil and grease from the effluent.

6.4 Raw Sewage Sump (Collecting Tank)/ Equalisation tank

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This sump is provided to dampen the flow fluctuations and, in order to keep the solids

in suspension, pre-aeration is provided with coarse bubble tubular diffusers.

The sewage collection tank has to have a storage size of 50% of daily sewage

generation/sewage treatment. The raw sewage from oil & grease trap is collected in a

raw sewage collecting sump. The raw sewage is pumped using submersible non-clog

SS pumps of suitable capacity. Facility has to be made to purge air in the collection

tank to keep its content homogenous and avoid high anaerobic condition in the tank.

6.5 Aeration tank with submerged membrane bioreactor

The Sewage will be pumped to aeration tank which comprises fine pore diffusers and

PVDF hollow fiber submerged membrane. The efficiency of BOD removal is

considered as between 90 – 97% in this bioreactor.

The MBR tank contains highly concentrated biomass, so called activated sludge,

which transforms the organic matter of the wastewater into carbon dioxide, water and

biomass. The activated sludge is kept in aerobic conditions at all times by continuous

aeration.

Sludge will be retained in the Aeration tank and excess sludge will be pumped/

passed to sludge holding tank and then pumped to Filter press whenever MLSS

measured is higher than designed.

6.5.1 PARAMETERS OF DESIGN OF MBR TANK

Process type – Aeration

Flow regime – Completely mixed

MLSS – 6000 - 10000 mg/lit

MLVSS/MLSS – 0.8

F/M Ratio – 0.1 – 0.12

6.6 Activated Carbon Filter and micron filter

Permeate from MBR tank is passed through activated carbon filter and micron filter

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to remove excess turbidity before chlorine dosing.

6.7 Disinfection unit (Chlorine Dosing)

Permeate of membrane is further treated with chlorinator and stored in final sump.

The Chlorine Solution shall be dosed in clear treated sewage with the help of Dosing

pumps as a disinfecting agent and allowed to react in the tank with adequate retention

time. Necessary flow pattern should be created in the tank for proper mixing and

allowing completion of reaction by providing baffles.

The quantity of disinfecting agent should be sufficient, to achieve the microbial count

as per the Prevailing norms for treated sewage as given by State Pollution Control

Board. The dosing system shall be suitable to .deliver on 24 hours continuous basis.

6.8 Sludge Sump

The waste sludge from aeration tank is passed to sludge holding tank and then

pumped through screw pump to filter press and solid cakes formed are carted out.

Excess sludge has to be drained from reactor drain valve and sent to sludge

dewatering press. Leachate from the press can be sent back to collection tank or final

treated water tank. Sludge cake should be stored in proper place as per the norms and

guidelines.

6.9 Solids Handling (Filter Press)

The Sludge from the sludge drying bed shall be pumped for solid- liquid separation

on to Filter Press. The filtrate from the Filter press will be collected and can be used

for horticulture or dispose in solid form.

7.0 MCC/ Plant Room and miscellaneous structures

MCC/ Plant room of required sizing with brick masonry walls, Aluminium doors,

windows & RCC roof and miscellaneous structures like cable trenches with supports

for cable trays, pipe supports, valve pits, inspection chambers and all interconnecting

piping shall be under the scope of contract. Micro grading of site as per requirement

shall be in the scope of Contractor.

7.1 PLC operated control panel

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All the pumps have to be controlled with PLC operated control system. Refer

minimum automation requirements listed under cl. 9.3. The plant has to be equipped

with required instrumentation like flow meters, Dissolved oxygen meters and pH

meter for smooth and trouble free operation.

8.0 Hydrotest of Sewerage System

Hydrotest of tanks/ Chambers and connected piping as per standard specifications

shall be under the scope of Contract at the quoted rates.

9.0 SCOPE OF SUPPLY OF EQUIPMENTS

Following equipments of suitable capacity shall be supplied by the Contractor.

Supporting calculations to arrive at the capacities shall also be furnished.

1. Cutter pumps – 3 Nos Casing/Impeller MOC – C.I

2. Coarse bar Screen – screen size 10 to 15 mm, MOC- Epoxy painted MS

3. Fine Screen – Mesh size 4 – 5mm, MOC – SS-304

4. Sewage Transfer Pumps – 1W+1S, submersible & non-clog pump

5. MBR Module equipped with hollow fibre membranes – 120m3/day

6. Membrane filtration pump with VFD – MOC -SS , 1W+1S

7. Treated water/Backwash pump, MOC –SS, 1 W+1S

8. Sludge transfer pump –MOC – SS, 1 W+1S

9. Air blower with acoustic enclosure – 1W+1S

10. Screw pump and Filter press

11. Miscellaneous items like interconnecting Piping with required fittings – UPVC,

class- 10MPa, Valves, construction fasteners, chlorine dosing system, Chain pulley

block- 1 No of adequate capacity MS hoist with galvanised chain pulley shall be

provided over Membrane tank for lifting membrane cassette.

12. Electrical and instrumentation items

Any other equipment required for smooth operation of the plant shall be under

the scope of contract at no extra cost.

9.1 CIVIL WORKS

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Civil works for the following tanks/ structures including the necessary excavation and

backfilling of earth shall be under the scope of Contractor. All RCC works shall be of

grade M30 using PPC cement. Design basis for civil works are specified separately.

1. Pumped manholes ,3 Nos, MOC RCC

2. Bar screen Chambers, MOC RCC

3. Oil & Grease Trap, MOC RCC

4. Equalisation tank- 1 No, RCC

5. Treated Water Storage Tank – 1 No RCC

6. Sludge Drying Bed 1 No RCC

7. Plant cum MCC Room, MOC Brick masonry walls with RCC roof slab

8. Chlorine Dosing facilities

9. Tank for cleaning membranes- 1 No Sintex or Eqvt tank of required capacity.

10. Grading/ levelling of site, foundations, pipe and underground cable trenches,

grouting, platforms, pipe supports, inserts, puddle pipes, structural supports for air

grids & pipes

11. Pile foundation for civil works is also included in the scope of this contract.

Design and construction of Piles shall be done assuming the following data :

600 mm dia bored cast insitu pile of M30 grade concrete, 35 m length, vertical

capacity of pile- 1000 kN. Representative borelog is attached for reference.

12. Vendor shall design the plant so as to limit the depth of RCC tanks below GL to

minimum possible extent. Necessary dewatering required for construction of

underground tanks shall be in the scope of contractor with no extra payment.

9.2 ELECTRICAL WORKS

9.2.1 BATTERY LIMIT

Separate MCCs shall be provided for STP. One number 200A,415V, 50 Hz, 3 phase and

neutral feeder shall be made available at the incoming terminals of vendor’s MCC.

Termination of incoming cables at vendor’s MCCs shall be done by the vendor .MCCs

for STPs shall be installed at the MCC room in STP area .Starter feeders for all drive

motors ,feeder for lighting, welding socket outlets, feeder for UPS etc. shall be provided

in MCC. The downstream cabling shall be included in vendor’s scope.

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Earthing of individual equipments in the package is also included in the vendor’s scope.

The package shall be completed on a turnkey basis by the vendor including supply and

erection of all electrics required for the STP. Supply and installation of electrics shall be

as per engineering specification 13ES924/14 , data sheet 8138-13-DA 92401 enclosed

with this document and CEA standards .

9.2.2 Lighting of the STP using suitable LED type lighting fixtures is also included the scope

of work.

9.2.3 Motors of suitable rating and protection shall be provided for all motor driven

equipments. Variable frequency drive as required shall also be provided as per the

enclosed specifications. All motors shall be energy efficient EFF-3 type.

9.2.4 Local Start/ Stop Push Button(PB) stations shall be provided near the motors. PB station

shall be provided with ammeter (digital type)for all motors rated 7.5KW and above.

9.2.5 Cabling inside MCC room /STP building shall be through over head GRP cable trays.

Cabling outside STP building shall be through GRP trays in built-in cable trenches with

RCC slab (to be provided by the vendor) .For details of cable trench refer civil

specifications.

9.2.6 Cables shall be PVC insulated , armoured FRLSH. Cables of size below 16 sq mm shall

be of Copper. Minimum size of power cable shall be 4 sq mm. Cables of size 16 sq mm

and above shall be Aluminium. Minimum size of control cable shall be 2.5 sq mm.

9.2.7 Make of items shall be as per the Sub Vendor list attached. For items not included in the

list the makes shall be got prior approved from the Purchaser.

9.2.8 Safety items / miscellaneous items including danger notice plate, insulation mat, welding

sockets etc shall be provided by the Vendor.

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9.2.9 Vendor shall provide all the necessary documentation and shall obtain approval for the

electrical installation from statutory authorities like Electrical Inspectorate (CEA) as

specified in Clause No.14 of 13ES924/14.

9.3 INSTRUMENTATION WORKS

The STP plant shall be operated continuously and automatically with interlocking of

tank level and pumps through a micro PLC mounted in a cubicle in the control centre

located beside the MCC room. In line with the P&ID for the STP plant, field

instruments like level, flow, temperature, pressure and analysers shall be with local

digital display. All powering of field instruments shall be through bulk power supply

110VAC/24VDC derived through a 110VAC UPS located at the control centre. The

micro PLC shall be interfaced to the MCC relay contacts and also to the level

switches for automatic operation. All the field instruments shall be terminated at

field junction boxes (FJB) (power/signal) through branch cables; and from the FJB to

the control panel multi pair cables shall be used for interconnection. The RITTAL

control panel shall be prewired and installed with all the necessary receiving

instruments for data and interlocking like multi point scanner/recorder with logging

facility, micro PLC etc. as a package. OPN/INDN of pumps has to be in PLC panel.

The following field instruments are covered in the scope of the vendor.

1. Level Transmitter with trip amplifier and switch for equilisation tank

2. Level Transmitter with trip amplifier and switch for treated water tank

3. Pressure gauges at the discharge of membrane filter pump, screw pump

and treated water pump.

4. Temperature transmitter with local gauge

5. Flow transmitters with local gauge (magnetic)

6. Open channel flow meter with local gauge (ultra sonic)

7. pH meter with display

8. Pressure switch

9. Control valve / Trip valve with SOV.

10. Chlorinator system

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11. Turbidity analyser with display

12. Dissolved oxygen analyser with display

All the instruments shall be powered from the control centre and appropriate cabling

for power and signal shall be used. All field instruments shall be mounted on

stanchions and installed as per hook-up drawings to be approved by consultant. All

cable glands shall be double compression SS 304. For interfacing the digital signals

with the micro PLC panel (RITTAL) cables shall be used. Appropriate separate

instrument earthing of the PLC panel (RITTAL) shall be carried out. The sub vendor

makes of all field instruments, PLC and panel, power supply (UPS), cables and field

erection accessories shall be as specified herein. The vendor shall furnish the final

P&ID with detailed instrument list, data sheets and catalogues for approval of the

consultant prior to placing P.O. Also the QAP/TC of each instrument and functional

reports of PLC etc. shall be furnished for review/approval of consultant prior to

despatch. For the PLC the logic scheme for the interlock system shall be vetted by

consultant prior to implementation, EPROM back up shall be provided for the PLC.

After site erection and cold loop check the entire instrument system shall be hot loop

checked with interlock system prove out.

Scanner with logging facility or multipont recorder (12 Point) to be provided on a

RITTAL panel of 800(L) x800(W) x 2100(H) dimensions, to be located at the control

centre. All field instruments shall be powered from the RITTAL panel through fused

terminals for isolation and two wire system shall be followed for transmitters of

24VDC. The control centre shall be enclosed type, dust proof and shall be provided

with 5 star rated split A/c type 2Nos with timer control for redundancy to ensure

performance of instruments. The UPS shall be standalone 110VAC , 5KVA of

consultant approved make only. The bulk power supply (BPS) shall be 24VDC ,10A

for instrument loop powering. The control centre shall be adequately lighted with

glare free LED lamps and shall be air conditioned (Split AC of 1Ton capacity) to

ensure proper performance of the instruments. This specification outlines the general

requirements for the instrumentation of the STP plant, however any additional

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instruments or accessories required to prove the performance of the plant shall be

supplied/erected / implemented by the vendor.

9.3.1 TECHNICAL SPECIFICATION FOR INSTRUMENTATION ITEMS

I MICRO PLC

1. I/O Capacity :.16 Input & 12 Output (Indicative only) 2. Power on LED : Required 3. Scan Time : 100 mSec or better 4. Enclosure : General, Indoor use 5. Mounting : Panel mounting 6. General

Power supply : 110 V AC 50 Hz/24VDC LED indication for I/O status : Required LED for diagnostics : Required Diagnostic functions : Required Programming : EPROM based- Through front panel/ programmer Programming language : Ladder Functions : Arithmetic/Bit operations/Timers/Counters etc. Facility to add expansion units Battery back up for program and data On line battery/ Memory replacement Automatic restart after power on. Min 20% installed Spare capacity. 25% provision to add future add module input as well as out put separately.

7. I/O Inputs : Potential free Out puts : Relay Contacts , Rating 110V Ac 2 A Isolation for I/O : Required Short circuit Protection : Required

8. Accessories Required Programmer with software, cable, battery, battery charger etc Accessories for panel mounting Documentation- Operation and Maintenance manuals Spare programmed EPROM For multiple voltage levels adequate number of interposing relays to be provided. Repeaters and trip amplifiers shall be provided for driving trip signals from

AI Interposing relays as required with appropriate rating.

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II LEVEL TRANSMITTER

Type : Non-contact - ULTRA SONIC Process Connection : 2” Power supply : 2 wire Measuring Range : As per vendor design Temperature : As per vendor design Sensor Material : PVDF Output : 4-20 mA, Digital communication via HART Cable Entry : 1/2” NPT

The Accessories like mounting bracket, stanchion and canopy, adapters (mating

flange) etc. are in vendor’s scope of supply.

III FLOW TRANSMITTER

Type : Electromagnetic/Ultrasonic Power supply : 2 wire Output : 4-20 MA +HART Cable Entry : 1/2” NPT Accuracy : + 0.1% FS

IV ELECTRONIC TRANSMITTER – TT/PT/DPT

Type : Std. 1/2" NPT, Smart 2 wire transmitter Output : 4-20 mA + HART Local indicator : Required, Digital, plug-in type LCD Enclosure : W/P IP 65 External zero/span adjustment : Required Accuracy : +/- 0.075 % FS Rangeability : 1 : 100 Compensation : Amb. Temperature/ Pressure Calibration : Manual/ By calibrator Electrical connection : ½” NPTF-2 nos., one entry plugged with SS

plugs Mounting stanchion/ Bracket, with bolts & nuts : Reqd in SS 304 Accessories : 2/3-valve manifold, Oval flange adaptor

double comp. Cable glands, flow element as required.

V PRESSURE GAUGE

Fluid : Water

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Case : Cast Aluminium Dial size : 150 mm Working pressure : As per vendor design Pressure range : As per vendor design Ring type : Screwed Element : Bourdon Location/size : Bottom ½ “ NPT (M) Connection type and rating : Screwed NPT (M) Mounting : Local Element : SS316 Case : SS304 Movement : SS316 Accessories : GAUGE CONNECTER – SS 316 Accessories connection : ½ “ NPT (M) Size/type : Blow out disc micrometer pointer Enclosure type : Weatherproof, IP 55

The gauge shall be a safety type with solid front where pointer and glass are partitioned off from the bourdon tube by a solid disc. Pressure gauges on vibrating equipment shall either be of oil filled type or a standard gauge with flexible connection and mounted on anti vibration pads. Pulsation dampners shall be installed with gauges where pulsating pressure occurs.

VI PRESSURE SWITCH

Element : Bourden/Bellow actuating a micro switch depending on

pressure, 110VAC, 6A

Connection : ½” NPT(F) Set point accuracy : + 0.5% with adjustable differential Enclosure Type : Weather proof

VII JUNCTION BOX SPECIFICATION

Type : Hinged, Die cast Aluminium Enclosure : W/P IP65 Mounting : Bracket / pedestal mounting Cable gland : Adequate double compression cable glands to be

provided Earthing terminal : Required Drain fittings : Required

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Tag plate : Non corrosive SS tag plate Terminals : Terminals shall be of Phoenix/Elemex make

VIII pH / Turbidity / Dissoved oxygen analyser

Power : 24VDC, 2 wire Output : 4- 20 with local digital indicator Transmission : Required pH : 0.00 – 14.00 pH Accuracy : + 0.1 pH Range : As per vendor Design

IX CONTROL PANEL

Make : RITTAL Type : Self standing, Std as per RITTAL Rear opening split door Atmpsphere : Air conditioned Size : 800(L) x800(W) x 2100(H) Painting / colour : RAL7035, powder coated & Galvanized MP. Gland plate : 3 mm minimum Cable Gland : Double compression , Nickal plated brass

Instrumentation cables shall be power/signal and control conforming to IS1554 and shall be supplied and laid as per actual requirements. Vendor/DS/TC of cables shall be furnished for approval of consultant prior to dispatch. The field cable routing and loop termination philosophy shall be furnished to the consultant for approval.

The data from the field transmitters shall be displayed on a multi point scanner/ recorder of minimum 12 channels with logging and recording facility and mounted on the RITTAL control panel fully interconnected and wired to the terminal strips. The panel wiring drawings and layout/ GA etc. shall be furnished for approval along with BOM and specific data sheets/catalogues to the consultant. The entire instruments and accessories shall be integrated on the RITTAL control panel and tested at vendors shop prior to dispatch in an exhaustive and comprehensive manner acceptable to the consultant.

In addition to the above, the Contractor has to arrange for complete system to be fully

functional and operational. The complete set up has to be installed at site along with

the details mentioned below:

1. Power cable upto control panel

2. Piping from inlet to the plant to outlet from treated water storage tank

3. Testing facility for testing raw and treated effluent

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4. Approval from local authorities

5. Oil free instrument air inside plant room for automation

6. All supplies, works and services not specifically mentioned but required for

successful running and operation of the system.

7. Interfacing of PLC with MCC and field instruments.

8. Powering of field instrument from UPS/PLC cubicle.

10.0 Approval from Pollution Control Board

Obtaining necessary approval from Pollution Control Board shall be under the scope of

STP Contractor. All statutory fees shall be paid by the contractor and shall be reimbursed

by BPCL-KR provided the fee invoices are raised in the name of BPCL-KR. All expenses

related to liaison, travel of statutory authorities, lodging and any other expenses incurred

thereby shall be borne by the contractor and shall not be reimbursed by BPCL-KR.

11.0 PERFORMANCE GUARANTEE

The guarantee is applicable for the performance of individual process equipment as

well as overall performance of the Sewage Treatment Plant.

11.1 Manufacturer’s Guarantees

The manufacturer’s guarantee for design, workmanship and performance for all

bought out items shall be made available to the owner and shall be valid at least for

the entire performance guarantee period.

In the event of failure of any particular equipment which fails more than three times

during the guarantee period as mentioned in clause below, the contractor shall

replace the equipment at his own cost. Manufacturer’s / Contractor’s guarantee, for

such replaced equipment shall also be made available to the Owner and should be

kept at least for one year from the date of last replacement.

11.2 Performance Guarantee for Sewage Treatment Plant

The Contractor shall give guarantee for a period of three years from the date of

successful Commissioning of the treatment plant against design, defective materials,

workmanship and performance. The contractor shall give guaranteed treated waste water

quality as indicated in Table – A. Any defects found in the workmanship, materials or

performance of the unit shall be made good by the Contractor at his own expense within

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the time specified by Engineer-In-Charge.

Table A : Guaranteed Quality of Treated Wastewater from STP

The treated sewage shall have following characteristics to suit water for flushing purpose : pH 6.5 – 8.5 BOD (3 days at 270C) mg/l less than 3 mg/l COD Less than 30 mg/l Suspended Solids Less than 10 mg/l Oil & Grease less than 1 mg/l Boron ,maximum Nil Total Coli form MPN/ 100 ml, maximum < 200 Faecal Coli form MPN/ 100 ml, maximum < 200 Faecal streptococci MPN/ 100 ml, maximum

< 200

In case the quality of treated Sewage from STP varies from what is required, the

Contractor shall rectify the plant at no extra cost so as to achieve the requisite

performance guarantee and satisfy commissioning of the plant to the Engineer-In-Charge.

11.3 Equipment Guarantee

The Contractor shall guarantee for the period of three years from the date of successful

commissioning of the treatment plant against defective performance of all equipment /

instruments / mechanical or electrical parts under Contractor’s scope of supply. Any

defects found either in materials or workmanship shall be made good by the Contractor at

his own expense within the time specified by the Engineer-In-Charge.

11.4 Guarantee for Membrane

The Contractor shall guarantee for the period of five years from the date of successful

commissioning of the treatment plant against defective performance of MBR Membrane

and shall replace the defective membrane at his own expense within the time specified by

the Engineer-In-Charge.

11.5 Testing and Trial Run

The Vendor shall have to test the each equipment used for the plant for at least 72 hours

continuous running with designed load and to the full satisfaction of Engineer-In-Charge.

Any defects found, has to be rectified by the contractor at his own cost immediately and

DATA SHEET


PAGE 20 OF 25 R0


12FT026A/94

within reasonable time to be decided by client.

The contractor shall have to dry test each process equipment used for the plant for about

48 hours continuous running to the full satisfaction of the Engineer-In-Charge. After

satisfactory testing of the individual equipment, the Contractor shall run the whole plant at

no extra cost to the owner for at least 30 days as directed by the Engineer-In-Charge and

ensure the treated Sewage quality.

Necessary instruments, gauges, supervisory personnel etc. shall be furnished / provided

by the Contractor free of cost for conducting the trial runs.

11.6 Commissioning and Approval from Pollution Control Board

During trial runs as described above, the Contractor shall satisfy the Engineer-In-Charge

in all respects regarding the satisfactory quality of materials, equipment and workmanship

used in the plant and quality of treated Sewage. Only after satisfying himself, regarding

the above points the Engineer-In-Charge will issue the completion certificate and such

date shall be deemed as date of commissioning.

The performance guarantee Period described above will start from the date of

commissioning or on obtaining approval from Pollution Control Board by the Contractor

whichever is later.

Vendor shall specify the minimum wastewater required for commissioning of STP with

TENDER. By the time of commissioning if sewage is not available at the inlet point, the

same shall be arranged by the Contractor at his expenses.

12.0 VENDOR DATA REQUIREMENTS

The following documents shall be submitted by Vendor.

Data sheets to be duly filled before submission

final P&ID with detailed instrument list, data sheets and catalogues

QAP/TC of each instrument and functional reports of PLC prior to despatch.

Detailed specification with guarantee details of the equipment.

Efficiency curves and catalogues for the equipments used.

Design and Layout of pile foundation for civil structures

DATA SHEET


PAGE 21 OF 25 R0


12FT026A/94

Design calculations and drawings for Civil structures

“As built” drawing after completion of project.

Manual for operation, maintenance & trouble shooting.

Recommended list of spare parts, which are frequently required for trouble free

operation.

Separate drawing and details for cleaning and backwashing of membranes.

Warranty of membranes with manufacturer certificate.

Also see vendor data requirements of electrical & mechanical items.

13.0 GENERAL CONDITIONS/ INFORMATION TO BIDDERS

1. All tools/tackles/materials/ scaffolding/machinery/ manpower, all incidental items

not specified but implied necessary for the successful completion of the work etc.

shall be arranged by the Contractor.

2. Transportation and safe storage of all items for work/ equipments supplied by

the Contractor is in the scope of the contractor.

3. Work shall be carried out only on the basis of drawings marked “Good for

Construction” with addition, alteration, modifications, if any made to aforesaid

drawings as required from time to time that has to be approved by the client/

Consultant.

4. Supply of all types of laboratory equipment or its test report from any third party

approved by Owner/Consultant, during and after commissioning shall be under the

scope of Contractor

5. Tenderers are requested to visit the site to understand the nature of work and

familiarize with the location. They should gather sufficient idea about the lead and

lift of construction materials and constraints in executing the work before

submitting their offer. The offers shall be, deemed to have been made with full

knowledge of all features of the area as well as the procedures to be followed for

executing the work.

6. The work is going to be executed in a premise where other construction agencies

DATA SHEET


PAGE 22 OF 25 R0


12FT026A/94

are also doing work. The work should be carried out causing no hindrance/

disturbance to other agencies. The area should be properly protected and

barricaded wherever required to avoid any nuisance.

7. The contractor shall provide to the work force engaged by him and ensure the use

of the following personal protective equipment as found necessary and as directed

by the authorised officials/consultant.

(a) Safety Helmets conforming to IS-2925

(b) Safety Belts conforming to IS-3521

(c) Safety shoes conforming to IS-1989

(d) Eye, Ear & Face Protection devices conforming to IS-8520 and IS-8940,

IS-5983

(e) Hand & body protection devices conforming to IS-2573, IS-6994, IS-8807

& IS-8519.

(f) Rubber gloves for electrical purposes confirming to IS-4770

(g) Industrial safety gloves (leather & cotton gloves) confirming to IS-6994

(h) Industrial and safety rubber knee boots confirming to IS- 5557.

14.0 INDICATIVE MAKE OF EQUIPMENTS

Make of all piping/Equipments/Motors/Cables and Pumps shall be clearly stated in

the offer and shall be approved by Consultant before Supply & Installation. The

decision of Consultant in this regard shall be final and binding on the successful

Contractor.

Please refer to indicative list of equipments given below.

a. Bar screen - Enviro Pure Aqua Systems or equivalent

b. Membrane Modules & skid with Panel -GE/Hydranautics/Sinomo

c. Pressure transmitter - E&H, Instrumentation Ltd., Siemens Ltd., Honeywell

Automation India Ltd.

d. Level transmitter ‐ Endress & Hauser, Magnetrol Intl INC., Nippon FIisher Co. Ltd, Siemens Ltd.

e. Level switches - E&H , General Instruments Consortium, Instrumentation Ltd,

DATA SHEET


PAGE 23 OF 25 R0


12FT026A/94

Magnetrol Intl INC, Tokyo Keiso Co. Ltd.

f. Pressure indicators - H.Guru / Waree, Manometer (India) Pvt. Ltd., General

Instruments Consortium, Premier Instruments & controls Ltd.

g. PLC panel : ABB Limited, Siemens Ltd, Allen Bradley, Honeywell, Yokogawa

India Ltd

h. Temperature indicator - H.Guru, Switzer Instrument Ltd, Blue Bells Control

Systems Pvt Ltd.

i. Contol /Trip Valves - MIL controls Ltd., Emerson Process Management Ltd.,

Dresser Valve India Pvt. Ltd, Instrumentation Ltd.

j. SOV - ASCO/ROTEX

k. Pressure switches : Indfos Industries Ltd., Switzer Instrument Ltd., Vasu Tech

Ltd.

l. Cables - Associated Cables, Toshniwal cables , Universal cables, Ltd. Associated Flexibles & Wires Pvt Ltd

m. Junction Boxes - Baliga Lighting Equipment Pvt Ltd , Flexpro Electricals n. Scanner/ Recorder - Honeywell/ABB/Yokogawa o. Erection Accessories/flow element/hook up hardware. - Micro precision etc. p. Ball valves – stainless steel Normex / Equivalent

q. Butterfly valves (3” and above) Normex / Intervalve PLC Siemens

r. MCC, Motors, Cables- Refer sub vendor list for Electrical

s. Control & Instrumentation cables Polycab / Finolex / Equivalent

t. UPS -Emerson Network Power India Pvt. Ltd /DB Power Electronics, Pune/IGA

Tech Industrial Electronics Pvt. Ltd/Unicorn Power Solutions Pvt. Ltd

Note :

1. Also see suggested vendor list for mechanical items

2. Above makes and accessories are approved subject to their meeting the

specifications & requirements in tender. Contractor however shall seek approval of

specific Make

from the Engineer-in-charge before commencement of work. The final choice of

DATA SHEET


PAGE 24 OF 25 R0


12FT026A/94

make to be used in the work will rest with the engineer-in-charge whose decisions

shall be final & binding on the contractor.

2. For any item not covered in the above list, the contractor shall get the make & sample

approved from the engineer-in-charge before procurement. The final choice of make

to be used in the work will rest with the Engineer-in-charge whose decisions shall be

final & binding on the contractor in this respect.

3. The contractor shall supply ISI marked material as per the makes/brands indicated

above.

In case, the firm is not manufacturing ISI marked material for any of the brands, first

quality material shall be accepted.

4. The samples of the material shall be get tested and have to be got approved from the

engineer-in-charge.

5. Material where no make/brand has been mentioned, in this case ISI marked samples

shall be submitted by the contractor for approval of engineer-in-charge.

6. For those class of materials, where no firm exists with ISI approval, samples of first

quality material of the firm shall be submitted for the approval of Engineer-in-charge.

7. Contractor will be responsible to ensure the quality of products listed in approved

list of makes/brands. Contractor will have to replace the defective and substandard

materials at his own cost.

15.0 LIST OF ABBREVIATIONS

STP - Sewage Treatment Plant

KLD - Kilo Litres per Day

MBR - Membrane Bio Reactor

BOD - Biological Oxygen Demand

COD - Chemical Oxygen Demand

F/M Ratio- Food to Microorganism Ratio

PVDF - Poly Vinylidene Difluoride

MLSS - Mixed Liqour Suspended Solids

MLVSS - Mixed Liquor Violatile Suspended Solids

PLC - Programmable Logic Controller

DATA SHEET


PAGE 25 OF 25 R0


12FT026A/94

VFD - Variable Frequency Drive

GRP - Glass Reinforced Plastic

FRLS - Flame retardant Low Smoke

CEA - Central Electricity Authority

OPN/ - OPEN

INDN - INDICATION

SOV - Solenoid Operated Valve

EPROM - Erasable Programmable Read Only Memory

NPT - National Pipe Thread

TT/PT/DPT – Temperature Transmitter/Pressure Transmitter/Differential Pressure

Transmitter

GA – General Arrangement

Specification No./Task Rev. 0/Page 3 Date


SCHEDULE OF ITEMS OF WORK

BPCL-KOCHI REFINERY

DE

SL.NO

(1)

P

12FT0

1

CIVIL EPARTMENT

NAME OF W

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Design, detaile

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guarantee will

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TEMS OF WO

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BPCL-KOCHI REFINERY

SCHEMATIC P&ID AND DATA SHEET

.

DATA SHEET SEWAGE TREATMENT PLANT

(MEMBRANE BIO REACTOR - MBR)

8138-12-DS-009 (001)

Page 1 of 2 Rev. 0

0 27.03.2107 ENQUIRY RELEASE

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED


Sl.No Parameter Specification (to be filled in detail by the bidder)

1. Plant Capacity 120 KLD (120 m3/day), (1 day as 20 hours)

2. Membrane type

3. Make of Membrane

4. Material of Membrane

5. Pore size

6. Plan area

7. Depth

8. MLSS

9. Flux rate

10. Air requirement for membrane

11. Air requirement for biological unit

12. Cleaning system

13. Chemicals used

14. Sludge generated in %

15. BOD committed at exit of MBR

16. Sludge Management

17. Total Power requirement$

18. Operational Cost (Approx.)

19. Replacement Guarantee for Membrane

20. Mechanical Guarantee

21. Process Guarantee

22. Details of Similar Experiences

DATA SHEET SEWAGE TREATMENT PLANT

(MBR)

8138-12-DS-009 (001)

Page 2 of 2 Rev. 0


$ Equipment-wise break-up of power consumption shall be tabulated below.

Sl. No. Equipment Unit Power Total connected power

Total Connected HP



ENGINEERING SPECIFICATION

MECHANICAL

BPCL-KOCHI REFINERY

TECHNICAL PROCUREMENT SPECIFICATION

GENERAL REQUIREMENTS OF THE PROJECT (MECHANICAL)

8138-01-PS-009GEN(MECH)

Page 1 of 9 Rev. 0

0 27.03.2017 ENQUIRY RELEASE LA AAN AAN



1.0 END SUCTION PUMPS:

1.1 End suction pumps shall be horizontally mounted complete with drive

motor on a common base plate. The pump / drive coupling shall be of the

spacer type to facilitate removal of the pump rotating element and

bearing housing without dismantling the pump casing, adjoining pipe work

or drive motor.

1.2 The bed plate shall be of fabricated steel construction with floor fixing bolt

holes ready drilled. All holding down bolts etc. shall be supplied with the

units.

1.3 Impellers shall be provided with means to prevent abrasive matter

reaching the glands and with fully shrouded impellers, to prevent the

trapping of matter between the impeller vanes and the casing.

1.4 The speed of any pump shall not exceed 1,500 rpm.

1.5 Glands may be fitted with suitable mechanical seals or conventional soft

packing. The gland arrangement shall be designed for ease of adjustment

or removal of the seal or packing material. Shafts shall be sleeved around

the area of the gland when soft pack glands are used.

1.6 Flushing facilities shall be provided for mechanical seals or packed glands,

where pump fluid may be contaminated with abrasive material. Where

soft packed glands are used, means shall be provided for collection of the

gland leakage water, which shall be piped into the drainage system

through adequately sized ports.



8138-01-PS-009GEN(MECH)

Page 2 of 9 Rev. 0


1.7 Lubrication arrangements shall be so designed that there is no

contamination of the pumped fluid.

1.8 The pumps and associated pipe work shall be, wherever possible,

arranged so that air can be completely expelled during priming. Where

this is not possible, facilities shall be provided for the removal of the

trapped air. Adequate facilities shall be provided for drainage of the

pumps for inspection purposes.

1.9 Tapping shall be provided at both the suction and discharge flanges for

pressure gauge equipment.

2.0 SUBMERSIBLE PUMPS:

2.1 Submersible pumps shall be of the totally submersible centrifugal or mixed

flow type capable of operating below a 15m. head of water. The pumping

unit shall be suitable for continuous operation, designed to meet the

desired performance and capable of handling the pumped medium without

undue wear and tear.

2.2 The motor shall be direct coupled to its pump and rated for continuous full

load operation above or under water.

2.3 The insulation rating of the motor shall be Class F rated, but at full load

the temperature rise shall restrict to temperature limits of Class B

insulation. Supply rated output at deviations of up to + 10% of the rated

voltage and + 3% frequency. The motor shall be toIP68 BS 5490.

2.4 The cable termination shall be water tight and provided with a cable

sleeve and strain relief.

2.5 The motor shall have ball type bearings permanently greased and

maintenance free.



8138-01-PS-009GEN(MECH)

Page 3 of 9 Rev. 0


2.6 The pump and motor shall be separated by two mechanical face seals. The

lower seal shall rotate in the water medium and the upper seal shall rotate

in an oil bath medium.

2.7 The pump shall have a non-overloading performance characteristic and its

efficiency shall be high at the duty point and remain at a reasonably high

level over the duty range of the pumping system.

2.8 Rotating assemblies of pumps shall be statically and dynamically balanced.

2.9 The pump wear rings shall be easily replaceable.

3.0 INDUCTION MOTOR:

3.1 The motors shall generally conform to IS: 325 or relevant, equivalent

internationally approved standards.

3.2 Additionally the specific requirements mentioned in the document

13ES924/14 - ELECTRICS FOR TURNKEY INSTALLATION shall be met.

4.0 VALVES:

4.1 General:

4.1.1 Valves shall be as per internationally recognised standards. Flanges shall

be machined on faces and edges and conform to ISO 7005, IS 6392 or BS

4504 standard.

4.1.2 Valves shall be double flanged type and the face shall be parallel to each

other and flange face should be at right angles to the valve centreline.

Back side of valve flanges shall be machined or spot faced for proper

seating of the head and nut.

4.1.3 Valve buried or installed in underground chamber, where access to a hand

wheel would be impractical shall be operated by means of extension

spindle and/or keys.



8138-01-PS-009GEN(MECH)

Page 4 of 9 Rev. 0


4.1.4 Valve of diameter 450 mm. and above shall be provided with lifting eyes

and shall have detachable bolted covers for inspection, cleaning and

servicing.

4.1.5 Valve shall be suitable for frequent operation as well as operation after

long periods of idleness in either open or closed position.

4.1.6 The valve stem, thrust washers, screws, nuts and all other components

exposed to the water shall be of a corrosion resistant grade of stainless

steel.

4.1.7 Valves shall be free from sharp projections.

4.2 Butterfly Valves:

4.2.1 Butterfly valve shall be as per IS 13095 / BS 5155. Valve shall suitable for

mounting in any position.

4.2.2 The valve seat shall be secured to the valve body. When the valve is fully

closed, a seal shall seat firmly so as to prevent leakage. The seat surfaces

shall be machined smooth to provide a long life for the seal.

4.2.3 The valve seal shall be replaceable and securely clamped to the edge of

the disc by stainless steel seal retention members, or equivalent so as to

prevent leakage and to hold the seal securely during operation. The seal

retention member shall be securely clamped with stainless steel fasteners.

All fasteners shall be set flush so as to offer the least resistance possible to

the flow through the valve.

4.2.4 Valve shall be suitable for throttling purpose.

4.2.5 All valve spindles and hand wheels shall be positioned to give good access

for operational personnel.

4.2.6 Valve of diameter 450 mm. and above shall be provided with enclosed

gear arrangement for ease of operation. The operation gear shall be such

that they can be opened and closed by one man against an unbalanced



8138-01-PS-009GEN(MECH)

Page 5 of 9 Rev. 0


head 15% in excess of the maximum specified rating. Valve and any

gearing shall be such as to permit manual operation in a reasonable time

and not exceed a required rim pull of 400 N.

4.2.7 All hand wheels shall be arranged to turn in a clockwise direction to close

the valve, the direction of rotation for opening and closing being indicated

on the hand wheels.

4.3 Sluice Valves:

4.3.1 Sluice valve shall conform to IS 780 and IS 2906 or relevant internationally

recognised standards.

4.3.2 They shall be of rising or non-rising spindle type depending on application.

The valve shall be furnished with a bushing arrangement for replacement

of packing without leakage. They shall also have renewable channel and

shoe linings. The gap between the shoe and channel shall be limited to 1.5

mm.

4.3.3 The gate face rings shall be screwed into the gate or alternatively securely

pegged over the full circumference.

4.3.4 Valves of 450 mm. and above shall be provided with thrust bearing

arrangement for ease of operation.

4.3.5 Valve of diameter 450 mm. and above shall be provided with enclosed

gear arrangement for ease of operation. The operation gear shall be such

that they can be opened and closed by one man against an unbalanced

head 15% in excess of the maximum specified rating. Valve and any

gearing shall be such as to permit manual operation in a reasonable time

and not exceed a required rim pull of 400 N.

4.3.6 All valves, spindles and hand wheels shall be positioned to give good

access for operational personnel.



8138-01-PS-009GEN(MECH)

Page 6 of 9 Rev. 0


4.3.7 All hand wheels shall be arranged to turn in a clockwise direction to close

the valve, the direction to close the valve, the direction of rotation for

opening and closing being indicated on the hand wheels.

4.4 Non-Return Valves:

4.4.1 The valve shall be suitable for mounting on a horizontal pipeline and flow

direction shall be clearly embossed on the valve body.

4.4.2 The valves shall possess high speed closing characteristics and be

designed for minimum slam condition when closing.

4.4.3 In case of multi-door swing type check valve, the non-slam characteristic

shall be achieved by providing suitable combination of door and hydraulic

passages without any external damping arrangements or passages. The

angle of sealing and door weight shall be designed to provide the most

efficient working with least restriction to flow.

4.4.4 Valve of diameter greater than 450 mm. shall be provided, in addition to

others, feet and jacking screws. Hinge pins / shaft shall preferably be

square in section to ensure positive location of flaps and provide for secure

fixing.

4.5 Air Valves:

4.5.1 The valve shall be capable of exhausting air form pipe work automatically

when being filled. The air shall be released at a sufficiently high rate to

prevent the restriction of the inflow rate. Similarly the valve shall be

capable of ventilating pipe work automatically when being emptied, the air

inflow rate being sufficiently high to prevent the development of a vacuum

in the pipelines. The valve shall also automatically release air accumulating

in pipe work during normal working conditions.



8138-01-PS-009GEN(MECH)

Page 7 of 9 Rev. 0


4.5.2 Air valve shall be of the double orifice type with a large orifice for

ventilation or exhaust of the pipeline and smaller orifice for automatic

release of air under normal working pressure.

4.5.3 Air valve shall be designed to prevent premature closure prior to all air

having been discharged from the line. The orifice shall be positively sealed

in the closed position but the float (ball) shall only be raised by the liquid

and not by a mixture of air and liquid spray. The seating shall be designed

to prevent the floats sticking after long periods in the closed position.

4.6 Pressure Relief Valves:

4.6.1 Pressure relief valves shall be capable of relieving pressure in the system

to prevent the system being pressurised in excess of a pre-set maximum

allowable pressure. The valves shall be drop tight under normal operating

conditions.

4.6.2 The valve operation shall be achieved by the interaction of the inlet

pressure and an intermediate pressure produced by a pilot valve or relay

system acting on the upper side of the main valves.

4.6.3 The pilot valve or relay system shall be actuated by a diaphragm

connected to the inlet pressure on its underside and a constant pressure

on its upper side derived either from weight or from a spring.

4.7 Pipe Work:

4.7.1 All pipes, fittings, bolts, nuts, jointing materials and appurtenances for

piping required for execution of the Works shall be manufactured and

erected in accordance with the erection plans, specifications and directives

of the Engineer. All pipe work and fittings shall be to a class in excess of

the maximum pressure attained in service including any surge pressure.

4.7.2 The pipe work installation shall be so arranged to offer ease of dismantling

and removal of pumps or other major items of equipment. Flanged



8138-01-PS-009GEN(MECH)

Page 8 of 9 Rev. 0


adapter shall be included in the suction and delivery pipe work of all

pumps as well as on delivery header for easy dismantling, and provision

shall be made for a flexible joint arrangement to building structures. All

loose flanges shall be secured to fixed flanges by suitable tie-bolts. All pipe

work shall be adequately supported with purpose-made fittings. When

passing through walls, pipe work shall incorporate a puddle flange or other

suitable sealing device. Flange adapters and unions shall be supplied and

fitted in pipe work runs, wherever necessary, to permit the simple

disconnection of flanges, valves and equipment. The final outlet

connection of the pipe work shall match the connecting point of the

transmission main.

4.7.3 Flanged joints shall be made with minimum 3 mm thick full face, fabric

reinforced rubber gaskets, pierced to take the bolts, and the face of all

flanges shall be machined to give a true angle of 90o to the centre line of

the pipe or fittings. All necessary supports, saddles, slings, fixing bolts and

foundation bolts shall be supplied to support the pipe work and its

associated equipment in an approved manner. Valves, meters and other

devices mounted in the pipe work shall be supported independently of the

pipes to which they are connected.

4.7.4 The jointing work and materials necessary to fix and connect the pipes,

including adequate and efficient pipe support shall be included in the

Contract. The Contractor shall be responsible for ensuring that the internal

surface of all pipe work is thoroughly clean before and during erection and

before commissioning. Cleaning shall include removal of all dirt, rust, scale

and welding slag due to site welding. Before despatch from the

manufacturer’s works, the ends of the pipes, branch pipes, etc., shall be

suitably capped and covered to prevent any accumulation of dirt or



8138-01-PS-009GEN(MECH)

Page 9 of 9 Rev. 0


damage. This protection shall not be removed until immediately prior to

connecting adjacent pipes, valves or pumps. All small bore pipes shall be

blown through with compressed air before connection is made to

instruments and other equipment. No point of passage of pipes through

floors or walls shall be used as a point of support, except with the

approval of the Engineer-in-charge.

4.7.5 Material of steel pipes and fittings shall conform to IS: 1239 and IS: 3589.

Fabrication and testing shall be in accordance with IS:3589 for pipes and

IS:6392 for flanges.

4.7.6 All underground steel pipes shall be corrosion protected using 2 coats of

coal tar primer and 2 coats of each 2 mm thick coal tar based material

conforming to IS 10221 & AWWA 203.

4.7.7 All cast iron pipes shall be of Class B conforming to IS 1536 and fitting and

specials shall conform to IS 1538.

4.7.8 All HDPE pipes and fittings shall be UV resistant. The pipe fittings used

shall be either injection moulded/factory fabricated.

********************


SPECIAL REQUIREMENTS OF THE PROJECT (MECHANICAL)

8138-01-PS-009SPL(MECH)

Page 1 of 6 Rev. 0

0 27.03.2107 ENQUIRY RELEASE LA AAN AAN



1.0 NOISE AND VIBRATION

1.1 Noise level produced by any rotating equipment individually or collectively

shall not exceed 65 dB (A) measured at a distance of 1.5 meters from the

source in any direction.

1.2 The overall vibration level shall be as per zones A and B of ISO 10816-1.

Balance quality requirement shall be G 6.3 conforming to ISO 1940/1.

2.0 EQUIPMENT SPECIFICATIONS

2.1 Black Waste Pumps:

2.1.1 The Pumps shall be submersible centrifugal CUTTER Pumps. The impeller

should be of a non-clog design with smooth passage and solid handing

capability of 40 mm size.

2.1.2 The Pumps will have automatic coupling arrangement at discharge end, a

guide pipe and a chain for easy removal and lowering of Pumps.

2.1.3 The Pumps shall run smooth without undue noise and vibration. Vibration

shall be limited as per BS 4675 Part I.

2.1.4 The motor shall be squirrel cage type, suitable for three phase supply

continuous duty with class ‘F’ insulation. Motor shall have integral cable

parts and the cable entries shall be sealed. Complete rotor shall be

balanced dynamically.



8138-01-PS-009SPL(MECH)

Page 2 of 6 Rev. 0


2.2 Grey Waste Pumps:

2.2.1 The Pumps shall be submersible Pumps with centrifugal, CUTTER Pumps

of non-clog type design. The impeller should be of a non-clog design with

smooth passage and solid handing capability of 40 mm size.









Sl. No. Description Specification

1. Capacity and Head 6 m3/hr @ 10MWC [To be confirmed by the bidder]

2. No. of Pumps 2 nos. {1Working + 1Standby}

3. Type of Pumps Submersible / Horizontal Centrifugal CUTTER Pumps of non-clog design

4. Service Toilet (Night Soil) Waste

5. Solid Passage Size 40 mm max.

6. Efficiency More than 50%

7 Casing/Impeller MOC C.I



8138-01-PS-009SPL(MECH)

Page 3 of 6 Rev. 0


2.3 Kitchen Waste Pumps:

2.3.1 The Pumps shall be submersible sewage Pumps with centrifugal, CUTTER

Pumps of non-clog type design. The impeller should be of a non-clog

design with smooth passage and solid handing capability of 40 mm size.

2.4 Raw Sewage Pumps:

2.4.1 The Pumps shall be submersible centrifugal sewage Pumps. The impeller

should be of a non-clog design with smooth passage and solid handing

capability of 40 mm size.





4. Service Toilet (Soap Pit) Waste








4. Service Kitchen/Pantry Waste






8138-01-PS-009SPL(MECH)

Page 4 of 6 Rev. 0













3. Type of Pumps Submersible type non-clog design

4. Liquid / Specific Gravity Raw Sewage / 1.05


5. Installation Fixed


7. Insulation & Protection Class F / IP 68

8. Casing/Impeller Cast Iron IS 210Gr. FG 260

9. Shaft AISI 410

10. Motor Body/Cable Gland/Seal Cover Cast Iron IS 210Gr. FG 260

11. Automatic Coupling/Duck Foot Bend CI

12. Guide Pipe/Lifting Chain SS 304

13. Fasteners MS with GI Coating



8138-01-PS-009SPL(MECH)

Page 5 of 6 Rev. 0


2.5 Surplus Activated Sludge [SAS] Pumps / Return Activated Sludge

[RAS] Pumps:

2.6 Sludge Transfer {Filter Press Feed} Pumps:

2.6.1 Sludge Transfer {Filter Press Feed} Pumps shall be of positive

displacement type Screw Pumps suitable for handling biological sludge of

0.8 – 3.0% solids consistency.

Sl.No Description Specification



3. Type of Pumps Submersible / Horizontal Centrifugal non-clog design

4. Liquid Biological Sludge of 0.8 – 1% solids consistency

5. Specific Gravity 1.05



8. MOC SS 316


1. Capacity and Head As required [To be specified by the bidder]


3. Type of Pumps Positive Displacement Type Screw Pump

4. Liquid Biological Sludge of 0.8 – 3.0% solids consistency


6 MOC SS 316



8138-01-PS-009SPL(MECH)

Page 6 of 6 Rev. 0


2.7 Membrane Filter Pumps:

2.8 Treated Water Pumps:

2.9 Air Blowers:

Sl. No Description Specification

1. Capacity 20 Nm3/hr {To be confirmed by the bidder}

2. Quantity 2 nos. {1Working + 1Standby}

3. Type of Blower Twin Lobe, Rotary

4. Speed 1500 rpm

5. Material

5.1 Casing EN-GJL-200, Cast Iron

5.2 Rotor CS, Drop forged steel

6. Base Plate With vibration isolators




3. Type of Pumps Horizontal Centrifugal

4. Liquid Treated Water

5. M o C SS 316





3. Type of Pumps Horizontal Centrifugal

4. Liquid Treated Water

5. M o C SS 316




8138-01-PS-009SPL(MECH)

Page 7 of 6 Rev. 0


7. Electrical/Mechanical Relief Valve YES

2.10 Hoist for lifting the Pumps/Blowers:

2.10.1 2 Nos. of 5 MT manual Chain Pulley Block (CPB) with 300 MM ISMB rail

shall be provided to lift the Raw Sewage Pumps and Air Blower.

2.10.2 CPB for removal/replacement of Membranes of the MBR, if required, shall

be specified by the vendor.

2.11 Spares:

*********

Sl. No. Item Numbers/Lot

1. Bearings for each Motor 1 Set

2. Bearings for each Pump 1 Set

3. Gland Packing for Pumps 1 Set

4. Consumable such as Gaskets, Gland Packing, Seals, etc. For Three Year operation of the Plant

: : 1

: : 2

: X

6

: : 7

: : 8

: : 8

: : 9

: : 10

: : 11

: : 12

: : 13

:

:

: : 15

:

:

: : 17

: : 18

: 19

: 20

21

: 22

: 23

: 24

: 25

26

27

28


Rev DATE PRPD. CHKD. APPRD.

0 27.03.2017 LA AAN AANVENDOR

BPCL - KR

1 P.O No.

2 CLIENT

PROJECTSTP for BPCL-KR Township @Ernakulam, Kerala3

Is it suitable for direct coupling

:

Vendor shall submit filled data sheets for individual items (Pumps) listed under doc. 'Special Requirements ofthe Project (Mechanical)'.

4

Shaft

Type of Impeller

MATERIAL :-

Body

Impeller

Overall Dimension Size and type of cable for connections

:Mechanical Seal Detail

Skid Details Type of rotary movement

Operating Weight (kg) Method of starting

Solid Handling size. Is it suitable for direct coupling to pump

: 16Vibration Isolation Detail

14Delivery end I.D.

Details of N.P.S.H (Avail./Req.) Motor efficiency

No. of stages Class of Insulation

Suction end I.D. Details of additional protection in winding

:

Shut off head (Meters of WC) Rating

Efficiency (%) Over Load Capacity

Discharge (LPM / M³/Hr) Power Requirement (KW)

Head (Meters of WC) R.P.M.

Model Model

PUMP MOTOR

Make Make

3Applicable to Enquiry P.O As-built

Type Type

Item Equipment No.

DATA SHEET PUMPS8138-01-DA-009 (002)

PAGE 1 OF 1

Job No. 8138 TPS No 8138-12-PS-009

: : 1

: : 2

: X

6

: : 7

: : 8

: : 8

: : 9

: : 10

: : 11

: : 12

: : 13

:

:

: : 15

:

:

: : 17

: : 18

: 19

: 20

21

: 22

: 23

: 24

: 25

26

27

28

PAGE 1 OF 1

Job No. 8138 TPS No 8138-12-PS-009

Item AIR BLOWER Equipment No.

DATA SHEET BLOWERS8138-01-DA-009 (003)

3Applicable to Enquiry P.O As-built

Type Type

Model Model

BLOWER MOTOR

Make Make

Shut off head (Meters of WC) Rating

Efficiency (%) Over Load Capacity

Discharge (LPM / M³/Hr) Power Requirement (KW)

Head (Meters of WC) R.P.M.

No. of stages Class of Insulation

Suction end I.D. Details of additional protection in winding

:

Solid Handling size. Is it suitable for direct coupling to pump

: 16Vibration Isolation Detail

14Delivery end I.D.

Details of N.P.S.H (Avail./Req.) Motor efficiency

Overall Dimension Size and type of cable for connections

:Mechanical Seal Detail

Skid Details Type of rotary movement

Operating Weight (kg) Method of starting

Shaft

Type of Impeller

MATERIAL :-

Body

Impeller

PROJECTSTP for BPCL-KR Township @Ernakulam, Kerala3

Is it suitable for direct coupling

:

4

BPCL - KR

1 P.O No.

2 CLIENT


Rev DATE PRPD. CHKD. APPRD.

0 27.03.2017 LA AAN AANVENDOR

00F

T02

4/94

1 OF 2


8138-01-SV-009(MECH)

PAGE SUGGESTED VENDOR LIST

1.0 ALPHA HELICAL

2.0 HYDRO PROKAV

3.0 NETZSCH

2.0 CRI

4.0 KSB

5.0 KISHORE

6.0 JOYTHI KIRLOSKAR

A PUMPS: SUBMERSIBLE / HORIZONTAL CENTRIFUGAL / CUTTER1.0 GRUNDFOS

5.0 KAY INTERNATIONAL

D CHAIN PULLEY BLOCK

3.0 CROMPTON GREAVES

2.0 SWAM PNEUMATICS

3.0 AERZEN

4.0 ROBUSCHI BLOWERS

C AIR BLOWERS1.0 EVEREST TRANSMISSION

B PUMPS: SCREW

E PIPES: MS1.0 JINDAL

1.0 INDEF

2.0 HERCULES HOISTS Ltd.

3.0 W. H. BRADY & Co. Ltd.

4.0 RAMO

5.0 ROTO

F PIPES: SS

5.0 ZENITH

2.0 LLOYDS

3.0 SURYA ROSHNI

4.0 TATA

1.0 JINDAL

2.0 PRAKASH

3.0 REMI

7.0

8.0

ABS

HOMA

9.0 MATHER & PLATT


REV.NO. DATE DESCRIPTION PREPARED CHECKED APPROVED

0 3/27/2017 ENQUIRY ISSUE LA AAN AAN

00F

T02

4/94


SUGGESTED VENDOR LIST 8138-01-SV-009(MECH)

PAGE 2 OF 2

G PIPES: HDPE1.0 RELIANCE

2.0 DURALINE

3.0 HASTI

H PIPES: UPVC1.0 ASTRAL

2.0 GEORG FISCHER

I VALVES: KNIFE/GATE1.0 BDK

2.0 KSB Ltd.

3.0 NITON VALVE INDUSTRIES

4.0 KIRLOSKAR BROTHERS Ltd.

5.0 NSSL Ltd.

6.0 OSWAL INDUSTRIES Ltd.

I VALVES: NON-RETURN/BUTTERFLY1.0 BDK

2.0 CRANE

3.0 KSB Ltd.


5.0

J VALVES: BALL/NEEDLE1.0 BDK

2.0 AUDCO

3.0 KSB Ltd.


5.0 INTERVALVE

6.0 FOURESS ENGINEERING Ltd.

For any item not covered in the above list, the contractor shall get the make & sampleapproved from the Engineer-in-charge before procurement. The final choice of make tobe used in the work will rest with the Engineer-in-charge whose decisions shall befinal & binding on the contractor.


INTERVALVE

Above makes and accessories are approved subject to their meeting the specifications &requirements in the tender. Contractor however shall seek approval of specific Make fromthe Engineer-in-charge before commencement of work. The final choice of make to beused in the work will rest with the Engineer-in-charge whose decisions shall be final& binding on the contractor.

x

3P+1S

Installation, operation and maintenance manual ( Routine and preventive )

21.0 B & C 6P

3P+1S

20.0 C Inspection & test reports and material test certificates

3P+1S

18.0 C Lube data sheet 3P+1S


6.0 B Cross section drawing with list of parts and material of construction

3P+1S 4

REV. NO. DATE DESCRIPTION PREPARED CHECKED

19.0 C Packing list

APPROVED

0 27/03/17 ENQUIRY LA AAN AAN

Legend : Group code : A - For review and detailed Engineering , B - For review , C - For information and record

Document type : R - Reproducible , P - Print , S - Soft copyNotes :

' @ ' Vendor shall fill in proposed lead time if different from the required lead time

' @@ ' Each set of final documents shall be submitted in a folder. Two such folders shall be packed

and despatched with the equipment.

22.0 B Compliance statement 1S

617.0 C Technical literature and catalogues 1S16.0 C Reference list of previous supplies 1S15.0 A Utility consumption list 1S14.0 A Allowable nozzle forces and moments 3P+1S 6

3P+1S13.0 B Base plate drawing 3P+1S 412.0 B Coupling drawings 3P+1S 6

11.0 B Spares list for commissioning 1S10.0 B Spares list for two years normal operation 1S9.0 B & C Inspection and test procedure 3P+1S 4

8.0 B Auxiliary piping drawing7.0 B Mechanical seal drawings 3P+1S 4 3P+1S

5.0 A Foundation bolt details 3P+1S 44.0 A Foundation plan with load details 3P+1S 4 3P+1S3.0 A Dimensioned G. A drawings 1S 3P+1S 4 3P+1S

3P+1S2.0 A Predicted performance curves 1S 3P+1S 4

1.0 A Data sheets 1S 3P+1S 4

3P+1S

Qty

Reqd Prop@ Agrd

No Code DescriptionQty Qty

Lead time in weeks

Offer After Commitment Final@@

STATUS : PO No :ENQUIRY COMMITMENT

01F

T01

0B /

94-R

1

TECHNICAL

VENDOR DATA REQUIREMENTS8138-01-VDR-009(MECH)

PROCUREMENTSPECIFICATION PAGE 1 OF 2

CLIENT : TPS No : 8138-12-PS-009BPCL- KR

PROJECT : ITEM : PUMPSSTP BPCL Township at Ernakulam

Sl. Grp

x


B Cross section drawing with list of parts and material of construction

4.0

Calculations for shaft diameter, bearing selection and critical speed

6.0 A

7.0 A Forced feed lubrication oil system schematic and P&I diagram

REV. NO. DATE DESCRIPTION PREPARED CHECKED APPROVED

0 27/03/17 ENQUIRY LA AAN AAN

Legend : Group code : A - For review and detailed Engineering , B - For review , C - For information and record

Document type : R - Reproducible , P - Print , M - MicrofilmNotes :

' @ ' Vendor shall fill in proposed lead time if different from the required lead time

' @@ ' Each set of final documents shall be submitted in a folder. Two such folders shall be packed

and despatched with the equipment.

16.0 B Compliance statement 1S15.0 C Reference list of previous supplies 1S

3P+1S14.0 C Installation, operation and maintenance manual13.0 C Test records & Material test certificates

6P

12.0 B&C Inspection & Test procedure 3P+1S11.0 B Equipment Lubrication data sheet 3P+1S 6

3P+1S10.0 B Catalogues 1S9.0 A Auxiliary piping drawings 3P+1S 4

3P+1S8.0 A Auxiliary eqpt - data sheets, G.A. drawings, cross sectional drawings, foundation plan, etc.

3P+1S 4

3P+1S3P+1S 4

3P+1S3P+1S 4

3P+1S 4 3P+1S5.0 A Foundation drawings with load details

3P+1S

3P+1S 4 3P+1S

3P+1S3.0 A Dimensioned G. A drawings 1S 3P+1S 4

3P+1S2.0 A Predicted performance curves 1S 3P+1S 4

1.0 A Data sheets 1S 3P+1S 4

Qty

Reqd Prop@ Agrd

No Code DescriptionQty Qty

Lead time in weeks

Grp Offer After Commitment Final@@

STATUS : PO No :ENQUIRY COMMITMENT

01F

T01

1B /

94-R

1

TECHNICAL

VENDOR DATA REQUIREMENTS8138-01-VDR-009(MECH)

PROCUREMENTSPECIFICATION PAGE 2 OF

CLIENT : TPS No : 8138-12-PS-009BPCL- KR

2

PROJECT : ITEM : CENTRIFUGAL FANS / BLOWERSSTP BPCL Township at Ernakulam

Sl.



BPCL-KOCHI REFINERY

ENGINEERING SPECIFICATIONS

ELECTRICAL

.


SCOPE OF INSPECTION AND TESTS (ELECTRICAL)

Page 1 of 1 R0

0 16-1-‘17 Original Issue SM IK SG


13FT

924D

/94


TPS NO:

ITEM : ELECTRICS FOR TURNKEY INSTALLATION – STP

EQPT. NOS.:

The following inspection and test shall be conducted and records submitted

Sl. No.

Description Ins./test Reqd.

Witness Reqd.

Remarks

1.0 Routine tests at Manufacturer’s works on all electrics (Motors, cables,MV Switchboard/ MCC etc) as per relevant standards.

Reqd Reqd

2.0

Physical verification at Manufacturer’s works for compliance with purchase order specifications and approved drawings/ documents

Reqd Reqd

3.0 Verification of CMRI certificates for electrics of Hazardous area

4.0 Tests at site

4.1 Pre-commissioning tests and commissioning tests as per relevant standards

Reqd Reqd

4.2 Insulation Resistance test Reqd Reqd

4.3 Primary and secondary injection tests on CTs and Relays Reqd Reqd

4.4 Checking power, control and earthing system and connections. Reqd Reqd

5.0 Other specific tests


VENDOR DATA REQUIREMENTS (ELECTRICAL)

Page 1 of 1 R0

PROJECT:Township Facilities at Ernakulam ITEM: ELECTRICS FOR TURNKEY

INSTALLATION – STP

CLIENT : BPCL-KR TPS. NO:

STATUS : ENQUIRY COMMITMENT P.O. NO.:

Sl. No.

Grp. code

Description

Offer After commitment @@ Final

Qty. Qty.

Lead time in weeks

Qty.

Reqd. @

Propd Agrd.

Legend: Notes: @ @@

Group code: A - For review and detailed Engineering, B - For review, C - For information and record Document type: R - Reproducible, P - Print, M - Microfilm Vendor shall fill in proposed lead time if different from the required lead time. Each set of final documents shall be submitted in a folder. Two such folders shall be packed and despatched with the equipment. Final documents shall be submitted in soft copy also.

0 16-1-2017 Original Issue SM IK SG


13FT

924C

/94


1.0 A Item wise deviations, if any, from specification. 4P

2.0 A Technical particulars as per prescribed proforma 4P 4P 4 8P

3.0 A Single Line diagram of Power Distribution 4P 4P 4 8P

4.0 A List of Electrical loads with rating (kW/Amps) and quantity

4P 4P 4 8P

5.0 A General layout of the system indicating location of all electrics

4P 4 8P

6.0 B Power Layout 4P 4 8P

7.0 B Cable Schedule 4P 4 8P

8.0 B Lighting layout 4P 4 8P

9.0 B Earthing Layout 4P 4 8P

10.0 A Dimensioned GA drawing of individual electrics 4P 4 8P

11.0 A Schematic wiring diagram of controls of the MCC/Control Panel etc

4P 6 8P

12.0 B Bill of Materials for all electrics indicating make, type, quantity, rating, catalogue ref details etc.

4P 4P 4 8P

13.0 B Routine test certificates 8P

14.0 C Type test certificates of MV Switchboard/ MCC and cables

4P 4

15.0 B Recommended list of spares for 2 years trouble free operation


GENERAL REQUIREMENT FOR ELECTRICS

8138-13-DA-90001

Page 1 of 1 R0

PROJECT Residential Township Facilities

CLIENT M/s.BPCL-KR

P.O. NO.

VENDOR

0 16-1-‘17 SM IK SG

13

FT

900

A/9

4


1.0 Project Residential Township Facilities for BPCL-KR

2.0 Owner BPCL-KR

3.0 Location Ernakulam

4.0 Service conditions

4.1 Altitude < 1000m above mean sea level

4.2 Humidity Min 64%

4.3 Humidity max. 93%

4.4 Humidity design 100% at 200C

4.5 Ambient temperature 0 C-Min. 19.2

4.6 Ambient temperature 0 C-Max. 40

4.7 Ambient temperature 0 C-Design 40

4.8 Rain fall – Max . Record in an hour

4.9 Rain –fall Max record in 24 Hours *

5.0 Environment Tropical atmosphere

6.0 Wind velocity for structural design *

7.0 Seismic factor for design *

8.0 Soil data *

8.1 Soil resistivity *

8.2 Type of soil (hard / loose) * 9.0 Power system 9.1 Voltage (V) & Variation ( %) 11000V +/- 10% 415±10%

9.2 Frequency (Hz) & Variation ( %) 50Hz +/- 5% 50 Hz±5%

9.3 No of phases Three 3 9.4 No. of wires Three 4

9.5 Fault level (MVA) 500 MVA 35 MVA

9.6 Method of neutral earthing Solid earthing Solidly earthed

*If required these data to be collected from the purchaser

ENGINEERING SPECIFICATION ELECTRICS FOR TURNKEY INSTALLATION

13ES924/14

Page 1 of 10

PRPD. : CHKD. : APPRD. : ISSUED ON SEPT 2014


00F

T00

1

CONTENTS

1.0.0 SCOPE 2.0.0 REFERENCE 3.0.0 STANDARDS 4.0.0 GENERAL REQUIREMENTS 5.0.0 MOTORS 6.0.0 VARIABLE SPEED DRIVES 7.0.0 M.V.SWITCHBOARDS/ MOTOR CONTROL CENTRES (MCC) 8.0.0 LOCAL CONTROL STATIONS 9.0.0 CABLES AND CABLING 10.0.0 EARTHING 11.0.0 SAFETY ITEMS 12.0.0 HAZARDOUS AREA CLASSIFICATION FOR SELECTION OF ELECTRICS 13.0.0 ERECTION, TESTING AND COMMISSIONING 14.0.0 APPROVAL FROM ELECTRICAL INSPECTORATE 15.0.0 LIGHTING 16.0.0 MAKE OF ELECTRICAL EQUIPMENT/ ITEMS 1.0.0 SCOPE 1.1.0 This specification covers the requirements for design, engineering, supply, receiving materials at

site, inspection at site, storage, transportation at site, erection, testing and commissioning of all electrics required for the safe, efficient and smooth running of the turnkey installation / package.

2.0.0 REFERENCE 2.1.0 The following documents shall be read in conjunction with this specification 2.1.1 Engineering specification and Data Sheet of General Requirements for Electrics 2.1.2 Data Sheet of Electrics for Turnkey Installation. 2.1.3 Technical Particulars of Electrics for Turnkey Installation. 3.0.0 STANDARDS. 3.1.0 Requirements laid down in the latest revisions of the following Indian Standards and other relevant

standards shall be strictly adhered to.

IS: 325 Three phase Induction Motors. IS/IEC:60034 Rotating Electrical Machines. IS/IEC:60947 Low voltage switchgear and control gear. IS: 8623 Low voltage switchgear and control gear assemblies IS: 13947 Part:5 Low voltage switchgear and control gear- Part-5 Control circuit devices and switching elements. IS: 1248 Direct acting indicating analogue Electrical measuring instruments and accessories IS: 2705 Current transformers. IS: 13703 Fuses for voltages not exceeding 100V AC or 1500V DC IS: 10118 Code of practice for selection, installation and maintenance of switchgear and

control gear. IS: 732 Code of practice for electrical wiring installation. IS: 694 PVC insulated cables for working voltage upto and including 1100 volts. IS: 1554 PVC insulated (Heavy duty) Electric cables. IS: 3043 Code of practice for earthing.


13ES924/14

Page 2 of 10


00F

T00

1

IS: 2309 Code of Practice for the protection of buildings and allied structures against lightning.

IS: 7689 Guide for control of undesirable static electricity. IS: 5571 Guide for selection of electrical equipment for hazardous areas. IS: 5572 Classification for hazardous areas (other than mines) for electrical

installations.- Part 1 - Areas having flammable gases and vapors.

4.0.0 GENERAL REQUIREMENTS 4.1.0 The scope of work for electrics shall be complete in all respects and shall include necessary Medium

Voltage switchboards / Motor Control Centres, Motors, Local Control Stations, Cables, Earthing Materials, Safety items and interlocks, Cabling, Earthing, Lighting, etc. required for the installation, as specified in the data sheets.

4.2.0 The Purchaser will be providing adequate power supply at 415 Volts, 50 Hz, 3 phase and neutral

A.C. to the MV switch boards / Motor control centres provided by the vendor. The incoming cables shall be connected to the MV Switchboard / MCC by the purchaser. Voltage and frequency variation shall be +10%and +5%, unless otherwise specified in the Data Sheet.

4.3.0 For Motors/Equipments suitable for voltage rating above 415Volts, purchaser will arrange power

supply through purchaser’s circuit breakers. Necessary power cabling upto the motors /equipments and control cabling upto the local control stations of motors as well as termination of the above cables at both ends shall also be arranged by the purchaser in such cases. The interconnecting cabling for protection/ alarm required, between HV motors and purchaser’s HV switch board is included in the scope of purchaser.

4.4.0 The purchaser will be terminating the main earth bus at single point within battery limit (size and

material of main earth bus shall be as per Data Sheet). Further earthing within battery limit shall be included in the scope of the vendor.

5.0.0 MOTORS. 5.1.0 All drive motors required for the system shall be included in the scope of the vendor unless

otherwise specified in the Data Sheet. 5.2.0 Motors shall be suitable for the voltage ratings indicated in the Data Sheet and shall conform to the

following specifications. 5.2.1 Motors provided shall have adequate performance characteristics such as starting torque pull out

torque, etc. and rating for meeting the driving and starting duty of the driven equipment. 5.2.2 All motors shall be squirrel cage induction type with insulation Class B / F with temperature rise

limited to Class B and totally enclosed fan cooled enclosure with IP 55 / IPW55 degree of protection; except in cases of special types of motors such as slip- ring motors, variable speed motors, etc. required to meet special drive requirements, and environmental conditions. In all such cases, motors with necessary special features shall be provided and approval for the same shall be obtained from the purchaser. Degree of protection for the enclosure shall be as specified in the Data Sheet.

5.2.3 Motors shall be provided with 240V,50Hz, single phase anti- condensation heaters, if so specified in

data sheet and shall be wired up to separate terminal box with cable glands suitable for the cable sizes specified in Data Sheet.

5.2.4 Motors shall be provided with terminal boxes (where in all six winding ends are brought out), cable

glands, etc. suitable for the type and sizes of cables selected by vendor. In addition, the motor shall have the largest terminal box possible in the frame size.

5.2.5 All motors are envisaged to be started on Direct-On-Line unless otherwise specified in the Data

Sheet.


13ES924/14

Page 3 of 10


00F

T00

1

5.2.6 All motors shall be suitable for number of starts specified in the Data Sheet. 5.2.7 Motor frame sizes shall be in accordance with IEC recommendations / relevant Indian Standards. 5.2.8 For unidirectional motors, the direction of rotation shall be clearly marked on the body of the motor. 5.2.9 Motors shall have a starting time, which is less than hot locked rotor withstand time of motor by at

least two seconds at the rated conditions of voltage and frequency specified with driven machine coupled.

5.2.10 Motors shall be suitable for starting at 80% of the rated voltage against torque speed characteristics

of the driven equipment. 5.2.11 The terminal box of Medium Voltage motors shall be capable of withstanding the calculated fault

level in terms of the let through energy of combination starter unit at the place of installation. 5.2.12 An indelible warning inscription shall be provided on the motor to indicate that switching of

anticondensation heater supply shall also be ensured before carrying out any work on the motor. 5.3.0 In addition to the above requirements high voltage motors shall conform to the following: 5.3.1 Ensure that starting current is not more than 600% of full load current at rated voltage and

frequency. 5.3.2 All the six winding ends shall be brought out and marked, three to one terminal box for power supply

connections and three to another terminal box on the opposite side for star connection. Further main terminal box shall be phase segregated type and terminal boxes shall be suitable for system fault level for 0.25 seconds or as indicated in the Data Sheet.

5.3.3 If temperature detectors / oil level indicators etc. are provided as per Data Sheet, the same shall be

wired upto a terminal box with cable gland suitable for the cable sizes indicated in the Data Sheet. 5.3.4 Additional protection features such as zero speed switches for loads with high starting time,

embedded resistance temperature detectors for windings and bearings, oil temperature detectors and level indicators (with alarm and trip contacts) for oil lubricated bearings etc. shall be provided, if specified, in the Data Sheet. For resistance type winding / bearing temperature detectors suitable temperature scanner / monitoring relays with alarm and trip contacts shall be provided, in a weather proof enclosure, if specified in the data sheet.

6.0.0 VARIABLE SPEED DRIVES 6.1.0 The Variable Speed Drive System shall be suitable for the load characteristics and operation duty of

the driven equipment, the equipment shall be suitable for continuous operation. 6.2.0 The converter design shall impose minimum harmonics on the electrical power system in

accordance with the relevant standards and shall be acceptable to the Owners electrical network. 6.3.0 The Converter Vendor shall advise the percentage of current harmonics over the full range of

frequencies. Filters shall be fitted within the converter to minimise harmonic currents. 6.4.0 The converter shall incorporate a programmable microprocessor based control system allowing

updating / modifying of the logic functions of the converter by a simple programme procedure using a control panel keypad/ and panel display.

6.5.0 The converter shall be provided with self-check facilities including failure reporting and signalling.

The programme shall be protected against loss of supply voltage with back-up for the programme


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memory and the fault diagnostic and indication shall be equipped with a memory function to retain information with regard to tripping of the Converter.

6.6.0 If requested in the requisition, the converter shall be able to communicate with a remote

control/diagnostic system by means of a serial communication interface 6.7.0 The converter shall accurately control the driven equipment speed and torque of any standard

induction motor and shall be suitable for pump, fans, mixers, agitator applications etc., as specified in the requisition.

6.8.0 A reference signal of 4mA shall correspond with the minimum operational speed and the reference

signal of 20mA shall correspond with the maximum speed. 6.9.0 The Variable Speed Drive System shall be capable of running through voltage dips of up to 20% and

equipped with an automatic restart facility which will restart the system with voltage dips greater than 20% less than 4 seconds. Restart shall only take place with voltage recovery greater than 90%. Upon restart the converter shall be capable of synchronising onto rotating motor “flying restart” and develop full acceleration torque.

6.10.0 If the speed exceeds 105% of the maximum operational speed the VSDS shall trip, if the speed

reduces to 95% of minimum speed for more than 10 seconds the VSDS shall trip. The converter shall have available critical speed function where it is necessary to avoid certain speeds due to mechanical resonance problems.

6.11.0 Speed control will be carried out either manually for maintenance, or automatically via 4-20mA

signal from the process control. 6.12.0 Depending on operational requirements the motor start/stop will be either carried out manually by

push buttons or automatically via the process control system. 6.13.0 Emergency stop located at each motor shall trip the supply contactor, removal of power by an

emergency shall not cause damage. All stop buttons shall operate at all times. 6.14.0 When the converter is switched on, the drive shall breakaway at a minimum frequency consistent

with the slip of the motor. Once motor rotation is established the drive shall ramp up to the set point speed at a controlled rate. Set point speed having been established, change of set point speed shall also be at a controlled rate superimposed on the rate of change demanded by the operator or controller.

6.15.0 During all starting operations, the rate of increase of torque, up to the maximum limited by the

protection, shall also be at a controlled rate. The drive shall be suitable for a "windmilling" start with the motor being rotated by the driven equipment in either direction.

6.16.0 Programmable converter relay outputs shall be included with volt free contacts for control and alarm

functions. 6.17.0 VFD’s shall comply with IEEE 519 for total harmonic distortion calculation and measurement. If

harmonic filters are required to meet this specification, the VFD manufacturer must provide the filter and is fully responsible for the design, manufacturing and installation of the filter as an integral part of the VFD package.

6.18.0 The variable frequency drive shall provide near sinusoidal voltage and current waveforms

to the motor at all speeds and loads. Output current THD shall be less than 5%. Standard induction or synchronous motors shall not require derating or upgraded turn-to-turn insulation and shall not require additional service factor.


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6.19.0 Variable frequency drive induced torque pulsations to the output shaft of the mechanical system shall be less than 1% to minimize the possibility of exciting a resonance.

7.0.0 M.V. SWITCHBOARDS / MOTOR CONTROL CENTRES (M.C.C.) 7.1.0 The control gear for all Medium Voltage loads shall be housed in centralized MCC's installed in a

suitably located electrical room. 7.2.0 MCC's shall be rated for minimum 25 MVA symmetrical fault level with switch fuse/ MCCB incomers

and shall conform to the following stipulations: 7.2.1 Number of MCCs shall be selected in such a way to limit the incomer rating to 630 Amps, unless

otherwise specified in the Data Sheet. 7.2.2 MCC shall be of self-standing, dust, damp and vermin proof construction in fully compartmentalized

cubicle type execution. The MCC shall be single / double front, draw out / non draw-out type as specified in Data Sheet. The enclosure shall be of folded sheet steel construction. Thickness of sheet steel shall not be less than 2 mm except for certain non load bearing members like instrument mounting plates, partitions, doors, etc. for which a minimum thickness of 1.6 mm shall be ensured.

7.2.3 The construction of MCC shall be in such a way that each vertical row of modules shall have

separate vertical bus bars, vertical bus bar chamber and cable alleys. The width of the cable alley shall be sufficient to accommodate all the cables and shall have free access for cable terminations and in any case shall not be less than 150 mm.

7.2.4 For draw out type MCC the following stipulations shall also be adhered to: (i) Power and control contacts shall be of fully draw out, self aligning type which get automatically

disconnected when the module is withdrawn. (ii) A distinct and stable “TEST” position for each module shall be provided. Test push button for

checking the control circuitry shall be provided, if specified in Data Sheet. (iii) Identical feeder types shall be interchangeable with each other. Also all modules shall carry labels

identifying KW rating & type of control wiring. (iv) Necessary earthing arrangements shall be provided for the draw out module in TEST and SERVICE

positions. 7.2.5 The bus bar supports shall be of non-hygroscopic glass reinforced plastic material with anti-tracking

features. 7.2.6 Bus bars shall be provided with insulating sleeves and bus bar joints shall be shrouded. 7.2.7 MCC including dropper bus bars to each module shall be rated for the minimum symmetrical short

circuit level of 25 MVA at 415V. 7.2.8 MCC shall be provided with incoming feeders comprising of suitably rated AC 22 duty switch fuse

units/ Moulded Case Circuit Breakers, voltmeter with 3 way and off selector switch & fuses (connected on the incoming cable side) , CT fed ammeter with necessary CTs & 3 way and off selector switch and CT operated KWh meter. CTs & meters shall be of accuracy class 1.5 and meters shall be of size 96mm x 96mm.

7.2.9 Outgoing motor starter feeders shall comprise of suitably rated AC 23 duty load break

switches/MCCBs, HRC fuses, 100% capacity AC 3 category Air break contactors and bimetal overload relays. Feeder switches shall have AC 23 rating corresponding to the full load current of the motors connected. Rating of load break switch shall not be less than the rating of the HRC fuses.

7.2.10 The bi-metal overload relays shall be manual / auto reset type as specified in the data sheet. For

manual reset type, reset push button shall be provided on the door. These relays shall have single


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phasing protection feature. If built-in feature is not available, separate current operated type single phasing preventor shall be provided.

7.2.11 Overload relays for motor of blowers, fans, agitators, compressors, crushers & mills shall be of

heavy-duty - delayed action type to allow more starting time. 7.2.12 Ammeters shall be provided for outgoing feeders, if so specified in the Data Sheet. 7.2.13 CTs of ratio and VA capacity suitable to connect remote ammeters (in one phase) shall be provided

for all motor feeders of 15 kW and above unless otherwise specified in the Data Sheet. Secondaries of these CTs shall be of 1A rating. Minimum VA capacity shall be 7.5 and class of accuracy 1.5 unless otherwise specified in Data Sheet.

7.2.14 Control supply for the motor starters shall be 110V AC, 50 Hz, single phase AC unless otherwise

specified in Data Sheet. In case of 240 V control supply, each circuit shall be provided with individual control fuses and links.

7.2.15 For control voltages less than 240 volts separate control transformers (cast resin insulated type) for

each modules or common for each bus section shall be provided as specified in the Data Sheet. In case common control transformer for each bus section is envisaged, it shall have adequate capacity and provisions to feed entire control loads of both bus sections of switchboard, when required. The control transformer shall have +5% taps on primary side and with center tap of secondary winding earthed & having fuse protection on primary side and double pole MCB on secondary side. Common control transformers shall also have suitable switch fuse unit on primary side and additional tapping of +2.5% on secondary side. It shall be ensured that control supply of each feeder gets isolated automatically when power supply to that particular feeder is switched off.

7.2.16 If anti-condensation heaters are provided for motors, provision shall be made to feed the same

through isolator with HRC fuse protection/ MCB and NC contact of Main contactor of respective motor starter.

7.2.17 All power and control fuses shall be of the HRC link type, with operation indicators. 7.2.18 In each motor feeder module, at least one Normally Open and one Normally Closed auxiliary contact

shall be wired up to the terminal block as spare. The terminal block shall have at least 10% spare terminals, subject to a minimum of two.

7.2.19 All feeders controlled by contactors shall be provided with OFF buttons. Indicating lamps and Reset

button shall be provided, if specified, in the Data Sheet. 7.2.20 Providing pressure switches, limit switches, safety switches etc. wherever required for the safety of

the equipment and facilitating interlocking shall be the responsibility of the supplier. Interlock defeat switches, as required shall be provided on the control panel (where such panels are provided) or on local control station near the motor and not on the MCC.

7.2.21 All outgoing switch fuse feeders shall be provided with AC 22 load break switch, HRC fuses and

neutral link. 7.2.22 The incomer switch fuse unit shall have single phasing annunciators wired up to a terminal block, if

so specified in the Data Sheet. 7.2.23 In MCCs having two incomers each shall be of 100% capacity. Interlocks shall be provided

between incomers / bus coupler to prevent paralleling. 7.2.24 Facility shall be provided for padlocking feeder switches in the OFF position. 7.2.25 Necessary switch-to-door interlock shall be provided in all compartments so that the door of a

compartment can be opened only when the switch is in OFF position.


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7.2.26 Space heater/ anti condensation heaters (suitable for 240 V, single phase AC) shall be provided for each vertical panel if so specified in the Data Sheet. For double front MCC's space heaters shall be provided on both fronts. Space heaters shall be controlled through isolator with HRC fuse protection / MCB, thermostat etc.

7.2.27 Continuous earth bus of 70 sq. mm. bare Copper Conductor, or 120 sq. mm. bare Aluminium

conductor or 240 sq. mm. GI strip or as specified in the Data Sheet shall be provided for the entire length of the MCC. Duplicate earth terminals shall be provided for external connection.

7.2.28 Maximum allowable current density for bus bar sizing shall be 1.25 Amps/ sq. mm for copper or 0.78

Amps /sq. mm for Aluminium. 7.2.29 Horizontal busbars shall be of uniform cross section throughout the length of the switchboard.

Vertical busbars of all vertical panels of the switchboard shall also be of uniform cross section. 7.2.30 Power wiring shall be carried out with PVC insulated, stranded copper / aluminium conductors of

650 Volts grade having adequate current carrying capacity. Minimum size of conductor for power wiring shall be 4Sq.mm copper. Control wiring shall be carried out with 650 V grade, PVC insulated, copper conductor of size not less than 2.5 Sq.mm.

7.2.31 For draw out MCC, provision of control supply in the test position of draw out modules shall be

available. In draw out switchboards with module control supply, required test control supply feeder (complete with switch fuse/ and test control supply transformer with double pole MCB on secondary, centre tap of secondary winding earthed, etc. as in clause 6.2.15 above), associated test supply bus / wiring, etc. shall be provided.

7.2.32 The feeder arrangement shall be such that the operating height (ie. operating handle, switches,

push buttons, etc.) lies within 1828 mm, but above 300mm, from the floor level. 7.3.0 MOULDED CASE CIRCUIT BREAKERS

7.3.1 Where moulded case circuit breakers are used for feeder circuit protection, rating and characteristics shall be chosen in such a way as to ensure proper discrimination with other upstream and downstream protective devices within the assembly.

7.3.2 The MCCB should be current limiting type with trip time of less than 10 milli second under short circuit

conditions. The MCCB should be either 3 or 4 poles as specified in data sheet. 7.3.3 MCCB shall comply with the requirements of the relevant standards IS13947 – Part 2 and should

have test certificates for Breaking capacities from independent test authorities CPRI / ERDA or any accredited international lab.

7.3.4 MCCB shall comprise of Quick Make -break switching mechanism, arc extinguishing device and the

tripping unit shall be contained in a compact, high strength, heat resistant, flame retardant, insulating moulded case with high withstand capability against thermal and mechanical stresses

7.3.5 The breaking capacity of MCCB shall be as specified in the schedule of quantities. The rated service

breaking capacity (Ics) should be equal to rated ultimate breaking capacities (Icu). MCCB’s for motor application should be selected in line with Type-2 Co-ordination as per IS 13947-2. The breaker as supplied with ROM should meet IP54 degree of protection.

8.0.0 LOCAL CONTROL STATIONS 8.1.0 Each motor shall be provided with a local control station near motor. The enclosure shall be of Cast

Iron or Cast Aluminium construction with IP-55 / IPW 55 degree of protection, as specified in the Data Sheet.


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8.2.0 Local control stations for M.V motors shall be provided with ‘ON’ push button (Green) and 'OFF' push button (Red).

8.3.0 Local control station for H.V Motors shall be provided with 'ON' push button (Green), 'OFF' push

button (Red), Ammeter and five numbers Indication lamps. (viz 'ON'-Red , 'OFF'-Green, 'Tripped on fault' - Amber, 'Ready for start' -Clear, 'Space heater ON' - Yellow.).

8.4.0 For all motors of 15 kW and above or as specified in Data Sheet, suitable ammeters shall be

provided in the local control stations. Ammeters shall have an accuracy class of 1.5 unless otherwise specified in Data Sheet and shall have a suppressed end scale to suit the starting current.

8.5.0 The OFF push button shall be lockable with a pad-lock in pressed 'OFF' position. 8.6.0 If starting of motors / equipment are envisaged from more than one location or Auto / manual

operation is envisaged, necessary Local - Remote or Auto-Manual switches shall be provided either in the Local Control Station or in the Instrument Control panel, if any. Stop facility shall be available from any location irrespective of the position of selector switches.

8.7.0 All spare contacts shall be wired up to the terminal block. The terminal block shall have 10% spare

terminals subject to a minimum of two. 8.8.0 Nameplates in white perspex acrylic sheet with letters engraved in black shall be provided for each

control station indicating the service. 8.9.0 Circuit breaker contactors controlling motor feeders shall have rating at least 125% of the maximum

continuous rating of connected motors. 9.0.0 CABLES AND CABLING. 9.1.0 All power cables shall be PVC insulated, armoured and PVC sheathed with Aluminium conductor

unless otherwise specified in Data Sheet. 9.2.0 All control cables shall be PVC insulated, armoured and PVC sheathed with Copper conductor .The

control cable shall be laid segregated from the power cables. 9.3.0 The sizes of cables shall be so chosen that they are rated to carry the full load current continuously

after allowing for necessary derating factors for the service conditions of installation, and also that the voltage drop in cables does not exceed 3% for full load running. For motor starting, voltage drop up to 15% shall be permitted.

9.4.0 M.V power cables of 400 sq mm and above shall be laid with a clearance of 70 mm in between and

shall be clamped individually. Other cables can be laid touching and clamped in groups. 9.5.0 Cables shall be clamped at every 1500 mm interval on the horizontal trays / racks and at 750 mm

interval on the vertical trays / risers, at 400 mm interval for cables laid on walls, columns and other structural works, and at bends and take off points.

9.6.0 A clearance equal to one diameter of the bigger cable shall be maintained between two adjacent

power cables buried underground and no such clearance need be provided for control and lighting cables.

9.7.0 All fixing materials shall be given coatings of anticorrosive paint. Cable tags made of Aluminium

sheet shall be provided at every 10M interval. The purchaser will furnish the identity numbers of cables after submission of the cable schedule by the supplier. All the cable racks in trenches and overhead structure shall be bonded for continuity.

9.8.0 Selection of the size of cables for motors shall be done from the table indicated in the Data Sheet.

However, higher sizes may be used if warranted by voltage drop consideration in individual cases.


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9.9.0 Wherever cables pass through masonry or concrete work, they shall be taken through suitable PVC / GI pipes. For road crossing suitable GI or concrete pipe shall be provided.

9.10.0 After drawing the cables in GI / PVC pipes, the ends shall be sealed with cable compounds. 9.11.0 The size and minimum number of cores in control cables shall be as specified in the Data Sheet. 9.12.0 Type of cabling shall be overhead / buried in ground / through pipes / through permanently

constructed trenches with RCC / CI chequered plate covers as specified in Data Sheet. 10.0.0 EARTHING. 10.1.0 All electrical equipment shall be provided with duplicate earthing in conformity with relevant

standards / regulations applicable. The main earth bus shall be of bare / insulated aluminium or copper or galvanized iron strip as specified in the Data Sheet and earthing of individual equipment shall be done with conductors of type, sizes & material specified in the Data Sheet.

10.2.0 Earthing cables / strips shall be taken along with the power cables on the cable trays / racks / risers /

GI pipes / non-metallic pipes or buried. Earthing cables shall be clamped at intervals same as that of power cables. Bare earthing strips shall be clamped at 3000 mm interval on horizontal trays / racks, 1500 mm interval on vertical trays / risers, 800 mm interval on walls, columns, and at bends / take off points.

10.3.0 Metallic cable trays / risers shall be earthed at both ends. Electrical continuity of earthing throughout

the tray shall be ensured. 10.4.0 Earthing of equipment, vessels, pipe lines etc. if required towards protection against static electricity,

shall be done in conformity with relevant standards / regulations applicable. 10.5.0 Earthing system for protection of building and structures against lightning shall be provided if so

specified in Data Sheet in conformity with relevant standards / regulations applicable. 11.0.0 SAFETY ITEMS 11.1.0 Safety items required as per statutory regulations such as danger notice plates, rubber mat in front

of switch boards, fire extinguishers, resuscitation charts and fire buckets shall be supplied by the vendor, if specified in Data Sheet.

12.0.0 HAZARDOUS AREA CLASSIFICATION FOR SELECTION OF ELECTRICS. 12.1.0 All electrics and their installation shall be suitable for the hazardous/ Non-hazardous area involved

and / or specified in the Data Sheet. Electrics suitable for the hazardous area involved shall be selected as per the relevant Indian Standards and shall be of proven design approved by CIMFR / relevant statutory bodies. In such cases copies of relevant certificates shall be furnished for Purchaser’s approval.

13.0.0 ERECTION, TESTING AND COMMISSIONING. 13.1.0 Supply of all erection materials required for the erection of electrical equipments supplied by vendor

shall be the responsibility of the vendor. These items shall include all accessories for cable-jointing, cable terminations/ cable tray/ racks, supporting steel structures, pipes, clamps, bricks, sand, cement, rubble, compression type cable glands, insulating materials etc. Necessary grouting, fixing etc. also shall be arranged by the vendor.

13.2.0 It shall be the responsibility of the vendor to supply and install all items that are incidental and

necessary for the completion of the installation, whether specifically mentioned or not, so that the installation complies with relevant standards and regulations, at no extra cost to the purchaser.


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13.3.0 Commissioning works includes all precommissioning tests, checking of all power, control & earthing connections, testing and commissioning of all equipment / system supplied, erected and / connected by the vendor, as per relevant standards and as directed by purchaser.

13.4.0 The electrical installation work shall be carried out only through a contractor possessing valid and

competent electrical contractors license issued by the State Electricity Licensing Board for carrying out electrical installation work in the place of installation.

13.5.0 All equipments which do not come under a roof shall be provided with weather proof features, and

be suitably protected using hoods /canopies 14.0.0 APPROVAL FROM ELECTRICAL INSPECTORATE. 14.1.0 It shall be the responsibility of the vendor to ensure that the complete installation supplied and / or

erected by him fully meets with relevant standards / Acts / rules / Regulations applicable and duly got approved by statutory authorities like Electrical Inspectorate.

14.2.0 Any modifications / rectification required by the owner / Electrical Inspectorate resulting from

improper installation by the vendor or to make the same in full conformity with the relevant standards / Rules / Acts / Regulations applicable for the installation shall be carried out by the vendor without any extra cost to the purchaser.

15.0.0 LIGHTING. 15.1.0 If lighting is included in the scope of the vendor, the same shall conform to specifications for the

lighting installation attached. 16.0.0 MAKE OF ELECTRICAL EQUIPMENT / ITEMS 16.1.0 Make of Electrical equipment / items shall be as specified in Data Sheet / Sub vendor list attached. 16.2.0 Approval shall be got from the Purchaser for the individual makes of the different electrical items,

wherever makes are not specified in the Data Sheet, before placement of purchase order.


ELECTRICS FOR TURNKEY INSTALLATION (STP)-DATA SHEET

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PROJECT Township Facilities at Ernakulam

CLIENT M/s.BPCL-KR

1 27-4-‘17 SM IK SG P.O. NO.

0 16-1-‘17 SM IK SG VENDOR

REV. DATE PRPD. CHKD. APPRD.

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1.0 Power supply voltage (clause 4.2.0/ 4.3.0) 415V± 10%, 50 Hz ±5%, 3 Phase & neutral AC

2.0 MOTORS

2.1 Scope of supply of vendor (clause 5.1.0) Squirrel cage induction motors and submersible pump motors are included

2.2 kW range and voltage ratings of motors (clause 5.2.0)

a) Type of motor Squirrel cage induction motor and submersible pump motors.All motors shall be energy efficient – EFF 3 type

b) Motors of rating upto and including 149kW 415V ± 10%, 50 Hz ±5%, 3 Phase AC

c) Motors of rating above 149kW upto and 3.3kV ± 10%, 50 Hz ±5%, 3 Phase AC

2.3 Class of Insulation (Clause 5.2.2) Class F with temperature rise limited to Class B

2.4 Degree of Protection (Clause 5.2.2) a) IP55 for Indoor

b) IPW55 weatherproof for Outdoor c) IP 68 for submersible pump motor

2.5 Enclosure for (Clause 5.2.2

a) Non Hazardous area -

b) Hazardous area Safe area

2.6 Anti condensation heaters (Cl. 5.2.3) Required for motors of rating 37 KW & above

2.7 Method of Starting (Clause 5.2.5) Direct On Line

2.8 Number of Starts (Cl. 5.2.6)

a) Number of consecutive cold starts 3

b) Number of consecutive hot starts 2

c) Number of equally spaced starts/hr. 4

2.9 Additional requirements of H.V. Motors

(Cl.5.3) Not applicable

a) Starting Current (Cl. 5.3.1)

b) Main terminal box (Phase segregated)

(Cl. 5.3.2)

c) Star terminal box (Cl. 5.3.2)

d) Zero speed switches for motors of high

starting time required. (Cl. 5.3.2)


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e) Winding temperature detectors (Cl. 5.3.3)-

RTD

f) Bearing Temperature detectors (Cl. 5.3.3) -

RTD

g) Oil temperature detectors (Cl. 5.3.3)

h) Oil level indicator (Cl, 5.3.3)

i) Temperature scanner / Monitoring relays

with alarm and trip contacts for winding/bearing RTD

j) Foundation bolts for motors

Note : Submersible pump motor shall conform to IS 8034

3.0 MV SWITCHBOARDS / MOTOR CONTROL CENTRES (MCC)

3.1 Incomer rating (MCCB) To suit the load requirement (Min 200A MCCB),

3.2 Number of Incomers in each MCC One

3.3 Number of Bus coupler in each MCC N.A

3.4 Type of MCC (Clause 6.2.2) a) Single front

b) Draw out

3.5 Cable entry Top

3.6 Material of Bus bars PVC sleeved Aluminium/ Copper

3.7 Test Push Button (Cl. 6.2.4) Not Required (but test facility for control circuit

required)

3.8 Type of overload relay reset (Clause 6.2.10 &

6.2.19) Manual with reset button

3.9 Ammeters for outgoing feeders (Clause 6.2.12)

a) For Switchfuse/ MCCB feeders Not Required

b) For motor feeders Required for motors of rating 7.5kW and above

3.10 Current transformer for remote ammeter (Cl.6.2.13)

a) For motor feeders Required

b) Class of Accuracy 1.5

3.11 Control supply (Cl. 6.2.14) 240V

3.12 Control voltage Transformer (Cl. 6.2.15) Required, common for each bus.

3.13 Indication lamps on Motor feeders (Clause

6.2.19)

a) Motor ON (red) Required

b) Motor OFF (Green) Required

c) Overload Tripped (Amber) Required

d) Voltage rating for indication lamps 240V AC, with cluster type LED lamps.



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3.14 Short circuit rating of MCCB 50KA for 1 sec

3.15 Single phasing annunciator for incomer (Cl.

6.2.22) Not Required

3.16 Panel anti-condensation heaters (Clause

6.2.26) Required

3.17 Earth bus for MCC(Clause 6.2.27) Suitable for 50kA/3sec

3.18 Other requirements 1) Outgoing feeders as required shall be provided.1No.63A MCCB feeder for welding socket outlet and 1No.32 A MCCB feeder for lighting shall be provided.20% spare feeders of each rating shall be provided..

3) Wiring & termination shall provided for ON/OFF control motors from Local Control Stations.

3.18.1 Test control supply, test bus etc. Not Required

4.0 LOCAL CONTROL STATIONS (Required for motors if )

4.1 Material of construction (Clause 7.1.0) Cast Aluminium

4.2 Enclosure and degree of protection (Cl. 7.1.0)

a) Non Hazardous IP 55 weather proof for outdoor

b) Hazardous N.A

4.3 Ammeter (Cl. 7.4.0) Required for motors rated 7.5KW and above(digital type)

4.4 Accuracy class (Cl.7.4.0.0) Class 1.5

4.5 Local/Remote selector switch shall be provided as per process/operation requirement

4.6 Indication lamps – cluster type LED lamps Not required

4.7 Foundation bolt for LCS Required

5.0 CABLES & CABLING

5.1 Type of cable and material of conductor (Cl. 8.1.0 & 5.2.4)

a) Power cables - MV AYFY/AYWY FRLSH Aluminium for cable sizes equal to and above 16sqmm. Cable sizes below 16 sqmm shall be of Copper (YFY/YWY) FRLSH

- HV NA

b) Control cables YFY/YWY FRLSHCopper

5.2 Table of minimum cable sizes of Power cables (Cl. 8.8.0) Vendor shall provide adequate cable sizes to limit the running voltage drop to 3%).Sizes indicated are for Aluminium cables .Equivalent size of copper cable can be provided.

Motors 3.7 kW 1 # of 3 x 4 sq.mm

Motors>3.7kW 7.5 kW 1 # of 3 x 6 sq.mm .

Motors>7.5kW 11 kW 1 # of 3 x 10 sq.mm

Motors>11kW 15 kW 1 # of 3 x 16 sq.mm



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Motors>15kW 22 kW 1 # of 3 x 25 sq.mm

Motors>22kW 30 kW 1 # of 3 x 35 sq.mm MCCB feeders 32A 4 x 10 sq.mm

Motors>30kW 37 kW 1 # of 3 x 50 sq.mm MCCB feeders 63A 3.5 x 35 sq.mm Al

Motors>37kW 45 kW 1 # of 3 x 70 sq.mm MCCB feeders 100A 3.5 x 70 sq.mm Al.

MCCB feeders 200A 3.5 x 240 sq.mm Al.

Note: Submerssible cables suitable for the application of submersible pump shall be provided as per relevant standards.

5.3 Minimum sizes of control cables (Cl. 8.11.0)

a) Size in sq.mm 2.5

b) Minimum No. of cores for MV Motors (for LCS) As reqd. with 1 core, spare

c) Minimum No. of cores for HV Motors ( for LCS)

d) Interlock/ Interconnection cables to control panels/ eqpt etc.

Upto 7 core – 1 core spare, More than 7 core – 2 cores spare

5.4 Type of cabling (Cl. 8.12.0) a) MV equipment

1) Incoming cabling up to MCC for STP shall be done by other agency .Cable termination on MCC shall be done by the Vendor.

2) MCC shall be located in MCC room(under the scope of vendor) near STP. Cabling inside STP building shall be done using overhead GRP cable trays. Cabling in outdoor area shall be through GRP cable trays in built in RCC cable trenches with cover slab.

6.0 EARTHING

6.1 Main incoming earth bus (Cl. 4.3.0) 25mmx3mm copper strip(Battery limit in substation.

6.2 Plant main earth bus if any (Cl. 9.1.0) * sq mm bare Copper strip/ PVC covered Al

6.3 Equipment earthing (Cl. 9.1.0)-Type & material Bare Copper/ PVC covered Aluminium

* Vendor to furnish

6.4 Equipment earthing (Cl. 9.1.0)-Table of minimum sizes

MCC / Switchboards, fuse/ current limiting type MCCB protected

25mmx3mm copper strip

Motors 18.5KW & local control stations

25 sq.mm Al



DATA SHEET

8138-13-DA-92401

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Motors >18.5KW, 37KW 35 sq.mm Al

Motors >37KW, 55KW 50 sq.mm Al

6.5 Size of static earthing minimum (Cl. 9.4.0) 25 sq mm Aluminium

6.6 Lightning protection (Cl. 9.5.0) -

7.0 SAFETY ITEMS (CLAUSE 10.0.0)

7.1 Danger Notice plates Required

7.2 CO2 Fire Extinguisher (4.5kg) -

7.3 Insulation mat in front of MCC/ switchboards 1.1 kV grade insulation mat as per IS 15652:2006

of thickness not less than 2.5 mm and 1000 mm width shall be provided

7.4 Fire buckets ( 1 gallon) -

7.5 Resuscitation charts -

8.0 Area Classification (Cl. 11.0.0) Safe area

9.0 Weatherproof protection (hood) for outdoor

equipment (Clause 12.5.0) Motors & PB stns. Required with Aluminium sheet

10.0 Responsibility of getting approval from Electrical

Inspectorate (Cl. 13.1.0) Vendor shall be responsible for getting approval from Electrical Inspectorate(CEA)

11.0 Lighting (Clause 14.0.0) Required using industrial type LED type lighting

fixture .

12.0 Painting (Deviations if any on those specified in

13ES900) Epoxy painting. Final colour and finish of the equipment shall be Dark Admiralty Grey (shade No.632 as per IS5

13.0 MAKE (Cl. 15.0.0) Refer sub vendor list attached

14.0 OTHER REQUIREMENTS

14.1 Two Nos. additional CI plate electrode earth pits as per IS 3043 shall be provided in STP area

which shall be connected to main plant earth bus in duplicate

TECHNICAL PARTICULARS

ELECTRICS FOR TURNKEY INSTALLATION

8138-13-TP-924-01

Page 1 of 6

PROJECT

TOWNSHIP Facilities at Ernakulam

CLIENT BPCL-KR

P.O. NO.

VENDOR

REV. DATE PRPD. CHKD. APPRD.

13

FT

924

B/1

4


1.0 MOTORS

1.1 Make

1.2 Equipment No. / Name

1.3 Type of Motor

1.4 Motor rating

1.5 Speed in RPM (Syn.)

1.6 Frame size

1.7 Class of Insulation

1.8 Enclosure, Degree of Protection & Type of cooling

1.9 Direction of rotation

1.10 Full load current (Amps)

1.11 Starting Current (%FLC)

1.12 Slip (Percentage) at Full load

1.13 Efficiency (%) and power factor

a) At full load

b) AT ¾ load

c) At ½ Load

1.14 Locked rotor withstand time

a) Hot (seconds)

b) Cold (seconds)

1.15 Starting time of motor on DOL with driven equipment coupled

a) At 100% voltage

b) At 80% voltage

1.16

Minimum voltage required for starting with the equipment and corresponding starting time

1.17 Allowable number of starts with driven equipment coupled

a) Consecutive cold starts

b) Consecutive Hot starts

c) Equally spaced starts/Hr.

1.18 Guaranteed temperature rise under worst conditions of voltage and frequency

1.19 Speed Vs. Torque curve

1.20 Current Vs. time curve

1.21 Current Vs. Speed curve

1.22 Thermal withstand characteristics (hot & cold)

1.23 Start withstand time



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a) Hot (seconds)

b) Cold (seconds)

1.24

Margin between starting time and locked Rotor withstand time hot (Clause 5.3.1 of 13ES924)

1.25 CIMFR Certificate (for Flame-proof motors)

1.26 Bearings

a) Drive end bearing No. & type

b) Non-drive end bearing No. & type

c) Make of bearings

1.27 Lubricant

a) Make

b) Type

c) Lubrication Schedule of motor

1.28 Weight of Motor

2.0 LOCAL CONTROL STATIONS

2.1 Maker’s Name

2.2 Works at which units will be fabricated

2.3 Material of construction

2.4 Enclosures & Degree of protection

2.5 Technical details, leaflets etc

2.6 Standards applicable

2.7 Ammeter range & Accuracy class

2.8 CIMFR certificate for flame proof equipment

2.9 Type of Local control stations

3.0 CABLES

3.1 Make

3.2 Type & Material

Power Cable

Control cable


Power cable

Control cable

4.0 EARTHING CONDUCTORS

4.1 Make

4.2 Type & Material


5.0 OTHER DETAILS



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6.0 MOTOR CONTROL CENTRES

6.1 Number of MCCs

6.2 Incomer Rating

6.3 Maker’s name

6.4 Works at which the boards will be fabricated

6.5 Type of switchboards

6.6 Max. Temperature rise over ambient

6.7 Sizes of phase and neutral bus bars of the following ratings along with supporting calculations

a) 100A

b) 200A

c) 400A

d) 630A

e) 800A

6.8 Short time (1 sec.) rating of bus bars in KA(Rms)

6.9 Type, make, ratings/range/ratios and relevant details of individual components

6.10 Technical details, leaflets and type test certificates for the following items.

a) Heavy duty type switches

b) Air Break contactors (Power &Auxiliary)

c) HRC link type fuses (Power and Control)

d) Bus bars

e) Current transformers

f) Bimetallic thermal overload relays

g) Meters

h) Indicating lamps

i) Timers

j) Single phasing annunciators

6.11 Overall dimensions in mm of each switchboard

6.12 Weight of each switchboard in Kg. (Dynamic loading if any shall be furnished)

6.13 Material and area of cross section of conductors of

a) Bus bars to switch of each rating

b) Switch to fuses of each rating

6.14 Material and voltage class (grade) of insulation of above conductors if insulated



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6.15 COMPONENT / FEEDER DETAILS

Motor KW/ Fdr. rating

Full Load Amps

Mod- ule size

Switch/MCCB

HRC Fuse Contactor Over load relay range (A)

Size of wire used in modules

Rating of terminals in Amps.

Type AC22 rating (A)

AC23 rating (A)

Therm- al rating (A)

Let through energy

Type Therm- al rating (A)

AC3 rating (A)

1sec. Rating (A)

Power Control Draw- out

Fixed Outgoing

0.25

0.37 1.2

0.55 1.6

0.75 1.8

1.1 2.6

1.5 3.5

2.2 5.0

3.7 7.5

5.5 11

7.5 14

9.3 19

11 21

15 28

18.5 35

22 40

30 55

37 66

45 80

55 100

75 135

90 165

110 200

132 230

150 275

Sw

itch

fu

se/M

CC

B

feed

er

63

100

200

250

400

630



8138-13-TP-924-01

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7.0 VARIABLE FREQUENCY DRIVES

7.1 Make

7.2 Model Number

7.3 Country of manufacture

7.4 Type of reference

7.5 Standards to which the VVFD conforms to

7.6 Weight

7.7 Drive type

7.8 Dynamic Response

a) Speed fluctuation band

b) Speed recovery time after 100% torque step

c)Type of feed-back for speed control

d)Speed control accuracy

7.9

Waveform distortion factor (% harmonics) in output / input waveform (Number of harmonics and magnitude of each harmonic generated shall be furnished)

7.10 Rating expressed at (torque)

7.11 Speed control range

7.12 Overload capacity

7.13 Rating declared at (temp.)

7.14 Switching frequency at declared rating

7.15 Overload capability of converter

a) 115% In( for variable torque) for

7.16 Overall efficiency of drive (excl. motor) at

a) 100% load

b) 75% load

c) 50% load

7.17 Overall power factor of drive (excl. motor) at

a) 100% load

b) 75% load

c) 50% load

7.18 Control mode

7.19 Acceleration time (Adjustable)

7.20 Deceleration time (Adjustable)

7.21 Operation mode

7.22 Speed reference signal

7.23 Braking

7.24 Frequency setting

7.25 Communication protocols

7.26 PID function

7.27 Type of power converter

7.28 Type of cooling system provided

7.29 Type of output filter provided



8138-13-TP-924-01

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7.30 Panel Construction

a)Material of construction

b)Thickness

c)IP Rating

7.31 Cooling

i) Type

ii) Redundancy in cooling units

7.32 Panel space heater rating

7.33 Maximum noise level from the drive at 1-meter distance

7.34 Dimensions

a) Length

b) Height

c) Depth

d) Weight of cubicle

7.35 Earth bus

7.36 Size

7.37 Minimum fault current capacity


SUB VENDOR LIST (ELECTRICAL)

Page 1 of 3 R0

0 16-1-2017 Original issue SM IK SG


00ft0

24/9

4


SL NO ITEM VENDORS 1 CABLES-LT GLOSTER CABLES LTD

TORRENT CABLES LTD AHMEDABAD UNIVERSAL CABLES LTD BENGALURU CABLE CORPORATION OF INDIA LTD CHENNAI KEI INDUSTRIES LIMITED NEW DELHI NICCO CORPORATION LIMITED CHENNAI POLYCAB WIRE PVT LTD MUMBAI RADIANT CABLES LIMITED

2 CABLE LUGS AND CRIMPING TOOLS

DOWELLS ELEKTRO WERKE POWER ENGINEERING CORPORATION ELECTROMAC INDUSTRIES JAINSONS INDUSTRIES

3 GRP/ FRP CALE TRAYS ASSOCIATED ENGINEERING CORPORATION SINTEX INDUSTRIES LTD. INDIANA CABLE TRAYS CORPORATION SUMIP COMPOSITES PVT LTD. GENERAL COMPOSITES PVT. LTD ERCON COMPOSITES IDS COMPOSITES

4 MV SWITCH BOARDS (COMPONENTS AS PER SUB VENDOR LIST)

WAVES ELECTRONICS PVT LTD AKSHAR ELECMECH PVT LTD ANDREW YULE& COMPANY LTD ALSTOM T&D INDIA LTD HAVELLS INDIA LTD RYB SWITCH GEARS PVT LIMITED VIVIN INDUSTRIES GE POWER CONTROLS INDIA PVT LTD MEGAWIN SWITCHGEAR P LTD KERALA SWITCH GEAR SALES CORPORATION IMPERIAL SWITCH GEARS PVT LTD HESEL CONTROLS POWER CONTROL EQUIPMENTS

5 MCB INDO ASIAN FUSEGEAR LEGRAND HAVELLS L&T SIEMENS

6 ELCB INDO ASIAN FUSEGEAR ALSTOM SIEMENS HAVELLS MERLIN GERRIN LEGRAND

7 MCCB GE INDIA INDUSTRIAL PVT. LTD L&T SCHNIEDER ELECTRIC



Page 2 of 3 R0

00ft0

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4


ABB SIEMENS ALSTOM CGL LEGRAND GEPC HAVELLS

8 MULTI-FUNCTION METERS ABB LTD., BANGALORE L & T LTD., CHENNAI SIEMENS LTD., COIMBATORE SCHNEIDER ELEC. INDIA LTD., VADODARA

9 ENERGY METER AREVA T&D INDIA LIMITED ( T & D GROUP) AUTOMATIC ELECTRIC LIMITED MECO INSTRUMENTS PVT. LTD NIPPEN ELECTRICAL INSTRUMENTS CO RISHAB INSTRUMENTS PVT. LTD L&T

10 INSTRUMENT TRANSFORMER(CT) ELECTRICAL CONTROLS & SWITCH BOARDS (P) LTD. FRANK SUDHA CHAND & CO. LTD INTRANS SILKAANS ELEC. MFG. CO. UNIVERSAL ENGRS. ASWATHY ELECTRO ENGINEERS

11 CONTROL SWITCHES/ SELECTOR SWITCHES

AREVA T&D INDIA LTD.( T&D GROUP) HAVELLS INDIA L&T SIEMENS ALSTOM SWITRON DEVICES HOTLINE SWITCH GEAR AND CONTROLS EASUN REYROLLE KAYCEE ABB SALZER

12 CONTACTORS ABB BHARTIA CONTROLS & SWITCHGEARS CONTACTORS GE INDIA INDUSTRIAL PVT. LTD. L&T SIEMENS SCHNIEDER ELECTRIC ALSTOM

13 FUSES GE INDIA INDUSTRIAL PVT. LTD. INDO ASIAN FUSE GEAR L&T SIEMENS

14

5A & 15A SWITCHES AND SOCKETS

ANCHOR M.K ELECTRICS LEGRAND CRABTREE ABB L&T

15 FLEXIBLE COPPER WIRE FOR LIGHTING APPLICATIONS

FINOLEX POLYCAB



Page 3 of 3 R0

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4


HAVELLS ANCHOR UNIVERSAL CABLES NICCO

16 PUSH BUTTONS AND INDICATING LAMPS

BHARTIA INDUSTRIES CONTROLS AND SWITCHGEARS CONTACTORS SIEMENS SCHNEIDER ELECTRICTEKNIC CONTROLS

17 LIGHTING AND POWER DB LEGRAND HAVELL’S INDIA PVT LTD INDO ASIAN FUSE SWITCHGEAR LTD STANDARD ELECTRICALS LIMITED

18 PVC ADHESIVE TAPE WONDER STEEL GRIP

19 GI PIPE JINDAL ZENITH TATA

20 M.V. MOTORS ABB AREVA T&D INDIA LTD

BHARAT BIJLEE LTD CROMPTON GREAVES KIRLOSKAR ELECTRIC COMPANY SIEMENS BHEL

21 LED LAMPS BAJAJ ELECTRICALS LTD HAVELLS INDIA LTD GE LIGHTING INDIA LTD OSRAM INDIA PVT. LTD PHILIPS ELECTRONICS INDIA LTD SUNLIT ELECTRO CONTROLS PVT. LTD. ITARE PROJECT INDIA PVT. LTD TECHEXPRESS INDUSTRIAL SUPPLIES PVT. LTD

22 LIGHT FITTINGS BAJAJ ELECTRICALS LTD. GE LIGHTING INDIA HAVELS OSRAM PHILIPS INDIA LTD. CROMPTON GREAVES LTD

NOTE: ALL ITEMS SHALL BE GOT APPROVED FROM CLIENT BEFORE FINALIZING.



ENGINEERING SPECIFICATION

CIVIL

BPCL-KOCHI REFINERY

120KLD STP AT BPCL TOWNSHIP

CIVIL ENGINEERING DESIGN BASIS

PREPARED FOR

BPCL-KR

0 10-Feb-2017 ISSUED FOR COMMENTS PT LTA LTA

Rev. Date Description By Chkd Appd Client

Civil Design Basis STP Page 2 of 16

TABLE OF CONTENTS

1.0.0 Design Criteria ......................................................................................................................... 3 2.0.0 Design loads ............................................................................................................................ 5 3.0.0 Analysis of structures ............................................................................................................... 8 4.0.0 Structural Design of RCC Elements ........................................................................................ 8 5.0.0 Liquid Retaining Structures .................................................................................................... 12 6.0.0 Reinforcement Detailing ......................................................................................................... 13 7.0.0 Expansion Joints .................................................................................................................... 13 8.0.0 Steel Structures ...................................................................................................................... 14


1.0.0 GENERAL

1.0.1 This specification covers the design criteria and materials to be used and the

standards to be followed for the construction and commissioning of all civil and

structural works.

1.1.0 DESIGN CRITERIA

1.1.1 The design of all civil and structural work such as buildings, structures,

equipment foundations and pipe supports, platforms, walkways, ladders,

staircases etc. shall be carried out as per the design specifications and relevant

latest Indian Standard Codes of Practice. Items not covered in the IS codes

shall be designed based on accepted engineering practices.

1.1.2 Wherever structural steel is used, it is to be shot blasted and painted with

anticorrosive paint as per the detailed specification given in clause 8.10.

1.1.3 In designing buildings and structures, all relevant regulations, statutory building

laws and factory acts shall be followed in respect of ventilation, lighting,

clearances, staircases, walkways, handrails, emergency exits, fire fighting,

sanitation etc.

1.2.0 DESIGN CODES AND STANDARDS

1.2.1 The design of structures, foundations, water retaining structures etc. shall be as

per latest relevant Indian Standard codes. The design & construction shall

conform to the following codes:

a) Structural safety of buildings- Loading standards, IS 875 (Part I to V)

b) Earthquake resistant design of buildings, IS 1893

c) Plain and reinforced concrete, IS 456

d) Handbook on Concrete Reinforcement and Detailing, SP 34

e) Code of Practice for Design and Construction of Pile Foundations, IS

2911 (Part 1 / Sec 2)

f) Load Test on Piles, IS 2911 (Part 1V)

g) Code of Practice for General Construction in Steel, IS 800

h) Concrete structures for storage of liquids, IS 3370 (Part I to IV)

i) Design and construction of machine foundations, IS 2974 (Part 1 to 4)

j) Code of Practice For Structural safety of Masonry walls, IS 1905


k) Code of Practice For design & construction of foundations in Soils,

IS1904

l) Design and construction of shallow foundation, IS 1080

m) Ductile Detailing Of RCC Structures Subjected to Seismic

Forces IS 13920

n) Earth quake resistant construction of building, IS 4326

1.2.2 The materials used, construction practices etc., shall conform to relevant IS

codes. Only tested quality Material shall be used. Some of the relevant codes

for commonly used materials and construction practices are listed below.

a) High Strength Deformed Bars, IS 1786

b) Mild steel and medium steel bars for reinforcement, IS 432 (Part I)

c) Specification for Portland pozzolana Cement, IS 1489 Part 1

d) Specification for Sulphate Resistant Portland Cement, IS 12330

e) Specification for Coarse and Fine Aggregates from Natural Resources for

Concrete, IS 383

f) Handbook on Concrete Mixes, SP 23

g) Methods of Sampling and Analysis of Concrete, IS 1199

h) Methods of Test for Strength of Concrete, IS 516

i) Structural steel, IS 2062

j) Burnt clay building bricks , IS 1077

k) Construction of stone masonry, IS 1597 (Part I & II)

l) Brick work, IS 2212

m) Preparation and use of masonry mortars, IS 2250

n) Unplasticised PVC pipe for potable water supply, IS 4985

o) Cement and cement lime plaster finishes, IS 1661

p) Painting concrete, masonry and plaster surfaces, IS 2395 (Part I & II )

q) Painting of ferrous metals in buildings, IS 1477 (Part I & II)

r) White washing & colour washing, IS 6278

s) Laying in situ concrete flooring, IS 2571


t) Specification for Integral Cement Water proofing Compounds, IS 2645

u) Aluminum doors, windows and ventilators, IS 1948/ IS1949

v) Steel doors, windows and ventilators, IS 1038

w) Steel windows for industrial building, IS 1361

x) Measurement of Works, IS 1200

1.2.3 The list of codes given is not conclusive and the design, materials & Construction

shall conform to relevant codes published by the Bureau of Indian Standards or

other statutory bodies.

2.0.0 DESIGN LOADS

2.1.0 DEAD LOAD (DL)

Dead load is the vertical load due to actual weight of all permanent structural

and non-structural components of building such as floors, roofs, walls,

staircases, fixtures etc.

While estimating dead load due to process equipments, the empty weight of the

equipment including all fixtures and attached piping but excluding the contents

shall be considered.

Dead loads shall be estimated for purposes of design using the actual weights

of material of construction and finishes on the basis of unit weights given in IS

875- Part 1

The following densities shall be considered for computation of dead loads

Density of reinforced cement concrete 25 kN/cum

Density of plain concrete 24 kN/cum

Density of structural steel 78.50 kN/cum

Density of soil 18.00 kN/cum

2.2.0 IMPOSED LOADS (IL)

Imposed loads are the greatest loads assumed to be produced by the intended

use or occupancy of a building including weight of movable partitions.

The following imposed loads as specified in IS 875 Part 2 shall be considered

unless higher loads are specified by equipment suppliers. If higher loads are

specified for certain occupancies, the same shall be considered.

Office rooms 2.5 KN/M2


Records/ Store room 5KN/M2

Corridors, Passages Lobbies, staircases 4KN/M2

Corridors, Passages Lobbies, staircases subjected

to machine loads 5KN/M2

Cross-over 2.5KN/M2

Control Rooms 10KN/M2

Flat roofs with access provided 1.5KN/M2

Flat roofs with access not provided

except for maintenance 0.75KN/M2

In the absence of any suitable provision for live loads in IS codes for any

particular type of floor or structure, the assumed loading shall be got approved

by Consultant. Apart from the specified live loads, any other equipment load or

possible overloading during maintenance/ erection shall also be considered in

the design.

2.2.1 CRANES & MONORAILS

For purposes of design of gantry girders and monorails, the impact allowances

as specified by IS 875 part 2- Cl.6.3 shall be used to cover all forces set up by

vibration, shock from slipping of slings, kinetic action of acceleration and

retardation and impact of wheel loads.

2.3.0 WIND LOADS (WL)

Wind loads on the structure shall be calculated as specified in IS 875 Part 3.

Basic wind speed will be taken as 39m /sec.

To arrive at the Design Wind Speed, Basic wind speed shall be multiplied by

Factors K1, K2 & K3 where:

K1 = Probability factor (Risk coefficient) shall be selected from Table 1

according to the Class of structure

K2 = Terrain, height & structure size factor. Depending on class of structure

and height of structure, this factor shall be selected from Table 2.

The terrain shall be taken as Category 1 which corresponds to open

terrain with few or no obstructions

K3 = Topography factor. This shall be taken as 1.0 since the upwind slope

is not greater than 3


Design wind loads on the structure shall be calculated by adding up the load

given for each of the critical directions shown from all quadrants in Table 4 of IS

875. When calculating the wind load on individual structural elements such as

roofs, walls etc, the internal pressure coefficients also shall be considered as

given in clause. 7.3.2 of IS 875- Part 3 depending upon the percentage of

openings.

2.4.0 EARTH QUAKE LOADS (EL)

Seismic load on the structure shall be calculated as per IS 1893 by taking Zone

factor Z corresponding to Zone 111. The design value of horizontal seismic

coefficient Ah shall be computed by the following expression:

Ah = ZI Sa

2 R g

Where Z is the zone factor given in Table 2, the importance factor I shall be

taken considering category 3 structure, R is the response reduction factor given

in Table 4 and Sa/g is the average Response acceleration coefficient to be

taken from fig 1 corresponding to the natural period of the structure.

2.5.0 LOAD COMBINATIONS

The worst combination of loads shall be considered for design of structures.

The following combinations as specified in IS 875 Part 5 shall be considered for

analysis of general structures.

DL+ IL

DL+ WL

DL+ EL

DL+ IL+ WL

DL+ IL+ EL

In addition to the above combinations, other relevant combinations specified by

IS 875 Part 5 involving temperature loads (TL) or any other special loads shall

be considered for the analysis of structures subjected to such loads.

3.0.0 ANALYSIS OF RCC STRUCTURES

3.1.0 All buildings shall be of RCC framed construction except buildings with sheet

roofing. Frame analysis shall be carried out for all structures for all load

combinations using approved structural analysis and design software. Rigidity at

Column Beam joints shall be considered in the analysis.


3.2.0 Ductile detailing of RCC frames shall be done as stipulated in IS 13920 for

Industrial structures in Zone 3.

3.3.0 Minimum Grade of concrete for all structural RCC elements shall be M30 and

the minimum grade for general RCC works like cable trenches & drains shall be

M20. Ready Mixed Concrete (RMC) shall be used with prior approval of the

Engineer-in-charge.

4.0.0 STRUCTURAL DESIGN OF RCC ELEMENTS

4.1.0 Limit state design shall be adopted for design of all structural elements.

4.2.0 The following values of partial safety factors shall be considered as specified by

IS 456 for different load combinations

DL + IL DL 1.5 IL 1.5

DL + WL DL 1.5 WL 1.5

DL + WL DL 0.9 WL 1.5

DL + IL + WL DL 1.2 IL 1.2 WL 1.2

While considering earthquake effects, EL shall be substituted in place of WL

and appropriate portion of IL shall be considered as stipulated by IS 1893.

4.3.0 MINIMUM SIZE REQUIREMENTS OF RCC ELEMENTS

Minimum thickness of various RCC components of the structure shall be as

given below.

a) Floor slabs 120mm

b) Column footing 200mm

c) Pile cap 500mm

d) Under ground pit slab /walls 180mm

e) Minimum dimension of beam / column 250mm

f) Cable/Pipe Trench/Launder walls & base slab 100mm

g) Parapet/ Chajja 75mm

h) Louver/fin 50mm

i) Precast Trench cover slab 80mm

j) Precast louver/slab in contact with liquid 100mm

k) Liquid retaining/ leak proof structure walls


& base slab 150mm

l) Ground floor slab 150mm

4.4.0 Minimum cover for reinforcement shall be as per the provisions of IS 456 & IS

3370 for liquid retaining structures. The following values of nominal cover to

steel reinforcements including link shall be provided for general structures.

Foundations 75mm

Columns 50mm

Beams 30mm

Slab/Walls 20mm

4.5.0 REINFORCEMENT RODS

4.5.1 The reinforcement rods for concrete shall be as follows.

4.5.2 Main bars in columns, footings High strength deformed bars conforming to IS 1786.

slabs, foundations, etc

4.5.4 Lateral ties, stirrups, etc -DO-

4.5.5 Reinforcement for floors High strength deformed bars/Mild steel

bars/steel fabric

4.6.0 SLABS

Two way slabs shall be designed based on the Bending moment coefficients

given in annexure D of IS 456. For continuous one-way slabs moment

coefficients given in Table 12 of IS 456 shall be used. Deflection check of the

slabs as envisaged in IS 456 shall also be done.

4.7.0 BEAMS

Reinforcement steel shall be provided for the required moment of resistance

obtained from the analysis of frames. Shear stirrups shall be provided to

withstand balance shear after deducting the shear capacity of concrete section

based on the percentage steel provided to resist Bending Moment.

4.8.0 COLUMNS

Columns shall be designed for the combined effect of axial loads and biaxial

moments due to frame action obtained from the analysis for the worst load

combination and the detailed design output specifying the percentage steel to

be provided and the interaction ratios shall be furnished.

4.9.0 FOUNDATIONS


Pile foundation for civil structures is included in the scope of Contractor. Design of

Pile foundation shall be done based on the following data. 600 mm dia bored cast

insitu pile of M30 grade concrete, 35 m length, vertical capacity of pile- 1000 kN

For design purpose of bottom slab of tanks, ground water table shall be assumed at

ground level. While designing slabs, effect of uplift/ subsoil water table shall also be

considered.

4.9.1 Machine/ Equipment foundations

Depending on the type of machine/equipment, suitable foundation shall be

designed as per IS 2974. Besides carrying out static calculations, detailed

dynamic analysis shall be done for all major machine foundations. All the

machine/equipment foundations shall preferably be separated out from the

building structures and the joint shall be sealed to avoid any transfer of

vibrations and leakage of sub soil water.

4.9.2 The minimum cover of 75mm shall be provided for foundation pockets from the edge of foundation

4.9.3 Provision for isolation pads, vibration dampeners, bearing pads, springs etc. shall be

provided as per equipment manufactures specification.

4.9.4 Grouting of foundation bolts below base plates for equipments shall be as follows: a. Static Equipments SHRINKKOMP-10

b. Pumps SHRINKKOMP-20

c. Compressors SHRINKKOMP-30

4.9.5 All under ground pits, sumps, etc. shall be designed to take care of the uplift

forces due to buoyancy if required.

4.9.6 PCC 1:4:8 is proposed for levelling course, except for liquid retaining

structures. The thickness of levelling course shall be 80mm and when used as a

structural element, the minimum thickness shall be 150mm. Levelling course

below liquid retaining structures shall be of CC 1:3:6 mix

4.9.7 Concrete surfaces below GL shall be provided with 2 coats of anticorrosive

bituminous coating

4.9.8 MINIMUM HEIGHT OF PLINTH /PEDESTAL

The minimum height of plinth/pedestal above finished yard or floor level shall be as

follows.

1. Building plinth

a) General buildings 450mm above finished

yard level around building.

2. Pedestal / encasements of

structural columns

Open area 300mm

Covered area 150mm


3. Pedestal for all equipments

Open area as required but not less than 300mm

Covered area as required but not less than 150mm

4. Stair pedestal 150mm

5. Ladder pedestal 150mm

Finished yard level around buildings shall be 150mm above FGL

4.9.9 GRADE ELEVATION

Finished Grade Level ( FGL) for the project premise is +100.00m with respect to

temporary bench mark. Mean Sea Level(MSL) elevation is +97.6m. Approximate

existing elevation of proposed STP location is +99.00 m. Contractor has to consider

working from the existing levels.

5.0.0 LIQUID RETAINING STRUCTURES

5.0.1 Design shall conform to IS 3370 Part I to IV. All elements of water retaining

structures or similar structures in contact with water shall be designed as

uncracked section.

5.0.2 M30 grade concrete with minimum cement content of 400 kg/m3 shall be used.

5.0.3 For tanks resting on grounds cement concrete 1:3:6 mix levelling course shall

be provided.

5.0.4 The provisions regarding expansion joints, contraction joints, construction joints,

bitumen sliding layer above levelling course, etc. shall be provided as

recommended in the standards.

5.0.5 Acrylic swellable water stops shall be provided at construction joints/movement

joints of water retaining structures to make it leak proof.

5.0.6 For underground storage tanks, pits, trenches etc. where protection against

uplift due to buoyancy from subsoil water is to be considered, a min. factor of

safety of 1.2 shall be ensured. For purpose of calculating downward load due to

overburden, only the mass located vertically over the projected area of the base

shall be taken into account.

5.0.7 All liquid retaining/ storage structures shall be designed assuming liquid up to

the full height of wall irrespective of provision of any overflow arrangement.

5.0.8 The walls and base slab of liquid retaining/ storage structure shall be provided

with reinforcement on both faces irrespective of any thickness.

5.0.9 All embedded parts such as nozzles, pipes, bolts, etc. shall be provided at the

time of concreting.


5.0.10 Plastering with cement mortar 1:4, 10 mm thick, mixed with integral

waterproofing compound like Conplast X4211C of M/s. FOSROC or equivalent

shall be provided for inside surface after hydro test.

5.0.11 Hydrotest of all liquid retaining structures shall be conducted as per stipulations

in IS 3370. All leaks or wetting noticed during hydro tests, shall be rectified as

per approved methods, using approved materials.

6.0.0 REINFORCEMENT DETAILING

6.0.1 All requirements governing quantum of reinforcement and detailing of

reinforcement as per clause 26 of IS 456 and as detailed in SP 34 for detailing

of reinforcement shall be adhered to while preparing the construction drawings.

6.0.2 The recommendations for detailing for earthquake resistant construction given in

IS 13920 shall also be followed.

7.0.0 EXPANSION JOINTS

7.0.1 Expansion joints in concrete structures shall be provided as per IS 456 / IS

3414 Code provisions.

7.0.2 Bitumen impregnated fibreboards of approved manufacture as per IS 1838

Part 1 shall be used as fillers for expansion joints.

7.0.3 The gap between the expansion joints shall be thoroughly cleaned and the

bitumen fibreboards placed in position as per manufacturer’s specification and

the surface shall be sealed with elastomeric silicone rubber sealants.

7.0.4 All expansion/ separation joints in ground floor slabs shall be filled with sand for

the full depth of the slab except top 25 mm, which shall be filled with approved

mastic sealing compound.

8.0.0 STEEL STRUCTURES

8.0.1 Basic consideration of structural framework shall primarily be strength to

withstand the various loads mentioned in clause 2.0.0. Ease of fabrication,

erection and overall economy satisfying IS stipulations shall also be a criteria for

design. Design shall be done in working stress method based on allowable

stresses given in IS 800.The deflection limits specified in IS 800 shall also be

complied with.

8.0.2 MINIMUM THICKNESS OF STEEL

Trusses, Purlins, side girts & bracings 6mm

Columns & beams 7mm


For gussets, stiffeners, plate guides, etc. 8mm

For base plates 10mm

Chequered plates 6mm (on Plain)

Grating 5mm

However the minimum thickness of structural components (except gratings &

chequered plates) those are directly exposed to weather and inaccessible for

repainting shall be 8mm.

The minimum thickness of tubes shall be as specified in IS 1161 for medium

class tubes.

The min. thickness for rolled beams and channels shall be mean flange

thickness regardless of web thickness.

8.0.3 SLENDERNESS AND DEPTH RATIO.

The slenderness ratio of main members in tension and compression shall be in

accordance with IS 800. The following limiting ratios of depth to span shall be

considered as a general guide.

Trusses 1/10

Rolled beams and girders for ordinary floors 1/24

and rafters.

Supporting floor beams for 1/15

Vibrating machinery.

Roof purlins and girts 1/45

Gable columns 1/30

Gantry girders (Rolled sections) 1/15

Gantry girders (built up) 1/12

8.0.4 PERMISSIBLE DEFLECTION

The permissible vertical deflection for structural steel members shall be as

specified below:

Gantry girder for Electric overhead crane

Capacity up to 50t L/750

Gantry girder for Electric overhead crane


Capacity over 50t L/1000

Gantry girder for manually operated crane L/500

Girder/ Beam supporting dynamic equipment/

Hoist L/450

Grating/ Chequered plate L/200 or 6mm whichever is

Minimum

General structural members L/325

The permissible horizontal deflection due to lateral forces shall be l/325 where l is the actual length of column.

8.1 CONNECTIONS

8.1.4 As far as possible, the connections shall be welded. Field connections shall be

made with black bolts for ladders, hand rails posts, stair stringers, removable

members and floor plates, platform forming members 200mm and under in size,

purlins, girts and minor pipe support members that require not more than three

bolts per connection. The minimum size of bolts shall be 16mm unless limited

by the size of the connected parts. Any connection shall have at least two bolts.

8.2 MATERIAL

8.2.4 Unless otherwise specified, steel for hot rolled structural shapes and plates

shall conform to IS 2062.

8.2.5 Steel tubes for structural purpose shall conform to IS 1161.

8.2.6 Bolts shall conform to IS1367.

8.3 ERECTION LOADS

All loads to be carried by the structure or any part of it due to storage or positioning of

construction material and erection of equipment including all loads due to operation of

such equipment shall be considered as erection load. Proper provision shall be made

including temporary bracings to take care of stresses due to erection loads. The

structure as a whole and all part of the structure in conjunction with temporary

bracings shall be capable of sustaining this erection load without exceeding the

permissible stresses subject to the allowable increase of stresses. Dead loads, wind

loads and all such parts of live load as would be imposed on the structure during the

period of erection shall be taken as acting together with the erection load.

8.4 TEMPERATURE EFFECTS

Expansion and contraction due to changes in temperature on the material of the

structure shall become decisive in design and adequate precautions shall be made

for such effects.

8.5 FLOOR COVERING


Pultruded FRP gratings made of Isopthalic polyester resin containing glass fibre

content not less than 60% and having fire retardant characteristics, suitable for

imposed load of 250kg/sqm of colour yellow/grey and designed for a max support

span of 1000mm with bonded grit antiskid surface including fixing to structural steel

frames already provided by means of SS hold down clamps, locking arrangement

etc. complete shall be provided for floor covering. FRP Material should be UV

resistant meeting IS14887, 500 Hour Accelerated weathering test with tensile

strength not reducing more than 5% after 500 Hours of Exposure. Grating shall be

designed for a full live load plus a point load of 500kg minimum.

8.6 All steel stairways shall have a minimum clear width of 1000mm. The slope of

stairways shall be less than 40. All steel staircases shall have channels provided as

stringers with a min. size of ISMC 150. Stairways flight shall not exceed 3m between

platform landings, stairways tread shall be with gratings of load-bearing bars 30mm

deep x 5mm thick at 30mm cross centers and 6mm twisted cross bars at 50mm

centers. 8.7 Ladders shall be provided for access to platforms. However, stairways shall be

provided if the service requires frequent attention of operational personnel. Ladders

shall be tied to a firm structure at intermediate points when top of ladder is more than

4.5m above landing level. Ladders with more than 2400 height shall be provided with

safety cages. Access opening shall be provided at intermediate platform landings of

continuous ladders. Minimum width of ladder shall be 450 mm with 20mm dia rungs

spaced at 300mm(max). Ladder shall preferably be vertical and shall in any case not

exceed 5 slope.

8.8 GRP heavy duty Handrails shall be provided with minimum height of 1000mm with 50

mm square GRP pultruded pipe post of 5 mm thickness at 1.50 mtr spacing with pre

drilled holes, with 67mm Curved U shape top rail , mid rail and Kick Plate of 80mm

wide Half Round shape with extended Flange design of colour yellow with all

required stainless steel fasteners, clamps , specials, mounting hardware for fixing

post etc complete at all levels as per manufactures specifications.GRP materials shall

conform IS 14887 for UV resistance meeting 500 accelerated weathering test with

Tensile and flexural strength not reducing more than 5% after exposure and shall be

firmly supported. The Hand Rail must be able to withstand 70 Kg concentrated load at

mid span without any failure or crack.

8.9 Fabrication drawings of all major steel structures shall be prepared and got

approved before starting up the work.

8.10 All structural steel work shall be shot blasted and painted with epoxy paint as

per the following specifications

Preparation of Surface Shot blasting to near white metal grade SA 2.5 As per IS 9954

Primer P1-One coat of Ethyl silicate inorganic zinc

primer having DFT of 70 micron per coat.


Intermediate coat IP1-One coat of Epoxy MIO having DFT of 70 micron

. per coat.

Finish coat FP-1 One coat of finish epoxy paint using two

pack polyamide cured epoxy having DFT of 40

micron per coat. FP-2 One coat of Aliphatic Arcyclic

Polyurethane paint having DFT of 40 micron per coat.

.

One coat of primer before erection of structure (shop coat)

Intermediate coat& finish paint After erection and final setting out of structure

8.11 Grouting of foundation bolts below base plates for structural columns shall be

provided using SHRINKKOMP-10 or equivalent. Minimum thickness for grouting

shall be 25mm.

8.12 Expansion joints in steel structures shall be provided as per the guidelines in IS

800.

8.13 Roofing over steel trusses shall be with colour coated Zincalume steel sheets

with min. yield stress of 550Mpa and having min. Base metal thickness of

0.45mm. The sheets shall have a hot dip zinc aluminium alloy coating

consisting of 45% zinc and 55% aluminium with total coating mass of

200gm/sqm. The total colour coating thickness of 40 microns shall be provided

with super polyester XRW paint system comprising of 20 microns coat on

exterior surface and 10 microns on under side of sheet over 5 microns primer

coat on both sides. The total thickness of coated sheet shall be 0.5mm. The

sheets shall be fixed with hot dip galvanized self-drilling fasteners specified by

sheet manufacturer. The manufacturer’s instructions regarding spacing of

supports, laps, bolts etc. for the roofing shall be followed. All accessories like

flashing, capping, valley gutters etc shall be made of the above specified

material.

8.14 Roofs shall have a slope of 1:3. Rainwater gutters and pipes shall be provided

for proper roof drainage and collection of rainwater.

BPCL-KOCHI REFINERY

CONSTRUCTION OF 120 KLD SEWAGE TREATMENT PLANT FOR BPCL TOWNSHIP AT ERNAKULAM

Bidding Document

TECHNICAL SPECIFICATION FOR CIVIL WORKS IN 120KLD

SEWAGE TREATMENT PLANT FOR BPCL TOWNSHIP AT

ERNAKULAM

BPCL (KOCHI REFINERY)


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I N D E X

Page No.

1. General 3 2. Setting out 4 3. Clearing and grubbing 5 4. Excavations, Fillings & Back filling 5 5. Concrete Work (Plain and Reinforced) 8 6. Steel Reinforcement 25 7. Shuttering Works 28 8. Structural Steel 30 9. Brickwork 40 10. Cement Plastering for Walls and Ceilings 42 11. Aluminum Doors, Windows 46 12. Water proofing 48 13. Rigid PVC Pressure pipes & fittings 50 14. FRP Gratings 51 15. Documentation for Griha 53 16. Relevant Standards and Codes of practice 53



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1.0 GENERAL

1.1 The detailed specifications given hereinafter are for the items of works described in the schedule of quantities attached herein, and shall be guidance for proper execution of work to the required standards. It may also be noted that the specifications are of generalized nature and these shall be read in conjunction with the description of item in schedule of quantities and drawings. The work also includes all minor details of construction which are obviously and fairly intended and which may not have been referred to in these documents but are essential for the entire occupation in accordance with standard Engineering practice.

1.2 Unless specifically otherwise mentioned, all the applicable codes and standards published by the Indian Standard Institution and all other standards which may be published by them before the date of receipt of tenders, shall govern in all respects of design, workmanship, quality and properties of materials and methods of testing, methods of measurements etc. Wherever any reference to any Indian Standard Specifications occurs in the documents relating to this contract, the same shall be inclusive of all amendments issued thereto or revision thereof, if any, up to the date of receipt of tenders.

1.3 Wherever brand names and makes are specified in these Technical Specifications below, items shall be supplied from the attached vendors’ list.

1.4 In case there is no I.S.I. specification for the particular work, such work shall be carried out in accordance with the instructions in all respects, and requirements of the Engineer-in-Charge.

1.5 Samples of various materials, fittings, etc. proposed to be incorporated in the work shall be submitted by the contractor for approval of the Engineer-in-charge before order for bulk supply is placed. The contractor shall take instructions from the Engineer-in-charge regarding collection and stacking of materials in any place. No excavated earth or building materials shall be stacked on areas where buildings, roads, compound wall etc. are to be constructed.

1.6 The contractor shall maintain in perfect condition all works executed till the completion of the entire work allotted to him. Where phased delivery is contemplated, this provision shall apply to each phase.



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1.7 The contractor shall clear the site thoroughly of all scaffolding materials and rubbish etc. left out of his work and dress the site around the building to the satisfaction of the Engineer-in-charge before the work is considered as complete. In case any difference or discrepancy between the specifications and the description in the schedule of quantities, the schedule of quantities shall take precedence. In case of any difference or discrepancy between specifications and drawing, the specifications shall take precedence. The item wise detailed specifications under this section are intended for the general description of the work, quality and workmanship. The specifications are, however, not intended to cover minute details and the work shall be executed according to the relevant latest Indian Standard Code of practice. In absence of the above, work shall be executed according to latest specifications of KPWD/CPWD, New Delhi at the discretion of the Owner/Consultant. Owner/ Consultant’s decision shall be final and binding on the Contractor regarding clarification / interpretation of the standards / specification.

2.0 SETTING OUT

The Contractor shall be responsible for the true and proper setting out of the WORK in relation to original points, lines and levels of reference and for the correctness of the levels, dimensions and alignments of all parts of the WORK . If at any time during the progress of work any error appears or arises in the position of levels, dimensions, or alignment of part of the Work, the Contractor shall at his own expense rectify such errors to the satisfaction of the Engineer-in-charge. The checking of any line or level by the Engineer-in-charge shall not in any way relieve the Contractor of his responsibilities.

2.1 As directed by the Owner/Consultant, the Contractor shall fix permanent Benchmarks on the basis of reference control points provided by the Owner/Consultant from which all important levels for the excavation will be set. The Contractor shall provide all labour and materials for setting levels at his own cost.

2.2 These permanent Bench Marks shall consist of masonry pillars with top neatly plastered and levelled as per the directions of the Engineer-in-charge. Bench marks shall be well connected with the grid system or any other Bench Mark approved by Engineer-in-charge. The setting out of the related works shall be done as per the approved “Good for construction” drawings and Contractor shall be responsible for its accuracy, acceptable as per the specification.



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3.0 CLEARING AND GRUBBING

The area to be excavated or filled shall be cleared fully of rubbish, slush etc. and vegetation including trees. The roots of trees shall be removed up to sufficient depth below ground level.

4.0 EARTH WORK EXCAVATION

4.1 The excavation work shall be carried out in all classes of soil including any debris ,boulders,

rubble ,and old remains of RCC present in the earth etc without endangering the safety of

nearby structures or without causing hindrance to other activities in the area. All excavations

shall be done to the minimum dimensions as required for safety and working facility. The

Contractor shall obtain prior approval of Owner/Consultant before starting of excavation at

each location. The excavation must be carried out in the most expeditious and efficient

manner.

4.2 The existing ground levels at the locations e.g. center line of trenches for foundations of

structures are to be agreed with and jointly recorded with Owner/Consultant before any

excavation is commenced.

4.3 All checks and precautions shall be adopted to prevent over excavation. The rough

excavation may be carried out up to a maximum depth of 150 mm above the final level. The

balance shall be excavated with special care as directed by the Owner/Consultant.

Excavations for foundations are required to be done up to specified levels or to specified

limits. The Contractor shall not excavate the last 100 mm until immediately before

commencing the constructional work except where the Owner/Consultant shall permit

otherwise. Should the Contractor have excavated to less than 100 mm of these specified

limits before he is ready or able to commence the construction work, he shall, wherever

required by the Owner/Consultant, excavate further so as to remove not less than 100 mm of

materials immediately before commencing the construction work.



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4.4 All loose material and rubbish shall be removed from the excavation by hand before

commencing of any construction work so as to ensure that the work rests on a solid and

perfectly clear foundation or abuts against solid ground. The bed shall be compacted by

rammers to an even surface, wherever necessary. Soft and undesirable spots shall be

removed even beyond final excavations line, as directed by the Owner/Consultant. The extra

width of excavation shall be filled up as instructed by the Owner/Consultant and the cost of

this extra cutting/filling shall not be paid to the Contractor and shall be included in the rates

quoted.

4.5 If the excavation is done to a depth greater than that shown on the drawing or directed by the

Owner/Consultant due to the Contractor’s fault, the excess depth shall be filled up to the

required level at the Contractor’s cost with lean concrete of 1:5:10 mix. No extra cost will

be paid to the Contractor for such excess cutting and filling back with lean concrete.

4.6 In certain cases where deterioration of the ground, upheaval, slips, etc. is expected, the

Owner/Consultant may order suspension of the work or part of it at any stage. No extra

payment shall be made to the Contractor for such temporary suspension of work.

4.7 Disposal

The excavated surplus soil shall be disposed off by spreading and consolidating at designated

areas or as directed by the Owner/Consultant.

4.8 Inspection

The Contractor shall notify the Owner/Consultant for inspection of the excavation and until

his approval is obtained subsequent operations must be withheld. After obtaining the

approval no time shall be lost in starting the next phase of work to prevent damage or

deterioration to excavation.

4.9 Dewatering



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All excavation shall be kept free of surface as well as from any source of water. Sumps made

for dewatering must be kept clear of the foundations. Sufficient number of pumps should be

provided. Method of dewatering shall require approval of the Engineer-in-Charge.

4.10 Shoring

The type and extent of shoring required shall be approved by the Owner/Consultant prior to

the commencement of work. Approval by the Owner/Consultant shall not relieve the

Contractor of his sole responsibility for the adequacy of shoring.

4.11 Slips

If in spite of all and timely precautions as directed by the Owner/Consultant any slip occurs

due to any reasons, the Contractor shall have to remove the slip material for which no extra

payment shall be made to him.

4.12 IS Code

Some of the important Code Relevant to this specification.

IS: 3764 - 1992 Safety code for Excavation work

4.13 BACKFILLING

4.13.1 Back filling material shall be generally obtained from soil of excavation and shall be free

from clay, stones, concrete, salts, organic and other foreign matters. All clods of earth

shall be broken or removed. The Owner/Consultant, shall have the option, to direct the

contractor to get the filling material from approved borrow pits or other approved sources

for which the Contractor shall arrange the necessary formalities (Permission, royalties,

etc.) at no extra cost to the Owner/Consultant.

4.13.2 After construction and acceptance of foundations, footings, walls and other construction

below the final grade level, spaces around the foundation of structures in pits and trenches

shall be cleared of all forms, shoring, timber, brickbats, debris etc. prior to backfilling.



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4.13.3 Backfilling shall be done with approved earth in layers not exceeding 25 cm thickness,

each layer being watered, rammed and properly consolidated before the next layer is laid.

Each layer will be consolidated with standard equipment as per the relevant Indian

Standards (latest edition) and to the satisfaction of the Owner/Consultant. Trucks, rollers

or heavy equipment shall not be used for depositing or compacting backfill within 1.5 m

or more as found necessary of walls, piers or other facilities, which may be damaged due

to their weight or operation. Any damage caused due to inadvertent use of such heavy

equipment nearby shall be repaired and made good by the Contractor at his own expenses

and to the satisfaction of the Owner/Consultant. Pushing of earth for backfilling shall not

be adopted under any circumstances. The method of compaction shall be subject to

approval of Owner/Consultant.

4.13.4 No additional payment shall be made for backfilling the trenches using the excavated

earth. Surplus earth shall be shifted to areas pointed out in the project premises by the

Engineer-in-charge and spread in layers as per instructions.

5.0 CONCRETE WORK (PLAIN & REINFORCED)

Cement used for various grades of concrete and mortar for masonry and plaster shall be

Portland Pozzolana conforming to IS 1489 and shall contain more than 25% of fly ash.

5.1 Scope

The specification deals with cement concrete – Plain or Reinforced, for general use, and

covers the requirements for concrete materials, their storage, grading, mix design, strength

and quality requirements, pouring at all levels, reinforcements, protection, curing, formwork,

finishing, painting, admixtures, inserts and other miscellaneous works.

5.2 The provision of IS: 456 (latest revision) and all other relevant standards referred to therein

shall be complied with unless permitted otherwise and any other Indian Standard Code (latest



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revision) shall form a part of this specification to the extent it has been referred to applicable

within this specification.

5.3 Materials

5.4 Cement

Cement shall be Portland Pozzolana Cement conforming to IS: 1489 (Part 1- Fly ash based )

latest revision as specified in the Schedule of Items of work . Cement, which has set or

partially set, shall not be used. The fly ash content in all pozzolana cement used shall be

more than 25% by weight or volume to achieve desired GRIHA rating.

5.5 Aggregates

Aggregates shall conform to all provisions and test methods of IS: 383 latest revision.

Samples of aggregates, proposed to be used shall be submitted, free of charge, in sufficient

quantities to the Owner/Consultant with sieve analysis and other physical and chemical

analysis data for his approval. Approved samples shall be preserved by him for further

reference. This approval will not in any way relieve the Contractor for his responsibility for

producing concrete of specified qualities.

a. Coarse Aggregates

Coarse Aggregates shall be crushed hard granite broken stones brought from approved

source and consist of uncoated, hard, strong, dense and durable pieces of crushed

stone and shall be free from undesirable matters, viz. disintegrated stones, soft, flaky

or elongated particles, salt, alkali, vegetable matter or other deleterious substances.

The amount of different undesirable substances in coarse aggregates shall not exceed

the percentage limits by weight as specified in the relevant IS Codes, but in no case,

the total amount of all the undesirable substances shall exceed 5%.

Aggregates, other than crushed stones conforming to the provisions of the

specification may be used under special conditions, if permitted by the

Owner/Consultant.



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Washing of aggregates by approved means shall be carried out, if desired by the

Owner/Consultant at no extra cost.

The maximum size of coarse Aggregates shall be as follows unless specified

otherwise.

R.C.C. members with

very narrow space : 10 mm

Reinforced Concrete : 20 mm

Plain Concrete : 20 mm

Lean Concrete M 5 or M 7.5 : 20 / 40 mm

(The actual size to be agreed by the Owner/Consultant)

Grading of coarse aggregates for a particular size shall generally conform to relevant

IS Codes and shall be such as to produce a dense concrete of the specified proportions

and/or strength and consistency that will work readily in to position without

segregation.

b. Fine Aggregate

Sand shall be clean, sharp, River sand or manufactured sand conforming to IS: 383

(for selected items mentioned in Schedule of Items of Work) brought from approved

quarry/source and consist of siliceous material, having hard, strong, durable, uncoated

particles, free from undesirable amount of dust, lumps, soft or flaky particles or other

deleterious substances. The amount of different undesirable substances shall not

exceed the percentage limits by weight as specified in relevant IS codes, but in no

case, the total amount of all undesirable substances shall exceed 5% by weight.

Washing of aggregates by approved means shall be carried out if desired by the

Owner/Consultant at no extra cost to the Owner/Consultant.

Coarse and fine sand shall be well graded, within the limits, by weight as specified in

relevant IS Codes. Fineness modulus shall not vary by more than plus or minus 0.20



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from that of the approved sample. Fineness modulus for sand shall not be less than

2.5.

5.6 Water

Water shall be clean, fresh and free from any organic or other deleterious matters such as

oils, acids, alkalies, salts, sugar, organic materials & vegetable growth in solution or in

suspension in such amounts that may impair the strength or durability of the concrete. The

water to be used and the concrete obtained shall comply with requirements of clause 5.4 of

IS: 456 (latest revision). Potable water is generally satisfactory. IS: 3025 and IS:3550 may

be followed for testing, if required. Where water can be shown to contain any sugar or an

excess of acids, alkali or salt the Owner/Consultant may refuse to permit its use.

5.7 Admixtures

The use of admixtures in concrete for promoting workability, improving strength,

entertaining air or for any other purpose may be used only with the written approval of the

Owner/Consultant as per mix design. Addition of admixture should not reduce the specified

strength of concrete in any case. The admixtures shall conform to IS: 9103-1999 (latest

revision).

5.8 Storage of Materials

Cement

Cement shall be stored above the ground in dry, leak proof, well-ventilated warehouses in

such a manner as to prevent deterioration due to moisture or intrusion of foreign matter. The

storage platform should be at least 300 mm above the ground.

Cement shall be stored in easily countable stacks with consignment identification marks and

each consignment shall be used in the order of their receipts at site. Sub-standard or partly

set cement shall not be used and shall be removed from the site with the approval of the

Owner/Consultant as soon as it is detected.

5.9 Aggregates



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Each size of aggregates shall be kept separated with wooden or steel or concrete or masonry

bulkheads or in separate stacks and sufficient care shall be taken to prevent the material at the

edges of the stockpiles from getting intermixed. Stacks of fine and coarse aggregates shall be

kept sufficiently apart with proper arrangement of drainage.

5.10 Grades of concrete

For various grades of concrete, either Ready mix concrete as per IS 4926 shall be used

with the permission of Engineer in charge or the contractor can set up an electrically

operated, fully automatic batching plant of required capacity within the project

premises with noise control measures .

5.11 General

Concrete shall be design mix, in grades designated as M20 and M30 as specified in IS:456

(latest revision). In the case of liquid retaining structures, IS: 3370 shall be followed.

Concrete mix shall be of design mix except in case of mud mat concrete / lean Concrete.

Design mix concrete shall be adopted for all RC work. In exceptional case when it is

required to use nominal mix it shall be as per specific prior approval of Owner/Consultant.

Lean concrete shall be of mix 1:4:8 with aggregates of maximum size 40 mm and normally

be used below the foundations.

5.12 Nominal Mix concrete

Nominal mix concrete is recommended only for lean concrete. Nominal mix concrete shall

not require preparation of trial mixes. Concrete mix proportions for ordinary concrete shall

be as per IS:456 ( or latest revision). In proportioning concrete, quantity of cement, fine and

coarse aggregates shall be determined by volume. If fine aggregates are moist, allowance

shall be made (for bulking and in accordance with IS:2386 (Part-3). Allowance shall also be

made for surface water present in the aggregates when computing the water content. The

amount of surface water shall be determined by one of the field methods described in IS:2386



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(Part-3). All the above data shall be maintained properly to the satisfaction of the

Owner/Consultant.

The water-cement ratio shall not be more than those specified in IS:456 (latest revision). The

cement content of any nominal mix proportion shall be increased if the quantity of water in

mix has to be increased to overcome the difficulties of placement and compaction, so that the

water-cement ratio specified above for a particular mix is not exceeded. No additional

payment shall be made to the Contractor for use of the extra cement.

If ordinary concrete made in accordance with the proportions given above for a particular

grade does not yield the specified strength and fails to satisfy the requirement of “Acceptance

Criteria for Concrete” as specified in IS:456 (latest revision) the cement content shall be

increased as directed by the Owner/Consultant to obtain a specified strength at no extra cost

to the Owner/Consultant. The richer mix shall continue until the Owner/Consultant instructs

otherwise.

Ordinary concrete proportioned for a given grade specified shall not, however be classified as

a higher grade on the ground that the test strength were found higher than the minimum

specified.

5.13 Design Mix Concrete

Design mix concrete shall be used for all concrete works, except wherever specified

otherwise. Design mix concrete for use in plain and reinforced concrete structures shall be in

grades of M 20 or richer. Mix design has to be done in approved institutes and shall be

submitted for approval of Owner/Consultant.

The mix shall be designed with PPC (with fly-ash content >25%) for M20 and M30 grades

of concrete , with any two approved brands of cement for each grade. The mix shall have

required workability and characteristic strength not less than appropriate values given in



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Table -2 of IS:456 (latest revision). For mix design, procedure given in Indian Standard

Recommendation or any other standard procedure shall be adopted. As long as the quality of

materials does not change, an approved mix design done earlier not prior to one year may be

considered adequate for the work. Batching, mixing, sampling and strength test of concrete

shall be carried out in compliance with the relevant clauses of IS: 456 (latest revision) and all

other relevant Indian Standards recommended therein.

The mix designed by the Contractor at approved laboratories shall be used for works only

after obtaining a written approval of Owner/Consultant. The mix design shall be entirely

the responsibility of the Contractor and any approval by the Owner/Consultant shall not

relieve him of their responsibility in respect thereof.

The Contractor shall prepare all calculations, tabulations, graphs, etc. pertaining to mix

design or test result and supply copies of such calculations, tabulations, graphs, etc. as

required by the Owner/Consultant.

Owner/Consultant may ask the bidder to get the mix design done through any approved

reputed institution and bidder shall arrange the same at his own cost. Nothing extra shall be

paid for such works.

The minimum cement content for each grade of concrete shall be as per table below. The

contractor shall use the minimum cement content mentioned while doing concrete at site,

even though the mix design requires less cement than the minimum specified. If the actual

requirement of cement is found to be more than specified below, the Contractor shall provide

the required quantity of cement as per approved mix design at no extra cost.



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TABLE 1. Minimum Cement Content

Grade of

Concrete

Minimum Cement content /Cu.m.

of finished concrete (kg).

M20 320

M30 400

5.14 Strength Requirements

The strength of concrete sample shall be determined in accordance with the recommendations

of IS:456 (latest revision). The acceptance of strength of concrete for both design mix

concrete and nominal mix concrete shall be as per clause 16, “Acceptance Criteria” of IS:456

(latest revision). Concrete work found unsuitable for acceptance shall have to be dismantled

and replaced to the satisfaction of the Owner/Consultant by the Contractor free of cost to the

Owner/Consultant. No payment for the dismantled concrete, the relevant form work and

reinforcement, embedded fixtures, etc. wasted in the dismantled portion shall be made. In the

course of dismantling, if any damage is done to the embedded items or adjacent structures,

the same shall also be made good free of charge by the Contractor to the satisfaction of the

Owner/Consultant.

With permission of the Owner/Consultant, for any of the above mentioned grades of concrete,

if the water quantity has to be increased in special cases, cement shall also be increased

proportionately to keep the ratio of water to cement same as adopted in trial mix design for each

grade of concrete. No extra payment for additional cement shall be made.

The contractor shall furnish the details of quarry from where the aggregates are proposed to

be taken and have to ensure the adequate supply of materials till the completion of the

project. If any changes are made in the source of supply , a fresh design mix with materials of



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fresh source has to be established prior to use at site with the permission of the Engineer in

charge.

The strength of concrete cubes taken at site only will be considered for the acceptance criteria of concrete for ready mix concrete.

5.15 Ready Mix Concrete (RMC)

Alternatively, the contractor can be allowed to use Ready Mix Concrete conforming to IS 4926 (RMC)

with the Permission of Engineer-in-Charge, provided that the manufacturer assures that for RMC

supplied for the particular work contains the minimum cement content and it is in conformity of

approved design mix. The manufacturer of RMC has also to agree to the sampling and testing

procedure as specified, or alternatively he can propose his own sampling and testing procedure which

should in turn be approved by the Engineer-in-Charge. Normally, RMC supplied to site are mixed with

certain admixtures which enables the concrete to be used within 3 hours of supply at site. In case

RMC supplied is not consumed within 3 hours of supply the quantity of RMC remaining unused

beyond 3 hours shall be rejected and removed from site.

5.16 Workability

The degree of workability of concrete is to be such that the concrete can be placed and compacted

properly with the means available. Guidance for preferred limits of consistency shall be obtained from

IS:456 (latest revision). However, degree of workability to be achieved for the work in progress shall

be as per direction of the Owner/Consultant. Necessary tests in accordance with IS:1199 (latest

revision) shall be carried out at frequent intervals to check the workability of the concrete.

5.17 Workmanship

General

All workmanship shall be according to the latest standards.

Before starting a pour the Contractor shall obtain the approval of the Engineer-in-charge in a “Pour

Card” maintained for this purpose. They shall obtain complete instructions about the material and

proportion to be used, slump, workability, quantity of water per unit of cement, number of test cubes to

be taken, type of finishing to be done, any admixture to be added etc.

5.18 Mixing of Concrete



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The proportions of fine and coarse aggregate, cement and water shall be as determined by the

preliminary tests or according to fixed proportions in case of ordinary concrete and shall always be

approved by the Owner/Consultant. The quantities of fine and coarse aggregates shall be determined

by weight. The quantity of cement shall always be determined by weight. The water shall be

measured accurately after giving proper allowance for surface water present in the aggregate for

which the Contractor shall make regular check.

Concrete shall be mixed in a mechanical mixer / batching plant unless hand mixing is specifically

approved by the Engineer-in-Charge. The batching plant shall conform to IS: 4925. Mechanical

mixers shall comply with IS:1791 and 12119 and shall be maintained in satisfactory operating

condition. The water shall not be poured into the drum of the mixture until all the cement and

aggregate constituting the batch are already in the drum and dry mixed for at least one minute.

Mixing of each batch shall be continued until there is uniformity in colour and consistency, but in no

case shall mixing be done for less than two (2) minutes and at least forty (40) revolutions after all the

materials and water are in the drum. When absorbent aggregates are used or when the mix is very

dry, the mixing time shall be extended as may be directed by the Owner/Consultant. Mixer/ batching

plant shall not be loaded above their rated capacity as this prevents thorough mixing.

The entire contents of the drum shall be discharged before the ingredients for the next batch are fed

into the drum. No partly set or remixed or excessively wet concrete shall be used and it shall be

immediately removed from site. Each time the work stops, the mixer/ batching plant shall be

thoroughly cleaned and when the next mixing commences, the first batch shall have 10% additional

cement at no extra cost to the Owner/Consultant to allow for loss in drum.

Contractor has to find and develop suitable place to operate the mixing machine/ batching plant with

the help of Owner/ Consultant. Any extra lead, lift for transporting the concrete shall be borne by the

Contractor without extra claim.

When hand mixing is permitted by the Owner/Consultant for concrete to be used in levelling course, it

shall be carried out on a watertight platform and care shall be taken to ensure that mixing is continued

until the mass is uniform in colour and consistency. In case of hand mixing, 10% extra cement shall

be added to each batch at no extra cost to the Owner/Consultant.



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5.19 Conveying concrete

Concrete shall be handled and conveyed from the place of mixing to the place of final laying as rapidly

as practicable, by approved means, well before the initial setting time of cement considering the time

for placing and vibration. Concrete should be conveyed in such a way as will prevent segregation or

loss of any of the ingredients. If segregation does occur during transport, the concrete shall be

remixed. Conveying equipment for concrete shall be maintained and thoroughly cleaned before

commencement of concrete mixing. Such equipment shall be kept free from set concrete.

5.20 Placing concrete

Formwork and reinforcement shall be approved in writing by the Owner/ consultant before concrete is

placed. The forms shall be well wetted and all shavings, dirt and water that may have collected at the

bottom shall be removed before concrete is placed.

Concrete shall be deposited in its final position without segregation or re-handling. The interval

between adding water to the dry materials in the mixer and the completion of the final placing

inclusive of compaction of the concrete shall be well within the initial setting time for the particular

cement in use or as directed by the Owner/Consultant.

As far as possible concrete shall be placed in the formwork by means approved by the

Owner/Consultant and shall not be dropped from a height or handled in a manner which may cause

segregation.

Once the concrete is deposited and compacted in its final position, it shall not be disturbed.

The placing of concrete shall be a continuous operation with no interruption in excess of 30 minutes

between the placing of continuous portions of concrete. After the concrete has been placed, it shall

be spaded and thoroughly compacted by approved mechanical vibration to a maximum subsidence

without segregation and thoroughly worked around reinforcement or other embedded fixtures and into

corners of the formwork to correct form and shape. Vibration shall not be used for pushing and

shoveling concrete into adjoining areas.

Mechanical vibration complying with IS: 2506, IS: 2514 and IS: 4656 shall be used for compacting

concrete. Whenever vibration has to be applied externally, the design of formwork and disposition of

vibrator shall receive special consideration to ensure efficient compaction and to avoid surface

blemish. Experienced men must operate vibrators and over-vibration shall not be permitted. Hand



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tamping in some cases may be allowed subject to the approval of the Owner/Consultant. Care must

be taken to ensure that the inserts, fixtures, reinforcement and formwork are not displaced or distorted

during placing of concrete. No concrete shall be placed in open, while it rains. If there has been any

sign of washing of cement and sand the concrete shall be entirely removed immediately. Suitable

precautions shall be taken in advance to guard against rains before leaving the fresh concrete

unattended. No accumulation of water shall be permitted on or around freshly laid concrete. Slabs,

beams and similar members shall be poured in one operation normally. In special circumstances,

with the approval of the Owner/Consultant, these can be poured in horizontal layers not exceeding

fifty (50) cm. in depth. When poured in layers, it must be ensured that the under layer is not already

hardened. Bleeding of under layer, if any shall be effectively removed. Moulding, threading, drip

course, etc. shall be poured as shown in the drawing or as desired by the Owner/Consultant. Holes

shall be provided and bolts, sleeves, anchors, fastening or other fixture shall be embedded in

concrete as shown in the approved drawings or as directed by the Owner/Consultant. Any deviation

there from shall be set right by the Contractor at his own expenses as instructed by the

Owner/Consultant. Care shall be taken to avoid dislodgement of particles of aggregate. The surface

shall be thoroughly wetted. After removing all free water, the surface shall then be coated with neat

cement slurry. On this surface, a layer of concrete not exceeding 150 mm in thickness shall first be

placed and shall be well rammed against old work, particular attention being paid to corners and close

spots and works thereafter shall proceed in the normal way.

5.21 Protection and Curing of concrete

Newly placed concrete shall be protected by approved means from rain, sun and wind and extreme

temperature. Concrete placed below the ground level shall be protected from falling earth during and

after placing. Concrete placed in ground containing deleterious substances shall be kept free from

contact with such ground or with water draining from such ground during placing of concrete and for a

period of at least three days or as otherwise instructed by the Owner/Consultant. The ground water

around newly poured concrete shall be kept to an approved level by pumping or other approved

means of draining. Adequate steps shall be taken to prevent floatation or flooding. Steps as

approved by the Owner/Consultant, shall be taken to protect immature concrete from damage by

debris, excessive loading, vibration, abrasion, mixing with earth or other deleterious materials, etc.

that may impair the strength and durability of concrete.



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To minimize water requirement for curing in non horizontal surfaces , as soon as the concrete has

hardened sufficiently, approved curing compound may be applied as per manufacturer’s

specification. After seven days, the surfaces shall be covered either with hessian, canvas or similar

materials and kept continuously wet for next seven (7) days. This period may be extended, at the

discretion of the Owner/Consultant up to fourteen (14) days. Where as the horizontal surface ,cure

shall be done by spreading sand kept damp throughout the curing period of minimum seven days.

5.22 TESTING & ACCEPTANCE CRITERIA

General

The Contractor shall carry out all sampling and testing in accordance with the relevant Indian

Standards and as supplemented herein for the following items at their own cost unless otherwise

specified in this specification.

5.23 Site laboratory

In order to exercise the required degree of constant control over the concrete materials and their

preparations, the Contractor shall set up and maintain, at his own expense, a testing laboratory at

site. He shall provide all apparatus required for testing of concrete and concrete materials including

moisture tester for aggregates. The water cement ratio shall be maintained after adjusting the

moisture content in the aggregates used. Concrete works shall be supervised by an experienced and

qualified Engineer approved by the Engineer-in-charge, whose duty will be to supervise all stages in

the preparation and placing of concrete. All cubes shall be prepared and made by a qualified

Engineer and site tests carried out under his direct supervision in the presence of Engineer-in-charge

or his authorised representative. The Contractor shall submit to the Owner/Consultant the test results

in triplicate immediately after completion of the tests. The contractor shall also arrange to get the

materials/cubes/construction water tested by an approved lab at the cost of the contractor as per the

direction of the Engineer in charge.

5.24 Admixture

Tests for establishing the various properties of any admixtures which may be required to be added

shall be carried out by the Contractor free of charge to the Owner/Consultant.

5.25 Concrete



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The sampling of concrete, making the test specimens, curing and testing procedure etc. shall be in

accordance with IS:1199 and IS:516, the size of specimen being 15 cm cubes. Normally, only

compression tests shall be performed but under special circumstances the Owner/Consultant may

require other tests to be performed in accordance with IS:516.

A random sampling procedure shall be adopted to ensure that each concrete batch shall have a

reasonable chance of being tested that is, the sampling should be spread over the entire period of

concreting and shall cover all mixing units.

The minimum frequency of sampling of concrete of each grade shall be in accordance with the

following:

Quantity of

concrete

in the work ,m3

Number of

samples

1-5 1

6-15 2

16-30 3

31-50 4

51 and above 4 plus one additional sample

for each additional 50m3 or

part thereof.

At least one sample shall be taken from each shift. Three (3) specimens shall be taken from each

sample for testing at 28 days. Additional samples may be required for various purposes such as to

determine the strength of concrete at 7 days or at the time of striking formwork etc as instructed by

the Engineer-in-charge. To control the consistency of concrete from every mixing plant, slump tests

and/or compacting factor tests in accordance with IS:1199 shall be carried out by the Contractor

every two hours or as directed by the Owner/Consultant. Slumps corresponding to the test specimen

shall be recorded for reference. The acceptance criteria of concrete shall be in accordance with

Clause 16 of IS:456 (latest revision). However, in exceptional circumstances, the Owner/Consultant

may at his discretion, accept a concrete of lower strength than specified and which is otherwise

unacceptable according to IS:456.

Concrete work found unsuitable for acceptance shall have to be dismantled and replacement is to be

done as per specification by the Contractor.



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No payment for the dismantled concrete, the relevant form work and reinforcement, embedded

fixtures, etc. wasted in the dismantled portion shall be made. In the course of dismantling, if any

damage is done to the embedded items or adjacent structures, the same shall be made good, free of

charge by the Contractor, to the satisfaction of the Owner/Consultant.

5.26 Load Test

In case of doubt regarding the grade of concrete used, either due to poor workmanship or when the

test strength falls below the required strength and not acceptable as per “Acceptance Criteria” of

IS:456 (Latest revision), compressive strength test of concrete and/or load test on the basis of Cl. 17.4

and 17.6 of IS:456 (Latest revision) shall be carried out as decided by the Owner/Consultant. The

Contractor at their own expense shall make all arrangements for such tests and conduct the tests in

presence of Owner/Consultant.

5.27 Construction joints

Construction joints shall be provided in position as shown or described on the drawings or as directed

by the Engineer-in-charge. Such joints shall be kept to the minimum. These shall be straight and at

right angles to the direction of main reinforcement.

In a column, the joint shall be formed about 100mm to 150mm below the lowest soffit of the beam

framing into it. Concrete in a beam and slab shall be placed throughout without a joint but if the

provision of a joint is unavoidable, the joint shall be vertical and located within ⅓ to ¼ of the span,

unless otherwise shown on the drawings.

When stopping the concrete on a vertical plane in slabs and beams, an approved stop board shall be

placed with necessary slots for reinforcement bars. The construction joints shall be keyed by providing

a triangular or trapezoidal fillet nailed on the stop board. Inclined joints shall not be permitted. Any

concrete flowing through the joints of stop board shall be removed soon after the initial set. When

concrete is stopped on a horizontal plane, the surface shall be roughened and cleaned after the initial

set and a triangular or trapezoidal groove shall be provided for keying with the new concrete later.

When the work has to be resumed on a surface which has hardened, such surface shall be cleared of

any foreign materials and roughened to expose the tips of the coarse aggregate. This may be done by

manual chipping of concrete, with a high pressure water jet or by any other appropriate means as per

the direction of the Engineer-in-charge. It shall then be thoroughly washed and wetted before any new



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concrete is poured. Any set mortar or concrete sticking to the exposed reinforcing rods in and around

such joints shall be thoroughly removed. The reinforcements shall be wire brushed and washed just

before pouring any cement slurry or mortar. For vertical joints neat cement slurry shall be applied on

the surface before it is dry. For horizontal joints, the surface shall be covered with a layer or mortar

about 10 to 15mm thick composed of cement and sand in the same ratio as the cement and sand in

concrete mix. This layer of cement slurry or mortar shall be freshly mixed and applied immediately

before placing new concrete.

Where the concrete has not fully hardened, all laitance shall be removed by scrubbing the wet surface

with wire or bristle brushes, care being taken to avoid dislodgement of particles of aggregate. The

surface shall be thoroughly wetted and all free water removed. The surface shall then be coated with

neat cement slurry. On this surface layer of concrete not exceeding 150mm in thickness shall first be

placed and shall be well rammed against old work, particular attention being paid to corners and

close spots; work there after shall proceed in the normal way.

5.28 Acrylic Swellable Water Stops

Acrylic swellable water stops shall be provided at construction joints of liquid retaining tanks.

5.28.1 General :

The Acrylic sealing profiles which swell in contact with water “SikaSwell® S-2 “or equivalent of

specified width to be used at leak resistant construction joints, shall be of approved manufacture and

shall satisfy all the normal test parameters such as tensile strength, longation etc.

Sample :

A sample of Water swellable Profile water stop shall be got approved from the Engineer-in-

charge before procurement of bulk quantity.

5.28.2 Placing in Position:

The substrate must be sound, clean, dry, ‘mat damp’, free from all surface contaminants.

Substrate Preparation All loose particles, release agents, laitance, paint, rust and other poorly

adhering materials must be removed by suitable hand or mechanical preparation. Surfaces which are

excessively rough tend to leak later on. It is recommended smoothing of

freshly placed concrete with a batten where the sealing profile is to be placed . A Profile can be fixed

with SikaSwell® S-2 which must be extruded in sufficient quantity to level the roughness of the

substrate. Apply SikaSwell® S-2 in a narrow bed (size of triangular section ~ 10 mm) to the substrate.



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The profiles must be placed within 30 minutes and pressed well into the still fresh SikaSwell® S-2

sealant until small quantities of SikaSwell® S-2 ooze out from both side of the profiles. Allow

SikaSwell® S-2 to harden for 2 - 3 hours before placing concrete. Please consult the product data

sheet of SikaSwell® S-2. It is important that a full and continuous contact between the SikaSwell®-

Profiles and the substrate is achieved. Place SikaSwell®- Profiles in the centre of the concrete

section. Minimum cover to profiles on both sides must be 75 mm (reinforced concrete) or 150 mm

(non reinforced concrete). Connections and corners must be butt jointed and fixed with SikaSwell® S-

2. During concreting, compact well around SikaSwell®- Profiles to provide a dense concrete without

honeycombs or voids.

5.29 Separation Joint

Separation joint shall be obtained by using an approved alkathene sheet stuck on the surface against

which concrete shall be placed. Adequate care shall be taken to cause no damage to the sheet.

5.30. Expansion joint / Isolation joint

Expansion / Isolation joints in structures shall be formed in the positions and to the shapes shown in

the relevant drawings. Joints shall be filled with joint filling material as stipulated in the drawings /

schedule of Items. Isolation joints shall be provided around all equipment foundations, columns,

pedestals, trenches etc.

5.31 Exposed Surface in Concrete

5.31.1 Interior

Imperfect surfaces, where strength is not the criteria shall be patched and rubbed smooth with

carborandum stone. Immediately after the formwork is stripped off, fins and projections shall be

removed and the concrete surface affected thereby shall be rubbed smooth to the satisfaction of

Owner/Consultant at no extra cost.

5.31.2 Exterior

Imperfect surfaces shall not be patched. But shall be repaired by the removal and replacement of the

member or as directed by the OWNER/CONSULTANT. Small voids shall be filled with 1: 2 cement

and sand mortar pressed in to holes and floated smooth. Plastering and steel trowelling of surfaces

shall not be allowed except in exceptional cases as may be directed by the Owner/Consultant. Fins

and projections shall be treated as mentioned above.



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Exposed concrete surfaces below GL shall be provided with 2 coats of anticorrosive bituminous

coating.

5.32 Anchor bolts, openings, sleeves, conduits

a. Inserts & other Built-in-Fixtures

The Contractor shall provide openings, sleeves, conduits and chases etc. in concrete work as

required for erection of equipment and structures in steel. The material shall be of best quality

available of approved manufacturer and shall be upto satisfaction of the Owner/Consultant. Exposed

surfaces of the embedded materials are to be painted with one coat of approved anti-corrosive paint

and/or bituminous paint without any extra cost to the Owner/Consultant.

b. Material to be embedded

Anchor bolts and plates for machinery equipment and structural steel work / pre-cast

elements etc.

Inserts, hangers, anchors, opening frames, manhole cover frames, floor clips,

sleeves and conduits.

Dowel bars etc. for concrete work.

Flashing and jointing in concrete work.

Conduits for electrical work

Any other built-in-fixtures as may be required.

Correct location, exact alignment etc. of all these shall be entirely the responsibility of the Contractor

6.0 REINFORCEMENT STEEL

Reinforcement steel shall be clean and free from loose mill scales, dust, loose rust and coats of

paints, oil grease or other coatings, which may impair or reduce bond and shall conform to latest

revisions of the following IS specifications.

i) Fe 500D grade high strength deformed bars with elongation more than 14.5% & conforming

to other requirements of IS 1786

ii) Identification

Care shall also be taken to properly identify these bars at site. The staff shall be specially

trained for looking for identification marks on these bars given by the manufacturers which are

generally given colour code. It will be advisable to see that only one type/grade of bars are

brought to site and used in the project after conducting tests for each lot.



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iii) Storage of Materials

All materials shall be stored by the Contractor in a manner affording convenient access for

identification and inspection at all times. The storage arrangements shall be subject to the

approval of the Owner/Consultant. Storage of materials shall be as described in IS:4082 –

(latest revision). All materials shall be so stored as to prevent deterioration due to intrusion of

foreign matter and to ensure the preservation of their quality and fitness for the work. Any

material which has deteriorated or has been damaged or is otherwise considered defective by

the Owner/Consultant shall not be used for concrete, and shall be removed from site

immediately, failing which, the Owner/Consultant shall be at liberty to get the materials

removed and the cost thereof shall be realised from the Contractor’s dues. The Contractor

shall maintain up to date accounts of receipt, issue and balance (stock wise) of all materials.

The contractor has to develop areas for storing all materials at his own cost as per available

area at site.

6.1 Shop drawings – Bar Bending Schedules

The Contractor shall prepare and furnish to the Owner/Consultant with working drawing for all RCC

work, for review and approval by the Owner/Consultant before taking up the work. Bar bending

schedule shall be prepared for Site Work and records only.

6.2 Cleaning

All steel for reinforcement shall be free from loose scale, oil, grease, paint or other harmful matters

immediately before placing the concrete.

6.3 Bending

Unless otherwise specified, reinforcing steel shall be bent in accordance with procedure specified in

IS: 2502-1963 ( or latest) and/or as approved by the Owner/Consultant. Bends and shapes shall

comply strictly with the dimensions in the Bar Bending Schedule. The Contractor shall recheck

bending schedule before bending and they shall be entirely responsible for its correctness. Bars

correctly bent shall only be used.

No reinforcement shall be bent when in position in the work without approval of the Owner/Consultant,

whether or not it is partially embedded in concrete. Bars shall not be straightened in a manner that

will injure the material. Re-bending can be done only if approved by the Owner/Consultant.



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Reinforcement bars shall be bent by machine or other approved means producing a gradual and even

motion. All the bars shall be cold bent unless otherwise approved.

6.4 Transportation and Placing in position

All reinforcements shall be transported from place of bending / fabricating accurately fixed and

maintained in position as shown in the drawings by such approved means of mild steel chairs and/or

concrete spacer blocks. Bars intended to be in contact, at crossing points, shall be securely bound

together at all such points by No. 16 G black annealed iron wire. Binders and the like shall tightly

embrace the bars with which they are intended to be in contact and shall be securely held. The

vertical distance between successive layers of bars shall be maintained by provision of mild steel

spacer bars. They should be so spaced that the main bars do not sag perceptibly between adjacent

spacers.

The placing of reinforcements shall be completed well in advance of concrete pouring. Immediately

before pouring, the reinforcement shall be examined by the Owner/Consultant for accuracy of

placement and cleanliness and necessary corrections as directed by him shall be carried out. The

cover for concrete over the reinforcements shall be as shown on the drawings unless otherwise

directed by the Owner/Consultant. Concrete blocks shall be used for ensuring the cover and

positioning the reinforcement & they shall be made of same grade of concrete in which it is placed

and cured for at least seven (7) days. The size and location of the concrete blocks shall be approved

by the Owner/Consultant. Laps and anchorage lengths of reinforcing bars shall be in accordance with

IS: 456, unless otherwise specified. PVC cover blocks as approved by Engineer in- charge shall also

be used for ensuring the proper cover of the reinforcement with prior approval . If the bars in a lap

are not of the same diameter, the smaller diameter will guide the lap length for measurement purpose.

The laps shall be staggered as far as practicable and as directed by the Owner/Consultant. The

quoted rate of contractor shall include the cost of loading, unloading, transportation and straightening

the reinforcement etc.

7.0 SHUTTERING WORK

7.1 General



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If desired by the Owner/Consultant, the Contractor shall prepare before commencement of actual

work, design and drawings for formwork and centering and get them approved by the

Owner/Consultant. The formwork shall conform to the shape, lines and dimensions as shown in the

drawings. The centering shall be truly rigid and thoroughly braced both horizontally and diagonally.

The forms shall be sufficiently strong to carry without undue deformation, the weight of the concrete

as a liquid as well as working load. Where the concrete is vibrated the formwork shall be strong

enough to withstand the effects of vibration without appreciable deflection, bulging, distortion or

loosening of its components. The joints in the formwork shall be sufficiently tight to prevent any

leakage of mortar. The formwork shall be such as to ensure a smooth uniform surface free from

honeycombs, air bubbles, bulges, fins and other blemishes. Any blemish or defect found on the

surface of the concrete must be brought to the notice of the Owner/Consultant immediately and

rectified free of charge as directed by him. To achieve the desired rigidity, the bolts, spacer, blocks,

tie wires and clamps as approved by the Owner/Consultant shall be used but they must in no way

impair the strength of concrete or leave stains or marks on the finished surface. Where there are

chances of these fixtures being embedded, only mild steel or concrete of adequate strength shall be

used. Bolts passing completely through liquid (or, ground water) retaining walls/slabs for the purpose

of securing and aligning the formwork should not be used.

For exposed interior and exterior concrete surfaces of beams, columns and walls, marine grade

plywood or other approved forms like steel sheets and wooden planks, thoroughly cleaned and tied

together with approved corrosion – resistant devices shall be used. Rigid care shall be exercised

ensuring that all columns are plumb and true and thoroughly cross-braced to keep them so. All floor

and beam centering shall be crowned at less than 8 mm in all directions for every 5 metres span.

Unless described on the drawings or else where to the contrary beveled strips 25 mm shall be

provided without any extra charge, to form angles and in corners of column and beam boxes for

chamfering of corners. Temporary openings for cleaning, inspection and for pouring concrete shall be

provided at the base of vertical forms and at other places, where they are necessary and as may be

directed by the Owner/Consultant. The temporary openings shall be so formed that they can be

conveniently closed when required and must not leave any mark on the concrete.

7.2 Cleaning and Treatment of Forms



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All forms shall be thoroughly cleaned of old concrete, wood shavings, saw dust, dirt and dust sticking

to them before they are fixed in position. All rubbish/ loose concrete chippings, shavings, sawdust

etc. shall be scrupulously removed from the interior of the forms before the concrete is poured.

Along with wire brushes, brooms, etc. compressed air jet or water jet shall be kept handy for the

cleaning, if directed by the Owner/Consultant.

Before shuttering is placed in position, the form surface in contact with concrete shall be treated with

approved non-staining oil. Care shall be taken that the oil does not come in contact with reinforcing

steel or existing concrete surface. They shall not be allowed to accumulate at the bottom of the

shuttering.

The formwork shall be designed and routed so that the forms for slabs and the sides of beams,

columns and walls may be removed first, leaving the shuttering to the soffits of beams and their

supports in position. Re-propping of beams shall not be done except with the approval of the

Owner/Consultant, and props can be reinstated in anticipation of abnormal conditions. If formwork for

column is erected for the full height of the columns, one side shall be left open and built up in

sections, as placing of concrete proceeds. Wedges, spacer, bolts, clamps or other suitable means

shall be provided to allow accurate adjustment of the formwork and to allow it to be removed gradually

without jarring the concrete.

7.3 Removal of Forms

Forms shall be struck in accordance with clause 11.3 of IS:456 (latest revision) or as directed by the

Owner/Consultant with his prior approval. The Contractor shall record on the drawings or in other

approved manner, the date on which the concrete is placed in each part of the work and the date on

which the formwork is removed there from and have this record checked and countersigned by the

Owner/Consultant.

The Contractor shall be responsible for the safe removal of the formwork, but the Owner/Consultant

may delay the time of removal if he considers it necessary. Any work showing signs of damage

through premature removal of formwork or loading shall be entirely reconstructed without any extra

cost to the Owner/Consultant.

7.4 Tolerance in Finished Concrete



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The formwork shall be so made as to produce a finished concrete, true to shape, lines, levels, plumb

and dimensions as shown on the drawings subject to the tolerances specified in clause 11.1 of IS:

456 and as specified below or directed by the Owner/Consultant.

a) plumb : 1 in 1000 of height

b) Levels : 3 mm before any deflection has taken place.

The tolerances specified are for local aberrations in the finished concrete surface and should not be

taken as tolerance for the entire structure taken as a whole or for the setting and alignment of

formwork, which, should be as accurate as possible and true to shape required to the entire

satisfaction of the Owner/Consultant. Any error, within the above tolerance limits or any other may

be specially set up by the Owner/Consultant, if noticed in any lift of the structure after stripping of

forms, shall be corrected in the subsequent work to bring back the surface of the structure to its true

alignment.

7.5 Re-use of Forms

Before re-use, all forms shall be thoroughly scrapped, cleaned, joints etc. examined, and when

necessary repaired, and inside surface treated as specified herein before. Formwork shall not be

used/reused, if declared unfit or unserviceable by the Owner/Consultant.

7.6 Plywood

These shall be used in exposed surfaces, where an especially good finish is required and shall be

made of marine grade plywood to produce a perfectly level, uniform and smooth surface. Re-use

may be permitted upto a maximum of 6 times or up to the deterioration of ply wood materials

occurred whichever is first only after inspection and approval by the Owner/Consultant.

8.0 STRUCTURAL STEEL WORKS

8.1 Scope

The specification covers the requirements for materials, fabrication, assembly, testing, transportation,

erection. Grouting under bases, of all types of structural steel works consisting of columns, beams,

trusses, lattice girders, pipe racks, trestles, galleries, monorails, gantry girders, platforms,. Stairs,

ladders, handrails, purlins, side runners, equipment supporting structures, guide structure etc. for

general construction work.

8.2 General Specifications



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The requirements set forth in IS-800 for the design, fabrication and erection of structural steel for

buildings shall govern this work, except as otherwise noted on the drawings or as otherwise specified.

In cases of conflict between clauses of this specification and those in the Indian Standards, this

specification shall govern. Substitutions of sections or modifications of details or both shall be made

only when approved, in writing, by the Owner. The Contractor shall be responsible for all errors of

fabrication, and for the correct fittings of the structural members shown on the drawings.

8.3 Materials

Structural steel shall conform to IS: 2062/2011, 1S:4923 (weldable quality) unless specified otherwise,

Covered electrodes for metal arc welding of structural steel shall conform to IS:814/2004.Bare wire

electrodes for submerged arc welding of structural steel shall conform to IS:7280. The combination of

wire and flux shall comply with IS:3613.

Filler rods and wires for gas welding shall conform to IS:1278. Welding rods and bare electrodes for gas shielded arc welding of structural steel shall conform to IS:6419.Bolts and nuts (including locknuts) shall conform to IS:1363, IS: 1364, IS:1367, IS:3640, IS:3757, IS:6623 and IS: 6639 as applicable. Washers shall conform to IS:5369, IS:5370, IS:5372, IS:5374, IS:6610 and IS:6649 as applicable.

8.4 Storing of Materials

All sections shall be checked on receipt to ensure that they are free from surface defects such as pitting, twists, cracks and laminations. They shall be arranged by grade and quality and by lot. Welding wires and electrodes shall be segregated by quality and lots and stored inside a dry, enclosed room as per the recommendations of IS:9595. All care shall be taken to keep the electrodes in perfectly dry condition to ensure weld metal soundness and satisfactory operations. Manufacturers certificates for electrodes shall also be logged into the records.

8.5 Storage and Preparation The storage yard for fabricated steel parts shall be prepared in advance and got approved by the

Owner before the steel structures start arriving from the shop. All materials shall be set at least 150 mm clear from ground on wooden or steel blocks for protection against direct contact with the ground and to permit drainage of water. Steps shall be taken to prevent warping of items during handling at all stages.

8.6 Fabrication Drawings



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Fabrication and erection drawings shall be prepared by the Contractor based on the GFC (Good for Construction) drawings of the Owner. These drawings shall be thoroughly checked and stamped “Good for Construction” and signed by the Contractor’s authorized representative. The Contractor shall directly issue to site the fabrication and erection drawing in the correct order, simultaneously submitting three copies to Owner for their review. The Owner shall at his sole discretion review part or whole of all, some or none of the drawings. The review of fabrication drawings shall be limited to the layout, orientation and elevation of structures and members, the sections of members and the adequacy of connections. The review shall not include marking of members, erection clearances, cut length, matching of joints and holes.

Review of drawings by the Owner shall in no way relieve the Contractor of his responsibility for

correctness in the execution of the work, and the Contractor shall be required to modify / rectify the

structure at any stage of work in case Owner bring to his attention any mistake / omission in the

fabrication drawing and the fabrication based on this drawing or that the work does not conform to

good engineering practice. All such modifications / rectifications shall be made at no extra cost to the

Owner. The fabrication drawings shall include but not be limited to the following:

Marking plan/elevations/layouts

Details of joints, shop/field splices

Location, size, type and dimensions of weld and bolts.

Erection assemblies

Method of erection and special precautions to be taken during erection.

The Contractor shall update the fabrication drawings to include revisions made in design drawings

during the course of work at no extra cost. .

8.7 Fabrication

8.7.1 General

All fabrication shall be done as per specifications, IS:800, IS:9595 and other relevant IS Codes on the

basis of stamped and signed “Good for Construction” fabrication drawings. Fabrication shall also be

understood to include building up an element either by welding plates to a rolled section, a

combination of rolled sections, a combination of rolled sections with plates or a section built up entirely

with plates

The Contractor shall prior to starting any fabrication ensure that the fabrication yard is levelled and firm

enough to take weight of structures and equipment.

The Contractor free of cost shall replace any defective fabrication or material pointed out at any stage.

Tolerances for fabrication shall be as per IS:7215.



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8.7.2 Fabrication Procedure

i. Straightening

All materials shall be clean and straight. Cleaning shall be done either by shot blasting or by

mechanical cleaning as specified. If straightening or flattening is necessary, it shall be done by a

process approved by the Owner and in a manner that will not damage the material. Sharp kinks or

bends shall be a cause for rejection. The specified camber wherever necessary shall be provided.

. ii. Clearance

The erection clearance for members having end cleats or plates shall not be more than 2 mm at each

end, whereas for other types of end connections it shall not be more than 3 mm at each end. If for any

reason a greater end clearance is required, suitable settings, approved by Owner shall be provided.

iii. Cutting

The use of hand cutting torch is permissible only if the metal being cut is not subject to substantial stress during the operation. Gas cut edges subject to substantial tensile stress, shall be cut by mechanically controlled torch, or if hand cut, shall be carefully examined and any nicks removed by Grindings, Shearing, Cropping by gas cutting shall be clean, square and free from any distortion and should the inspector find it necessary, the edges shall be subsequently ground at no extra cost to the Owner to make them straight and uniform.

Cutting tolerances shall be as follows: For members connected at both ends: + 1 mm Elsewhere : +3mm iv. Holing

Holes for compound section passing through more than one thickness shall preferably be drilled after the members are assembled and tightly clamped or bolted together. In case the thickness of metal for each component is less than 16 mm, the holes may be punched prior to assembly provided the holes are punched 3 mm smaller in diameter than the required size and reamed after assembly to the required diameter. Dynamically loaded structures shall not be holed by punching. In case the material is not more than 12 mm thick and the connection is not a splice, the hole may be punched full size except in holes for close tolerance bolts or barrel bolts.

Holes may be drilled in one operation through two or more parts and the burrs removed from each part after drillings. Holes not drilled through all the thickness in one operation shall be drilled to a smaller size and reamed out after assembly. Holes for close tolerance bolts and barrel bolts shall be drilled through all the thickness in one operation and subsequently reamed to size after firmly holding the parts together with the aid of tacking bolts or clamps. Finished holes for high strength black bolts & high strength friction grip bolts shall not have a diameter more than 2 mm the diameter of the bolt



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passing through them or as specified in fabrication drawings. Holes for bolts shall not be formed, by gas cutting. v. Bending Bending of plates, flats & sections shall be carried out on bending rolls or in presses. Cold bending may be accepted when bending radius is equal to or more than 25 times member thickness for plates and flats. 25h or 25b for rolled steel beams and channels according to the bending plane. 45 b for angles

Where, h = section height b = flange width

When bending radius is less than that as indicated above, bending shall be done on hot metal by

heating the member upto 850C (light red radiance). Bending shall be discontinued when temperature

drops below 500C. Accuracy of bending operations shall be checked by means of templates and the clearance between member and template shall not be more than + 1 mm. Bent member shall not have cracks or deep indentations from bending equipment.

vi. Assembly

The component parts shall be aligned and assembled in such a fashion that they are not twisted or damaged in any way and have the prescribed camber. The clamps, jigs and other fixtures shall be placed so as to cause no imbalance, which would result in twisting/incorrect positioning of members. Due attention shall be paid to welding shrinkage and distortion.

vii. Bolting

All turned and fitted bolts shall be parallel throughout the barrel within the tolerance of 0.125 mm, unless otherwise specified and faces of heads and nuts bearing on steel work shall be machined.

All such bolts shall be provided with washers not less than 3 mm thick, so that when the nut is tightened, it shall not bear the unthreaded body of the bolt and the threaded portion of the bolt should not be within the thickness of the parts bolted together. The threaded portion of each bolt shall project through the nut by at least one thread. Square tapered washers shall be provided for all heads and nuts bearing on beveled surface. Flat washers shall be circular in shape. The bolts, nuts and washers, etc. shall be thoroughly cleaned and dipped in linseed oil. viii. Splicing In compound sections, splicing of components shall be staggered with respect to each other by a minimum of 500 mm. When the two parts of a component are not butt-welded to each other, the opposing ends at a joint shall be ground flush for bearing and suitable flange and web splice plates shall be designed to cater for the full strength of the flange/web of the sections. In case full strength butt weld is used to connect opposing ends at a joint, additional flange and web splice plates shall be provided capable of carrying 20% strength of the flange & web. ix. Shop Erection



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The steel work shall be temporarily erected in the shop to determine the accuracy of the fit. The extent of erection shall be either complete or as directed by Owner.

8.8 Inspection and Testing of Structures

Materials and workmanship at all times shall be subject to inspection by the Owner All inspection as far as possible shall be made at the place of fabrication and the Contractor shall co-operate with the Owner’s Inspector and permit access for inspection to all places where work is being done.; The Contractor shall supply free to the Owner all necessary gauges and templates necessary for inspection. However, such inspection shall not relieve the Contractor of his responsibility to furnish satisfactory work. Materials & workmanship, not conforming to provisions of the specifications, may be rejected at any time when defects are found during the progress of work. The Contractor shall obtain approval from the Owner of all fabricated items prior to commencement of their erection. However, any such approval shall not absolve the Contractor from his responsibility of correctness and workmanship of the entire work.

8.9 Shop Painting

The steel work shall be cleaned of all rust, scale and grease prior to the application of the primer. All structural steel sections shall be cleaned by shot blasting/ hand power tools as specified in the corresponding item. Shot blasting will not be permitted at site. It has to be done at outside premises set up by the Contractor for fabrication. Application of primer shall not be done near edges which are to be welded thereafter. Similarly, welds which are yet to be approved by Owner, shall not receive the primer coat. Parts, which are to be encased in concrete shall not be painted. Machine finished surfaces shall be protected against corrosion by a rust inhibiting coating that can be removed prior to erection.

8.10 Packing and Transportation

Loading and transportation shall be done in accordance with transport rules prevailing at that location. Items shall be packed to protect them from damage/distortion. Small parts shall be securely wired to their main members, Loose items such as bolts, nuts and washers shall be packed in crates.

8.11 Field Erection

1) The Contractor shall submit to the Owner the planned mobilization of plant and equipment for approval.

2) Prior to setting out of the steelwork the Contractor shall satisfy himself regarding the accuracy of the main axes of the structure and the correctness of the levels, alignment and location of concrete pedestals, columns, pockets and holding down bolts. In case there are any deviations regarding positions of foundations or anchor bolts which would lead to erection deviations, the Owner shall be intimated. Minor rectification such as chipping, cutting and making good, adjusting the anchor bolts, etc. shall be carried out by the Contractor at his own expense.



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3) The location and leveling accuracy, including plumbing of columns and placing of every part of the structure accurately shall be done in accordance with the drawings and to the satisfaction of the Owner.

4) Tolerances for erection of steel work shall be in accordance with the given specification & IS: 7215 whichever is more stringent.

8.12 Safety and Security

The Contractor shall take necessary safety measures to comply with IS: 7205 and shall ensure that hazardous or unsafe working conditions do not exist during any stage of erection. During erection the Contractor shall ensure that all loads due to wind, erection equipment etc, is catered for either by introducing temporary bracings or guy wires. The guy wires shall not be anchored from other adjoining permanent structures. Contractor shall provide proper access, platforms and safety arrangements at no extra cost. Permanent bolting and welding shall be done only after ensuring proper alignment.

8.13 Field Connections

1 Field Bolting This shall be carried out with the same care as shop bolting.

2 Field Welding Field welding after field assembly shall follow the same requirements as laid down for shop assembly and shop welding.

8.14 Grouting

Prior to erecting the steel work over concrete pedestals, columns or brackets, the top of concrete shall be cleared with wire brushes, chipping and compressed air to remove all laitance and loose material and made thoroughly wet. The structural member shall then be erected, aligned and plumbed with the base plates and shoe plates maintained at specified levels using shims/pack plates or wedges. After the structure is erected, formwork shall be done all around and the joints sealed to be watertight. The grout under the base plates, including in pockets and sleeves shall be grout as specified in drawings. Non-shrink grout shall be of premix type and shall be prepared as per manufacturers instructions. Non-shrink grout shall be of quality and type approved by Owner The grout shall be poured in by grout pumps continuously from one side till the intervening space is filled completely and the grout is carried to the far side of base plate. The grout shall be spread with flexible steel strips and rammed with rods to ensure the gap is filled completely. After the grout has sufficiently hardened the shims/pack plates/wedges, which are accessible, may be removed and anchor bolts tightened. The alignment of the structure shall be rechecked and the voids left by removal of the shims/pack plates/wedges shall be filled with a similar mix of grout. In case the structure is not properly aligned, the grout shall be removed, the structure realigned and grouting operation repeated.

8.15 Painting after Erection



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General Painting work after erection shall be carried out with the best quality of approved material. Workmanship in line with good engineering practice shall be ensured. As far as possible the application instructions of paint manufacturers shall be followed. Painting shall not be done during foggy or frosty weather or if humidity is high causing condensation on the surface to be painted. Paints shall be stored in such a manner so as to avoid extremes of temperature. Primers and finish coats shall be from the same manufacturer so as to ensure compatibility. Shop coated surfaces shall be cleared of all dirt, dust, grease, rust etc.using emery/abrasive paper or warm fresh water and air-dried. Areas where the shop primer has got damaged shall be touched up

After the primer is hard and dry, the surfaces shall be dusted off and two coats of chemical resistant enamel paint/ approved finish paint as specified in the relevant item (of approved shade and colour ) shall be applied by brushing or spraying. The first coat shade shall be slightly lighter than that of second coat to aid identification. The second coat of paint shall be applied after the first coat is hard and dry. The final painting scheme shall be adopted after approval from Owner

8.16 Inspection and Testing of Paint

Paint shall be procured from reputed manufacturers approved by the Owner. Owner at his discretion may require additional tests to satisfy himself regarding the quality of paint including batch wise test of wet paints for physical and chemical analysis. The cost of all such testing shall be borne by the Contractor. The various stage wise inspections shall be at the following stages; surface preparation primer application wherever applicable Each coat of paint.

8.17 Erection Tolerances

Tolerance allowed in the Erection of Structural Steel Buildings frames shall be as per code: Component Description Variation allowed Main columns

a) Shifting of column and Roof Posts axes at foundation level wrt to true axes -in longitudinal direction - in lateral direction

+ 5 mm + 5 mm

b) Out of plumpness of column axis from true vertical as measured at the top - For a column upto & including 30m ht. - For a column greater than 30 m height

+25mm or +H/1000 (whichever is less) +35 mm or +H/1200 (whichever is less)



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c) Deviation in straightness in longitudinal and transverse planes of column at any point along the height

+10mm or + H/1000 (whichever is less)

d) For any individual column deviation of any bearing of resting level from level shown on the drawings

+5 mm

e) Difference in the erected position of adjacent pairs of columns across the width of the building prior to placing of truss/beams wrt. true distance

+ 5 mm

f) For adjacent pairs of columns either across the width of building or longitudinally, level difference allowed between bearing or seating level supposed to be at the same level.

+ 5 mm

8.18 WELDING i. General

Welding of steel shall be in accordance with IS: 9595 as applicable. Welds shall be made only by operators who have been previously qualified by tests by the Owner. A welder shall produce satisfactory evidence of his ability to do a given type of work and shall prove his ability to produce a connection of the strength required. Evidence of welder’s qualification tests shall be produced if required by the Owner. Owner may reject any welder found not suitable during actual work. Welding wire and electrodes shall be sorted separately by quantities and lots inside a dry and enclosed room, and as per instruction given by the Owner. Electrodes shall be perfectly dry and drawn from an electrode oven, if required.

ii. Preparation of Members for Welding

Edge preparation of fusion faces for welding shall be carried out as per details given in IS:9595 or as shown on drawings. All tolerances for such work shall be as per IS:9595. Surfaces to be welded shall be cleared to ensure that they are free from loose scales, slag, rust, grease, paint and other foreign matter, and shall be maintained. Preheating of members shall be necessary when the base metal temperature (based on ambient temperature) is less than the temperature required for that welding procedure. The preheating shall be done in such a manner that the part on which weld metal is to be deposited is above the specified temperature for distance of 75 mm on either side of the weld line. The temperature shall be measured on the face opposite to the face being heated. In case access is limited to only the face being heated, the source of heat shall be removed and sufficient time allowed to elapse for heat equalization prior to measurement. (1 minute per 25 mm of plate thickness). Column splices and butt joints of compression members shall be accurately ground and close butted over the entire section to ensure full contact for load transmission. The tolerance for such work shall be maximum 0.2 mm. In the case of column bases and caps the ends of the section along with connected gussets, stiffeners, angles, channels, etc. shall be ground so as



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to ensure a minimum contact area of 90%. The fitting of angles and channels should be sufficiently accurate to limit the reduction in thickness on account of grinding to 2 mm. The ends of bearing stiffeners shall be ground so as to fit tightly at both top and bottom. Slab bases and cap plates shall be accurately ground over bearing surfaces to ensure minimum 90% contact area with columns.

iii Welding Process Any one or more of the following welding processes may be used: Manual Metal Arc Welding Process Submerged Arc Welding Process Gas Metal Arc Welding Process Flux cored Arc Welding Process

The Contractor shall submit the welding procedure and the consumables proposed to be used to the Owner for approval. Combination of processes or electrodes may be permitted only with the specific approval of the Owner.

iv. Sequence of Welding

a) The direction of welding shall be from points relatively fixed with respect to each other towards points having more flexibility.

b) Welding shall be carried out continuously to completion with the required number of runs.

c) For compound section splices, each component part shall be spliced prior to welding with other component parts.

d) Weld shall progress in a sequence that will balance the applied heat so as to reduce distortion.

e) Joints having more shrinkage shall be welded prior to joins having less shrinkage. f) The sequence causing minimum distortion or shrinkage shall be chosen.

v. Welding Technique

The fusion faces shall be properly aligned and the gap set to the distance specified. The root pass of butt joint shall be done such that full penetration is achieved as also complete fusion of root edges. On completing each run the weld and the parent metal shall be cleared by wire brushing and light chipping to remove all slap and splatters. Visible defects, if any such as cracks, cavities etc. shall be removed to sound metal prior to depositing subsequent run of weld. All full penetration butt weld shall be completed by grouping/chipping the back of the joint and depositing a seal run of weld metal. Alternatively a backing strip shall be provided. All care shall be taken to prevent any kind of movement, shock or vibration of components during welding to prevent weld cracks.

vi. Inspection and Testing of Welds



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All testing shall be as per IS 822 and the extent of inspection and testing shall be in conformity with the relevant standard or as directed by Owner. The Contractor shall extend to Owner all facility required to inspect all stages of fabrication and erection including welding procedure qualification and welders / procedures qualification. No painting of weld shall be undertaken prior to inspection and approval.

vii. Visual Inspection 100% welds shall be visually inspected to ascertain absence of the following defects. a) Surface cracks in weld or parent metal, or undercut, burning, overheating of parent metal. b) Blow holes, exposed porosity in the weld or unused welds. c) Defects in the profile such as excessive convexity or concavity, unequal leg lengths

incompletely filled grooves, excessive penetration beds, root grooves, etc. d) Distortion due to welding and misalignment.

viii. Repair of Welds Welds not meeting the requirements of the specification and IS codes shall be removed and replaced. Repairs to defective welds shall be carried out only after the repair procedure submitted is approved by the Owner.

9.0 BRICK WORK: The specification covers the materials, laying, jointing, curing, testing, etc of brick masonry work.

9.1 Material

9.1.1 Bricks

All bricks shall conform to IS: 1077 and shall be of class 5 (average compressive strength not less

than 5N/mm2) unless otherwise specified. The sampling and testing of bricks shall be done in

accordance with the procedure laid down in IS: 5454 and IS: 3495 respectively.

9.1.2 Cement Mortar

Cement and water shall conform to the requirements laid down for cement concrete work.

Sand for masonry mortars shall be coarse sand generally conforming to IS: 2116 maximum quantities

of clay, fine dust shall not be more than 5% by weight. Organic impurities shall not exceed the limits

laid down in IS: 2116.

Mix of mortar for building brickwork shall be as specified.

Mixing of mortar shall be done in a mechanical mixer. When quantity involved is small, hand mixing may be permitted by the Engineer-in-Charge. Any mortar remaining unused for more than 30 minutes after mixing shall be rejected.



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9.3 Construction

9.3.1 Soaking bricks

Bricks shall be thoroughly soaked in clean water before use for at least six hours and until air bubbles

cease to come out. The soaked bricks shall be kept on wooden planks or brick platforms to avoid

being contaminated with earth.

9.3.2 Laying

Brick work (one or more brick work thickness) shall be laid in English bond, unless other wise

specified. Half or cut bricks shall not be used except when needed to complete the bond. The walls

shall be taken up truly plumb. If battered, the batter shall be truly maintained. All courses shall be laid

truly horizontal and all vertical joints shall be truly vertical. The level and verticality of the brick work in

walls shall be checked frequently.

At the junction of any two walls, the brick shall, at each alternate course, be carried into each of the

respective walls so as to thoroughly unite the work. Brick work shall not be raised more than 14

courses per day.

All iron fixtures, pipe spouts holdfasts of doors and windows, which are required to be built into the

wall shall be embedded in cement concrete blocks 1:2:4 mix (1 cement : 2 coarse sand : 4 graded

stone aggregate, 20 mm nominal size) 150 mm x 100 mm x 100 size unless otherwise indicated in

their correct position as the work proceeds.

9.3.3 Jointing

Joints shall be restricted to 10mm in brick work. The vertical joints in alternate courses shall come

directly one over the other and shall be truly vertical. The joints in faces which are to be plastered or

pointed shall be squarely raked out to a depth of 12mm while the mortar is still green. The raked joints

shall be well brushed to remove loose particles. After the work, the faces of the brick work shall be

cleaned with wire brush and all mortar droppings removed.

9.4 Half Brick Masonry:

The work shall be done exactly as brick work of one or more brick thickness except that all courses

shall be laid with stretchers. Reinforcement comprising 2 nos. 6 mm dia. MS bars shall be provided

over the top of the first course and thereafter at every third course.

9.5 Curing:

Brickwork shall be protected from rain by suitable covering when the mortar is green. Masonry work

shall be kept thoroughly well watered on the all faces for at least ten days after completion.

.



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10.0 CEMENT PLASTERING FOR WALLS AND CEILINGS

10.1 Scope of work:

The work covered under these specification consists of supplying all material for

rendering all types of plaster / pointing finishes strictly in accordance with these

specifications, applicable drawings etc.

10.2 General

For plastering works cement mortar 1:4, 15 mm thick shall be used for rough faces and

12 mm thick for fair faces of brick masonry. For RCC surfaces CM 1:3, 6 mm thick

plastering shall be applied. Cement, sand and water required for the work shall conform

to specifications laid down herein before under section cement concrete (plain and

reinforced), except that sand for plastering shall generally conform to IS 1542. The

plastering works shall generally conform to IS 1661 (Pt.III) Code of practice for cement

plaster finish on walls and ceilings). All general precautions as specified in I.S. 1661-

(pt.III) clause 8, shall be taken.

10.3 Cement Mortar Application :

The surface to be plastered shall first be thoroughly cleaned of all muck and cleaned

down. All joints shall be racked to in case of brick work / stone masonry and closely

hacked in case of concrete as the work proceeds. The surface to be plastered shall be well

wetted for a minimum period of 6 hours before commencing to work.. After erection of

scaffolding and before commencement of plastering work, top most junctions / joints /

sides with beam / column shall be thoroughly packed with PMM to prevent cracks.

Before commencement of plastering operation, the contractor shall ensure that all the

service pipes, electrical conduits, boxes, switch boxes etc. have been installed in position

by other agencies and the plastering surface is duly approved by the Engineer-in-charge.

All the cuttings of chases for plumbing/electrical/or for any other works shall be neatly

re-plastered with PMM after providng fiber mesh of sufficient width for proper bonding

at no extra cost.



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In order to enable other service contractors to fix the electrical conduit boxes, EDB's,

pipes, outlets etc. in proper level and line with reference to the finished surface of the

plaster, the entire work of preparation of surface before plastering shall be coordinated by

the main civil contractor with all other agencies working at site. Just before actual

plastering work is taken up in hand, all the ceilings and walls etc. shall be marked with

plaster buttons indicating the thickness of plaster required and which shall be in true line,

level and plumb.

The contractor shall get these marks approved by the Engineer-in- charge before starting

the plastering work. The contractor shall also be responsible to render the final surface

true to line, level and plumb etc.

All building operations like construction of walls, concreting etc. shall have been

completed before plastering is taken up. The plastering operation should be taken up only

after the service pipes etc. that are to be embedded in the wall or ceiling are completed

and suitably protected against corrosion by other agencies and cleared by the Engineer-

in-charge. Damage if caused to any of the existing fittings, fixtures, including doors and

windows etc. during the plastering operation shall be made good by the contractor at his

own cost. If the surface which is to be plastered either internally or externally is out of

plumb and not in line and level and if the plastering to be done is more than specified

thickness to bring the plastered surface to perfect line and levels in such specific cases,

chicken wire mesh is to be provided by the contractor at his own cost and the plaster

should be done to required line and level with no extra cost whatsoever.

The finished plastered surface shall be free from cracks, fissures, crevices, hair cracks,

blistering, local swellings and flaking. The finished surface shall be true to line, level,

plumb and plane and durable. The adhesion of the mortar with the background surface is



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of prime importance as this affects durability of plaster. Preparation of surface which has

to take plastering work should be got approved by the Engineer-in-charge.

In order to avoid the formation of deep and side cracks and dispersion for cracks at the

junctions between concrete surfaces and brick masonry works, precautionary measures

such as fastening and lapping of chicken mesh over the junction areas should be carried

out over which the plastering work has to be taken up as required by the Engineer-in-

charge. The minute gap between window / door frames with sills and jambs should be

filled up / caulked by plaster of Paris / epoxy putty / silicon sealants, Rubber based

sealants by approved methods as instructed / approved by Engineer-in-charge.

10.4 Grooves :

The grooves if shown in drawings shall be of required dimensions. The same shall be

made to turn wherever necessary. The finish, inside, shall be of the same finish as that of

the plaster. The lines of the grooves shall be well defined and rounded. The grooves that

are to be provided in plastering in internal and external surfaces shall be included in the

rates wherever mentioned in the schedule of quantities.

10.5 Mix Proportion :

The mortar for plastering shall be of proportion as specified in the item schedule. The

mixes specified in the schedule are volumetric.

10.6 Mixing :

Cement and fine aggregates shall be mixed dry in the required proportions to obtain a

uniform colour. Water shall then be added to get the required consistency for the plaster.

Mixing shall be done mechanically. However, manual mixing will be allowed only in

exceptional circumstances at the discretion of the Engineer-in-charge. Manual mixing, where

adopted, shall be carried out on a clean water tight platform. After water is added during

mixing, the mix shall be held back and forth for 10 to 15 minutes.



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In machine mixing, Cement and sand in the specified proportions shall be mixed dry

thoroughly in a mixer. Water shall then be added gradually and wet mixing continued for at

least three minutes. Only so much quantity of mortar which can be used within half an hour

after the addition of water shall be prepared at a time. Any mortar for plaster which is set or

partially set shall be rejected and shall be removed forthwith from the site.

10.7 12mm Plaster :

The plaster shall be laid with somewhat more than 12mm, thickness and pressed and leveled

with wooden ruler to a finished thickens of 12mm. Straight edges shall be freely used to

ensure a perfectly even surface. All exposed angles and junctions of walls, doors, windows,

beams, slabs etc. shall be carefully finished so as to furnish a neat and even surface.

10.8 6mm Plaster:

The proportions of sand and cement shall be as specified and shall cover all irregularities,

undulations, depressions due to chasing etc. in the surface o be plastered. The mortar shall be

applied slightly more than 6mm thick and pressed and leveled with wooden ruler or straight

edge to finished thickness of 6 mm.

Straight edges shall be freely used to ensure a perfectly even surface. The finished surface

shall be true and even and present uniform texture throughout and all joining marks shall be

eliminated. All corners, edges and angles shall be made perfectly to line, place and plumb.

All exposed angles and junction of walls, doors, windows, beams, slabs etc. shall be carefully

finished so as to furnish a neat and even surface. Plastering items amongst all other things as

described in various items also include:

1) Preparation of surface to receive the plaster, providing cement plaster of he specified

average thickness and proportions with specified number of coats.

2) All labour, materials, scaffolding, use of tools and equipment to complete the

plastering work as per specifications.

3) Curing for 10 days.



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4) Cleaning the surface of doors, windows, floors or any other surfaces where plastering

might have splashed.

Neat plastering around DBs, junction boxes, M.S. boxes etc. should be done and made

matching with the wall finish after installation of electrical equipments. All BD's service

boxes, covers etc. should be covered by a plastic cloth or other suitable covering material

such that water or materials should not splash the same during brick work and plastering

work. This is to be done in such a way that electrical equipments as well as painted surfaces

are not spoiled. For fixing M.S. boxes, DBs etc. marking should be given such that the

required face of the M.S. box, DB covers etc. in line with final finished plastered surface.

The item shall also include rounding up of corner and angles, making sharp corners and

angles, finishing around ceiling rose and electrical fittings etc. fixed by other agencies,

finishing of top of dado and skirting, junctions of roof and wall or beam with the finish as

specified in the item. Plastering of brick and concrete cornice and copings and plastering in

restricted areas if any shall not be measured separately. Architectural bands and narrow

widths of plaster over surfaces in specified line when prepared in the same thickness of

plaster shall not be measured separately and shall be covered by respective plaster items.

11.0 ALUMINIUM DOORS, WINDOWS AND VENTILATORS

Scope of work :

The scope of work in the tender item includes fabrication, supply and installation of polyester

powder coated matt finished aluminium windows, ventilators, composite units, glazing etc.

strictly in accordance with these specifications and relevant detailed approved shop drawings

for pump/ MCC room.

11.1. General :

The aluminium extruded sections shall conform to IS 733 and IS 1285 for chemical

composition and mechanical properties. The stainless steel screws shall be of grade AISI 304.



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The permissible dimensional tolerances of the extruded sections shall be as per IS 6477 and

shall be such as not to impair the proper and smooth functioning/operation and appearance of

door and windows. Aluminium glazed doors, windows etc. shall be of sizes, sections and

details as shown in the drawings.

11.2. The thickness of the finished polyester powder coating measured by micron meter shall not

be less than 50 micron nor more than 120 micron at any point. It is mandatory that all

aluminium members shall be wrapped with self adhesive non-staining PVC tape, approved by

Engineer-in-Charge.

11.3 The door frames in shutter shall be single action or double action as indicated in drawing with

spring closer in floor.

11.4 . Fixing of Frames

The holes in concrete/masonry/wood/any other members for fixing anchor

bolts/fasteners/screws shall be drilled with an appropriate electric drill.

Windows/doors/ventilators etc. shall be placed in correct final position in the opening and

fixed to teak wood backing using stainless steel screws of star headed, counter sunk and

matching size groove of required size at spacing not more than 250 mm c/c or dash fastener.

11.5 All glazing work shall conform to IS: 1083 and IS: 2835.All glazing clips, bolts, nuts, putty,

mastic, cement etc., as required shall be supplied and thoroughly cleaned before putting in

position. Each glass panel shall be held in place by special glazing clips. After completing the

glazing work, all dirt, stains, excess putty etc., shall be removed and cleaned. All broken,

cracked or damaged glass shall be replaced by new glass

11.6 Neoprene gaskets with snap fit glazing beads shall be fixed as per manufacturer’s instruction

to give leakproof installation

11.7. Hardware :

All cut outs, recesses, mortising or milling and operation required for fixing the hardware

shall be accurately made reinforced with packing plate as required to ensure adequate

strength of the connection. All the hardware, accessories shall be of best approved type and of



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powder coated finish same as for the frame and other sections. All hardware shall be free

from defects which may affect the appearance and serviceability. All hardware shall be fixed

after obtaining the prior approval of the Engineer-in-charge. Approved samples of hardware

shall be kept in the custody of Engineer-in-charge.

11.8. Glazing :

The glazing shall be of Indian make plain sheet / frosted / glass of special selected quality and

size as mentioned in item description and glass shall be of M/s Triveni / Saint Gobain /

I.A.G./ Modi make .

11.9 Fixing of Shutters

Door shutter shall be side hung on three bolt hinges of size 100 mm, one at the centre and the

other two at 200 mm from the top and bottom of the shutter. The flat of the hinges shall be

neatly counter sunk in to the recesses cut out to the exact dimensions of the hinge flap. The

door shall be drilled on the thickness to fit hinges. Screws for fixing the hinges shall be

screwed in with screwdrivers and not hammered. The length of the screws should be 8

mm/30 mm. The hinges used should be of stainless steel.

11.10 Tolerance

The tolerance on the width and the height of the door shall be + 5 mm and the tolerance on

the nominal thickness of the door shall be + 2 mm

11.11 Fittings

Fittings shall be provided as per schedule of fittings specified in item description in Schedule

of Items of Work. Hardware such as handles, tower bolt, stopper, buffer etc. should be

directly screwed (not pre-drilled) and fitted on the door.

12.0 WATERPROOFING 12.1 Waterproofing over RCC Terrace

12.1.1 Products

All components of the specified waterproofing system shall be products of CERA-CHEM or

equivalent approved products



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12.1.2 Product delivery, storage and handling a. Deliver materials to the job site in the manufacturer's original, unopened containers or

wrappings with the manufacturer's name, brand name and installation instructions intact

and legible. Deliver in sufficient quantity to permit work to continue without interruption.

b. Comply with the manufacturer's written instructions for proper material storage.

1. Store Diamond Shield, CERA POLYMER LATEX in the original undisturbed

plastic wrap in a cool, shaded area and cover with light-colored, breathable, waterproof

tarpaulins.

2. Store curable materials (adhesives and sealants) between 60°F and 80°F in dry areas

protected from water and direct sunlight. If exposed to lower temperature, restore to

60°F minimum temperature before using.

3. Store materials containing solvents in dry, well ventilated spaces with proper fire and

safety precautions. Keep lids on tight. Use before expiration of their shelf life.

4. Any materials which are found to be damaged shall be removed and replaced at the

applicator's expense

12.3 Surface Preparation

All surfaces which are to receive the coating must be free from oil, laitance, grease, wax, dirt

or any other form of foreign matter which might affect adhesion. Typically concrete surfaces

can be cleaned using high pressure water jet or grit blasting or by proper wire brushing.

12.4 Application

The sub-base of the roof top structure should be cleaned of all dirt, loose material and kept

dry. In case of pot holes/cracks, the same shall be repaired with cement putty using some

bonding agent. Over the prepared roof slab apply Diamond Shield, CERA POLYMER

LATEX or equivalent approved water proofing compound - one coat and subsequently apply

two part ready to mix modified mortar reinforced with LDPE flexible net as per

manufacturer's specification and instruction of Engineer-in-Charge. Final coat consists of

application of water based co-polymer compound containing inert pigment and special fillers



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CERA FLEX or equivalent approved compounds as per manufacturer's specification and

instruction of Engineer-in-Charge including cost of all materials, labour etc.

12.5 At Parapet wall

The work consist of preparation of surface and application of water based co-polymer

compound containing inert pigment and special fillers like CERA FLEX or equivalent

approved compounds coating as per manufacturer's specification and instruction of Engineer-

in-Charge including cost of all materials, labour etc. on parapet walls and adjoining wall of

slab .

The waterproofing work shall be done by authorized applicators as specified by the

manufacturer.

13.0 RIGID PVC PRESSURE PIPES AND FITTINGS

The PVC pressure pipes and fittings shall be used for conveying wastewater. The pipes shall

be of pressure rating of 10 Kg/cm2. PVC pipes and fittings shall be jointed with solvent

cement. Fittings shall be of injection moulded PVC conforming to IS 7634 (Part1).

13.1 LAYING AND FIXING

The pipe laying and jointing shall be done in accordance with IS 7634 (Part 3). Pipes shall be

cut to size and chamfered well. Burrs if any, shall be removed. Pipes and fittings shall be

jointed using solvent cement or rubber ring joints. The pipes and fittings shall be jointed

accurately without any stress to achieve leak proof joints. The cost of drilling holes in RCC

slab, floor, RCC/masonry retaining wall with the core cutting machine and making good the

same with approved quality cement concrete etc., to the satisfaction of the Engineer shall be

included in the quoted rate. Separate rate for core cutting shall not be paid to the contractor.

13.2 TESTING

The method, which is commonly in use, is filling the pipe with water, taking care to evacuate

any entrapped air and slowly raising the system to the test pressure. The test shall be done in

accordance with IS 2065 - code of practice for water supply in buildings. The test pressure

shall be 5 kg/cm2 or the maximum working pressure plus 50%, whichever is greater. The



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pressure shall be maintained for at least 4 hours. The Engineer shall examine carefully all the

joints for leakage. The cost of equipments and accessories required for testing the system

shall be supplied by the contractor at his own cost.

13.3 MANHOLE AND INSPECTION CHAMBERS

Inspection chambers of Internal size 600mm x 600mm up to a depth of 0.9 m and manholes

of varying sizes as per IS 4111 shall be constructed beyond 1.2m (depth of the sewer line

from the Formation Ground level).

LOCATION AND SIZES

The size indicated in the drawings shall be the internal size of chamber. The inspection

chambers are provided at all changes of direction of drains and where branch drain meets the

main drain. Chambers shall be of such size as to allow necessary examination and clearance

of drains. The minimum internal sizes shall be taken as per detailed drawings. The

requirements stipulated in IS 4111 (Part I) Code of Practice for Ancillary Structures on

Sewerage System shall be followed. The work shall be done strictly as per standard drawings

and the specifications: Depth of manhole shall be the clear vertical depth between the

manhole cover to the outgoing invert of the main drain channel.

MANHOLE COVERS

The manhole covers shall be of heavy duty type (ductile iron) with lifting hooks. The shape

of the cover shall be as per the drawings.

14.0 FRP GRATINGS

FRP Gratings are of one - piece monolithic construction without joints or sealing. The

construction is such wherein, the glass fibres are continuous through out the length, breadth,

height & cross section of the gratings. The gratings should be made of Isopthalic polyester

resin having colour and properties as detailed in the schedule of rates/ drawings.

14.1 Characteristics of Fibre Glass Gratings



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a Slip resistant

FRP Grating shall have excellent slip resistant properties and shall be comfortable to stand

thus reducing fatigue.

b Impact resistant

Fibre glass grating shall be flexible and be repeatedly deflected without causing permanent

deformation. Once the load is removed, it should return to its original shape, unlike metallic

grating, which will remain deformed and require replacement.

c Fire resistant

When tested in accordance with ASTM E-84 tunnel test, it should achieve a Class 1 flame

spread rating of 25 or less.

d Corrosion resistant

The grating should be resistant to chemicals and should be perfectly suited for use even in

the harshest of environments.

e Light weight

Fibre glass gratings shall be very easy to install due to light weight. No heavy lifting

equipments are required for installing the gratings.

f Non- magnetic

The gratings can be used in sensitive installations being non- magnetic.

g Non- sparking

Grating shall be suited for area where a fire is likely to occur from sparks produced from

electrical installation.



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14.2 Fixing of Gratings

The gratings shall be fixed to the structural steel frame work already provided by using

Stainless steel (SS 316) holding down clamps. There are three kinds of clamps- one for

securing the grating to the support frames, second for preventing the grating from turning in

all the four directions and the third one for connecting two adjacent grating bars. The fixing

shall be carried out as detailed in the schedule of rates/ drawings.

15.0 DOCUMENTATION FOR GRIHA

Contractor shall furnish certificates from the manufacturer to prove that products used for all

the items including waterproofing are green products as required by GRIHA and shall also

submit the Purchase orders/bills for materials brought to site.

16.0 RELEVANT STANDARDS AND CODES OF PRACTICE

AGGREGATES, CEMENT, CONCRETE & MASONRY

1. IS:456 - Code of practice for plain and reinforced concrete.

2. IS:4925 - Specification for concrete batching and mixing plant.

3. IS:4926 - Code of practice for ready mixed concrete.

4. IS:1199 - Method of sampling and analysis of concrete.

5. IS:9013 - Method of making, curing and determining compressive strength of

accelerated cured concrete test specimens

6. IS:383 - Specification for coarse and fine aggregate from natural source for concrete.

7. IS:6461 - Glossary of terms relating to cement concrete ( Part 1 to 12 )

8. IS:5891 - Specification for Hand operated concrete Mixers.

9. IS:1200 - Method of measurement of building and civil engineering works (Part 1to26).

10. IS:2722 - Specification for portable swing weigh Batchers for concrete.

11. IS:650 - Specification of standard sand for testing of cement.

12. IS:7320 - Specification for concrete slump test apparatus.



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13. IS:1489 - Specification for Portland Pozzolana cement.

14.IS:12269- Specification for 53 grade ordinary Portland cement.

15. IS:1791 - Specification for batch type concrete mixers.

16. IS:5892 - Specification for concrete transit mixers and Agitators.

17. IS:3025 - Methods of sampling and test(physical and chemical) for water and wastewater

18. IS:9103 - Specification for admixtures for concrete.

19. IS:4082 - Recommendations on stacking and storage of construction materials at site.

20. IS:1077 - Specification for common burnt clay building bricks.

21. IS:2212 - Code of practice for brickwork

22. IS. 10262 - Recommended Guidelines for Concrete Mix Design

IRON AND STEEL

1. IS:2502 - Code of practice for bending and fixing of bars for concrete reinforcement.

2. IS:2751 - Recommended practice for welding of mild steel plain and deformed bars for

reinforced construction.

3. IS:1786 - Specification for High strength deformed steel bars and wires for concrete

reinforcement.

4. IS:432 - Specification for mild steel and medium tensile steel bars and hard drawn steel

wire for concrete reinforcement.

5. IS:5525 - Recommendations for Detailing of Reinforcement in Reinforced Concrete

works.

6. IS:4455 - Steel wires for mechanical springs

7. IS:9954 - Pictorial surface preparation standards for painting of steel surfaces

8. IS:277 - Galvanized steel sheets

9. IS 2062 - Specification for Hot rolled medium and high tensile structural steel



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TESTING OF MATERIALS

1. IS. 9399 - Specification for Apparatus for Flexural Testing of Concrete

2. IS 9376 - Specification for Apparatus for Measuring Aggregate Crushing Value and

Ten Percent Fines Value

3. IS 9377 - Specification for Apparatus for Aggregate Impact Value

4. IS 9284 - Method of Test for Abrasion Resistance of Concrete

5. IS2386 - Methods of test for aggregates for concrete ( Part 1 to 8 )

6. IS:516 - Method of test for strength of concrete.

7. IS. 1331 - Non-Destructive Testing of Concrete-Methods of Test: Part 2 Rebound

Hammer Test

SAFETY

1. IS: 7205 - Safety Code for Erection of Structural Steelwork

2. IS:11057 - Specification for industrial safety nets

3. IS 4130 - Demolition of Buildings – Code of Safety

DOORS AND WINDOWS

1. IS 1948 - Specification for Aluminium Doors and windows

2. IS:733 - Wrought Aluminium and Aluminium alloy bars, rods and sections

3. IS:1286 - Wrought Aluminium and Aluminium alloys – extruded round tube and hollow

sections.

PIPES AND CONDUITS

1. IS:13592 - UPVC pipes for solid and waste discharge systems.

2. IS:5382 - Rubber sealing rings for gas mains, water mains and sewers

3. IS:4985 - UPVC pipes for potable water supplies.

4. IS:1239 - Steel tubes, tubular and other wrought steel fittings.

CONSTRUCTION OF BORED CAST INSITU PILE FOUNDATIONS FOR STP AT BPCL TOWNSHIP, ERNAKULAM

Page 1 of 20

CONSTRUCTION OF BORED CAST IN SITU REGULAR PILE FOUNDATIONS

FOR THE SEWAGE TREATMENT PLANT FOR BPCL TOWNSHIP AT

ERNAKULAM

TECHNICAL SPECIFICATIONS


Page 2 of 20

CONTENTS

1. Introduction

2. Scope

3. Materials

4. Installation

5. General Requirements for Piling

6. Relevant Standards and Codes of Practice


Page 3 of 20

TECHNICAL SPECIFICATIONS FOR BORED CAST INSITU REINFORCED CONCRETE

PILING WORKS

1.0 INTRODUCTION

This document defines the scope of works for RCC bored cast-in-situ regular piles and its

specific requirements for the proposed Sewage Treatment Plant for BPCL Township at

Ernakulam.

2.0 SCOPE

2.1 General

Contractor’s scope include construction of bored cast in situ piles of the specified type as per the

approved design and construction drawings and detailed specifications including supply of all

materials and labour for the work.

The scope of workfor pile foundations for the proposed STP consists of constructing regular

bored cast insitu RCC pile foundations of diameter 600 mm terminated at a depth of 35 m below

the cut off level. The safe load capacity of 600 mm diameter pile terminated at 35 m below cut off

level is taken as 1000 kN and accordingly the Contractor shall arrive the number and spacing of

the piles as per the design and shall get approval from the Consultant before proceeding with

the actual execution.

The work involves but not limited to the following:

(i) Construction of bored cast insitu pile foundation of diameter 600 mm, with depth of

termination at 35 m below cut off level.

(ii) Clearing the muck from the site after completion of piling works.

(iii) Chipping of concrete in the pile up to the cut off level and clearing the debris.

(iv) Exposing the reinforcement of the pile for anchoring in to the pile cap.

2.2 Surveying and Staking

It is the responsibility of the contractor to bring to site all surveying instruments necessary for the

marking out, fixation of levels, etc. and conduct the survey operations with utmost accuracy.


Page 4 of 20

Contractor shall put-up stable bench marks. as necessary for the work. Client / Consultant will be

present when this work is being carried out and will inspect all these operations with the

Contractor’s assistance. The contractor shall be entirely responsible for accurate setting out of

the work and he shall at his own expense make good any defects arising from errors in line and

levels.

2.3. Dewatering

Dewatering of accumulated water in all locations on job site from whatever source or cause until

the virtual completion of the entire work shall be done by the contractor at his own expense and

shall not be paid separately. The rates quoted by the contractor shall be deemed to be inclusive

of the same.

3.0 MATERIALS

All materials which may be used in the piling work shall be of standard quality conforming to IS

or equivalent unless otherwise approved by the Engineer-in-Charge. The contractor shall get all

materials approved by Engineer-in-Charge prior to its procurement and before the actual use.

The Engineer-in-Charge shall have the right to determine whether all or any of the materials

offered or delivered for use in the works are acceptable. Any material brought to site and not

conforming to specification and instruction of Engineer-in-charge shall be rejected and the

contractor shall have to remove the same immediately from site at his own expense.

3.1 Drilling Fluid

Bentonite, as supplied to the site and prior to mixing, shall be in accordance with Annex - D of

IS:2911 (Part-1/ Section2) for regular piles. A certificate shall be obtained by the Contractor from

the manufacturer of the bentonite powder, showing the properties of each consignment delivered

to site. This certificate shall be made available to the Engineer-in-charge on request. Bentonite

shall be mixed thoroughly with clean fresh water to make a suspension which will maintain the

stability of the pile bore hole for the period necessary to place concrete and complete

construction. Where saline or chemically contaminated ground water occurs, special precautions

shall be taken to modify the bentonite suspension so as to render it suitable in all respects for

the construction of piles, without any extra cost.


Page 5 of 20

The frequency of testing drilling fluid and the method and procedure of sampling shall be

proposed by the Contractor prior to the commencement of the work. The frequency may

subsequently be varied as required, depending on the consistency of the results obtained.

Control tests shall be carried out on the bentonite suspension, using suitable apparatus. The

density of freshly mixed bentonite suspension shall be measured daily as a check on the quality

of the suspension being formed. Tests to determine density, viscosity, pH value,etc shall be

applied to bentonite supplied to the pile boring. For average soil conditions the results shall

generally be within the ranges specified in IS:2911.The tests shall be carried out until a

consistent working pattern has been established, taking into account of the mixing process, any

blending of freshly mixed bentonite suspension and previously used bentonite suspension and

any process which may be used to remove impurities from previously used bentonite

suspension. When results show consistent behaviour, tests to determine density shall be carried

out as agreed with the Engineer-in-charge. In the event of a change in the established working

pattern, tests for viscosity and pH value shall be reintroduced for a period if required. The costs

for all tests shall be borne by the Contractor.

3.2.1 Cement

3.2.1.1 General

The cement used shall be Portland pozzolana cement conforming to IS: 1489 and the make of

the same shall be approved by the Engineer in charge.

3.2.1.2 Tests after Delivery

Each consignment of cement may, after delivery on the site at the discretion of the Engineerin-

Charge, be subjected to any or all of tests and analysis required by the relevant Indian Standard

Specifications. Facilities for testing shall be provided by the Contractor at his own cost.

3.2.1.3 Storage on the Site

The cement shall be stored in a suitable weather-tight building and in such a manner as to

permit easy access for proper inspection to prevent deterioration due to moisture and to

minimize warehouse deterioration. Cement of different type and brands shall be kept in separate

storage. All accepted cement stored on the site shall be arranged in batches, and used in the

same order as received from the manufacturer. The contractor shall maintain a cement register,


Page 6 of 20

in which all entries shall be completed day to day showing the quantities received, date of

receipt, source of dispatch, type of cement, etc. and also the daily cement consumption on site.

The register shall be accessible to the Engineer-in-charge for his verification.

3.2.1.4 Rejection of Cement

The Engineer-in-charge may reject any cement as a result of any tests thereof, notwithstanding

the manufacturer’s certificate. He may also reject cement which has deteriorated owing to

inadequate protection from moisture or due to intrusion of foreign matter or other causes. Any

cement which is considered defective by the Engineer-in-charge shall be promptly removed from

the site of work by the contractor at his own expense.

3.2.2 Aggregates for Concrete

3.2.2.1 General

Coarse and fine aggregates for concrete shall conform in all respect to IS: 383, “Specification

for Coarse and Fine Aggregates from Natural Sources for Concrete”. Aggregates shall be

obtained from a source known to produce those satisfactory for concrete. Aggregates shall

consist of naturally occurring sand and granite/basalt trap stone, crushed or uncrushed, or a

combination thereof. They shall be chemically inert, hard, strong, dense, durable, clean and free

from veins, adherent coatngs and shall be of limited porosity. Flaky and elongated pieces shall

not be used. The source of aggregates shall be approved by the Engineer-in-Charge and shall

not be changed during the course of the job without his approval. Rejected aggregates shall be

removed from the work site by the contractor at his own expense.

3.2.2.2 Deleterious Materials

Aggregates shall not contain any harmful materials such as iron pyrites, coal, mica, shale or

similar laminated materials, clay, alkali, soft fragments, sea shells, organic impurities etc. in such

quantities as to affect the strength or durability of the concrete. In addition to the above, for

reinforced concrete, any material which might cause corrosion of the reinforcement and

aggregates which are chemically reactive with the alkalis of cement shall not be used. The

maximum quantities of deleterious materials in the aggregates, as determined in accordance

with IS: 2386 (Part-II) “Methods of Test for Aggregates for Concrete”, shall not exceed the limits


Page 7 of 20

given in Table-I of IS: 383. The sum of the percentages of all deleterious materials shall not

exceed five. Deleterious materials also include material passing 75 micron IS sieve.

3.2.2.3 Coarse Aggregates

Coarse aggregate is aggregate most of which is retained on 4.75 mm IS sieve. These may be

obtained from crushed or uncrushed granite/basalt trap stone and may be supplied as single

sized or graded aggregates given in Table-II of IS: 383. The Engineer-in-Charge may allow all-

in-Aggregate to be used provided they satisfy the requirements of clause 4.4 and T able-IV of IS

383.

3.2.2.4 Fine Aggregates

Fine aggregate is aggregate most of which passes 4.75 mm IS Sieve but not more than 10%

pass through 150 microns IS Sieve. These shall comply with the requirements of grading zones

I, II and III and given in Table-III of IS: 383. Fine aggregate conforming to grading zone IV shall

not be normally used in reinforced concrete unless tests have been made by the contractor to

ascertain the suitability of the proposed mix proportion and approved by the Engineer-in-Charge.

Fine aggregate shall consist of natural sand resulting from natural disintegration of rock and

which has been deposited by streams or glacial agencies, or crushed stone sand or crushed

gravel sand.

3.2.2.5 Sampling and Testing

In case of doubt the Engineer-in-Charge may require the contractor to carry out tests, at the

contractor’s expense in accordance with – IS: 516 – Method of Tests for Strengths of Concrete;

and IS: 2386-Method of Tests for Aggregates for Concrete.

3.2.2.6 Storage of Aggregates

The contractor shall at all times maintain at the site of work such quantities of aggregate as are

considered by the Engineer-in-Charge to be sufficient to ensure continuity of work. Each type

and grade of aggregate shall be stored separately on hard firm ground having sufficient slope to

provide adequate drainage to rain water. Any aggregate delivered to site in a wet condition or

becoming wet at site due to rain shall be kept in storage for at least 24 hrs. to obtain adequate

drainage, before it is used for concreting, or the water content of mix must be suitably adjusted

as directed by Engineer-in-Charge.


Page 8 of 20

3.2.3 Water

Water used for concrete shall be clear and free from injurious amounts of Oil, Acid Alkali,

Organic matters or other harmful substances in such amount that may impair the strength or

durability of structure. Potable water shall generally be considered satisfactory for mixing and

curing concrete. The Engineer-in-Charge may require the contractor to prove at latter’s expense,

that the concrete mixed with water proposed to be used should not have a compressive strength,

lower than 90% of the strength of concrete mixed with distilled water. The Engineer-in-Charge

may require the contractor to get the water tested from an approved laboratory at his own

expenses and in case the water contains any sugar or an excess of acid, alkali, any injurious

salts, etc. the Engineer-in-Charge may refuse to permit its use.

3.3 Admixtures

Admixtures may be used in concrete only with the approval of Engineer-in-Charge.

3.4 Reinforcement

Reinforcement shall conform to IS: 1786 (latest version) grade Fe-500D for mechanical

properties and shall be steel of approved make. The reinforcements shall be made into cages

sufficiently rigid to withstand handling without damage. In case the reinforcement cage is made

up more than one segment, the same shall be assembled by providing necessary laps preferably

by welding. Stirrups to the main bars shall be tack welded.

Care shall be taken to ensure that the reinforcement bars do not come closer while the cage is

lowered down the hole. Proper cover and central placement of the reinforcement shall be

ensured by use of suitable concrete spacers or rollers, specifically for the purpose.

3.4.2 Welding

Field welding of reinforcing bars will not be permitted without the written consent of the Engineer-

in-charge. Where welding is permitted it must be at staggered locations. Tests shall be made to

provide that the joints are of the full strength of bars connected. Welding of reinforcement shall

be done in accordance with the recommendation of IS: 2751.


Page 9 of 20

3.4.3 Storage

The steel reinforcement shall be stored in such a way as to avoid distortion and to prevent

deterioration and corrosion.

3.4.4joints in Reinforcement

Joints in longitudinal steel bars will be permitted unless otherwise specified. Joints in

reinforcement shall be such that the full strength of the bar is effective across the joint and shall

be made so that there is no relative displacement of the reinforcement during the construction of

the pile.

3.5 Concrete

The grade for reinforced concrete shall be M30 having a minimum compressive strength of 30

N/sq. mm at 28 days. The cement for concrete shall be Portland pozzolana cement and the

cement content shall be governed by Design Mix or a minimum cement content not less than

400 kg/cum for tremie concreting whichever is higher. The Engineer-in-charge may allow

marginal adjustment in water/cement ratio to obtain concrete of good workability.

3.5.1Slump of Concrete

Slump of concrete shall range between 100 to 180 mm depending on the manner of concreting.

4.0 INSTALLATION

4.1 General

Installation of piles shall be carried out in accordance with the approved pile lay out drawings.

Cut-off level of the piles shall correspond to those given in the working drawings. To ensure

dense and sound concrete at the cut-off level, concreting shall extend above cut-off level while

casting the piles. However, no extra payment shall be made for this and the rate quoted shall be

inclusive of this. In case the reinforcement cage is made up of more than one segment, the

same shall be assembled by welding only, before lowering, as per IS: 456-2000 by providing

necessary laps.The vertical reinforcement shall project 50 times its diameter above the cut-off

level. Concrete shall be placed by tremie. All precautions for obtaining clean and sound pile shaft

shall be strictly observed. For tremie concreted piles, a sample of drilling fluid shall be taken from

the base of the borehole by means of an approved sampling device in the first few piles and at


Page 10 of 20

suitable interval of piles thereafter. Concreting shall not proceed if density of fluid exceeds 1120

kg/cu.m.

4.2 Workmanship

4.2.1 Setting Out

The contractor shall check the casing position for each pile during and immediately after placing

the casing, and agree it with the Engineer in charge.

4.2.2 . Diameter of Piles

The diameter of pile shall be as specified in the drawing.

4.2.3 Equipmentand Accessories

The equipment and accessories for installation of bored cast-in-situ piles shall be selected giving

due consideration to the subsoil conditions and the method of installation, etc. These shall of

standard type and shall have the approval of the Engineer-in-Charge. The capacity of the rig

shall be adequate so as to reach the desired depth. Provision shall be kept for chiseling within

the borehole in case of any underground obstruction/hard strata. However, chiseling shall be

carried out only with the approval of Engineer-in-Charge. In case pile is required to be socketed

in medium or good quality rock strata, the equipment mobilized shall have adequate capability to

do so up to the required socket length.

4.2 Pile Installation

4.2.1 Control of Alignment

The piles shall be installed as accurately as possible as per the designs and drawings. The

permissible positional deviations shall be governed by IS: 2911 (Part I /Sec.2) and IS: 2911 Part

-3. In case of piles deviating beyond such permissible limits, the piles shall be replaced or

supplemented by additional piles, as directed by the Engineer-in-Charge.

4.2.2 Boring

The boring operations shall be done by percussion type rigs or rotary rigs using direct mud

circulation or reverse mud circulation methods to remove the cuttings and the equipment and

construction shall be as per IS:2911 (Part I / Se. 2).

4.2.3 Temporary Casings


Page 11 of 20

Temporary casing of approved quality shall be used to maintain the stability of pile excavation

which might otherwise collapse. Minimum length of two metres temporary casing as specified in

the standard shall be inserted in each bored pile unless otherwise specified and additional length

of temporary casing may be used depending on the nature of soil strata, ground water level, etc

without any extra cost.

Temporary casings shall be free from significant distortion. They shall be of uniform cross-

section throughout each continuous length. During concreting they shall be free from internal

projections and encrusted concrete which might prevent the proper formation of piles.

4.2.4. Boringnear recently cast Piles

Piles shall not be bored so close to other piles which have recently been cast and which contain

workable or unset concrete that a flow of concrete could be induced from or damage caused to

any of the Piles.

4.2.5 Stability of pile bore using drilling fluid

Where the use of drilling fluid is approved for maintaining the stability of a boring, the level of

the fluid in the excavation shall be maintained so that the fluid pressure always exceeds the

pressures exerted by the soils and external ground water, and an adequate temporary casing

shall be used in conjunction with the method to ensure stability of the strata near ground level

until concrete has been placed. The fluid level shall be maintained, at a level not less than 1 m,

above the level of the external ground water. In the event of a rapid loss of bentonite suspension

from the pile excavation, the excavation shall be back filled without delay and the instructions of

the Engineer in charge shall be obtained before excavation at that location is resumed, without

any extra cost.

4.2.6 Spillage and Disposal

All reasonable steps shall be taken to prevent the spillage of bentonite suspension on the site in

areas outside the immediate vicinity of boring. Discarded bentonite shall be removed from the

site without delay.


Page 12 of 20

4.2.7 Pumpingfrom Bore Holes

Pumping from a bore hole shall not be permitted unless a casing has been placed into a stable

stratum which prevents the flow of water from other strata in significant quantities into the boring,

or unless it can be shown that pumping will not have a detrimental effect on the surrounding soil

property.

4.2.8 Continuity of Construction

A pile constructed in a stable cohesive soil without the use of temporary casing or other form of

support shall be bored and concreted without prolonged delay and in any case soon enough to

ensure that the soil characteristics are not significantly impaired.

4.2.7 Cleanliness of Pile Bases

On completion of boring, loose, disturbed or remolded soil shall be removed from the base of the

pile.

4.3 Concreting of Piles

Method of placing and the workability of concrete shall be such that a continuous monolithic

concrete shaft of the full cross section is formed. Concrete shall be placed without such

interruption as would allow the previously placed batch to have hardened. The method of placing

shall be approved. Contractor shall take all precautions in the design of mix and placing of the

concrete to avoid arching of the concrete in a casing. No spoil, liquid or other foreign matter shall

be allowed to contaminate the concrete. Care shall be exercised to preserve correct cover and

alignment of reinforcement and avoid any damage to it throughout the complete operation of

placing the concrete.

The top of the pile shall be brought up above the cut off level minimum as specified in IS: 2911

Part – 1/ Sec. 2 and IS: 2911 Part -3 so as to permit removal of all laitance and weak concrete

before capping and to ensure good and sound concrete at the cut off level for proper

embedment into the pile cap. Any defective concrete in the head of the completed piles shall be

cut-away and made good with new concrete.

4.3.1. Workability of Concrete

Slump of concrete shall range between 100 to 180mm depending on the manner of concreting.


Page 13 of 20

Slump measured at the time of discharge into the pile boring shall be in accordance with IS

2911.

4.3.2. Compaction

Internal vibrators shall not be used to compact concrete unless the contractor is satisfied that

they will not cause segregation or arching of the concrete and unless the method of use has

been approved.

4.3.3. Placing Concrete in Dry Borings

Approved measures shall be taken to avoid segregation and bleeding and to ensure that the

concrete at the bottom of the pile is not deficient in grout.

4.3.4. Placing Concrete Under Water or Drilling Fluid

Concrete to be placed under water or drilling fluid shall be placed by tremie and shall not be

discharged freely into the water or drilling fluid. Before placing concrete, measures shall be taken

to ensure that there is no accumulation of silt or other material at the base of the boring and the

Contractor shall ensure that heavily contaminated bentonite suspension, which could impair the

free flow of concrete from the pipe of the tremie, has not accumulated in the bottom of the hole.

A sample of the bentonite suspension shall be taken from the base of the boring using an

approved sampling device. If the specific gravity of the suspension exceeds 1.12 the placing of

concrete shall not proceed. In this event the Contractor shall modify or replace the bentonite as

approved to meet the specification. The slurry should be maintained at 1.5m above the ground

water level. The concrete shall be a rich coherent mix of high workability in accordance with the

standards. The concrete shall be placed in such a manner that segregation does not occur.

During and after concreting care shall be taken to avoid damage to the concrete from pumping

and dewatering operations.

The hopper and pipe of the tremie shall be clean and watertight throughout. The pipe shall

extend to the base of the boring and a sliding plug of polystyrene or similar material lighter than

water and approved by the Engr-in-charge shall be placed in the pipe to prevent direct contact

between the first charge of concrete in the pipe of the tremie and the water or drilling fluid. The

pipe shall at all times penetrate in to the concrete, which has previously been placed, and shall

not be withdrawn from the concrete until completion of concreting. At all times a sufficient

quantity of concrete shall be maintained within the pipe to ensure that the pressure from it


Page 14 of 20

exceeds that from the water or drilling fluid. The internal diameter of the pipe of the tremie shall

be not less than 150 mm for concrete made with 20 mm aggregate and not less than 200 mm for

concrete made with 25 mm aggregate. It shall be so designed that external projections are

minimized, allowing the tremie to pass through reinforcing cages without causing damage. The

internal face of the pipe of the tremie shall be free from projections.

4.4 Extraction of Casing

Temporary casings shall be extracted while the concrete within them remains sufficiently

workable to ensure that the concrete is not lifted.

4.5 Concrete Level

When the casing is being extracted a sufficient quantity of concrete shall be maintained within it

to ensure that pressure from external water, drilling fluid or soil is exceeded and that the pile is

either reduced in section nor contaminated. No concrete shall be placed in the boring once the

bottom of the casing has been lifted above the top of the concrete; it shall be placed

continuously as the casing is extracted until the desired head of concrete is obtained.

Adequate precautions shall be taken in all cases where excess heads of water or drilling fluid

could be caused as the casing is withdrawn because of the displacement of water or fluid by the

concrete as it flows into its final position against the walls of the shaft. Where two or more

discontinuous lengths of casing (double casing) are used in the construction the proposed

method of working shall be approved.

4.6Water level

In the event of the ground water level being higher than the required pile head casting level

shown on the Drawings, the Contractor shall submit his proposals for approval prior to placing

concrete. The pile head shall not be left below the ground water level unless approved

precautions are taken. All costs due to this shall be included in the quoted rate of piling item.

4.7 Temporary backfilling above Pile Casting Level

After each pile has been cast any empty bore remaining shall be protected and shall be carefully

backfilled as soon as possible with approved materials, as directed by the Engineer-in-Charge.


Page 15 of 20

4.1 Termination of Piles

Piles shall be terminated at the depth specified in the drawings. The termination depth in all

cases shall be certified by Engineer-in-Charge and shall be binding on the tenderer.

4.2 Replacement of Rejected Piles

Piles/boring/casing that are defective or exceed the tolerances specified above shall be left in

place or pulled out as directed by the Engineer in charge without adversely affecting the

performance of adjacent piles. In case the piles/casing cannot be removed they shall be cut out

as directed by Engineer In Charge. Voids resulting from rejected borings or extraction of the

piles or casings shall be filled with gravel or sand and the method shall be approved by the

Engineer in charge.

4.3 Defective Piles

Defective piles shall be removed or left in place, as judged convenient by the Engineer-in-

Charge, without affecting the performance of adjacent piles and the capping above and

additional piles shall be provided to replace them as directed by the Engineer in charge.

4.5 Recording of Data

A competent supervisor shall be present to record the necessary information during the

installation of piles. The data to be recorded shall include:

a) The dimensions of the piles, including the reinforcement detail and the mark of the pile.

b) The boring method employed.

c) The type of soil in which pile is terminated.

d) The depth bored.

e) The depth of water table.

f) When drilling mud is used, the specific gravity of the fresh supply and contaminated mud

in the borehole before concreting is taken up, in case of first few piles and subsequently

at suitable interval of piles.

g) The time taken for concreting.

h) The cut-off level/working level, and

i) The consumption of cement.

j) Any other important observations.


Page 16 of 20

Typical data sheets of recording piling data shall be as given in Appendix-D of IS: 2911 (Part I/

Sec.2).

Any deviation from the designed location, alignment or load carrying capacity of any pile shall be

noted and promptly reported to the Engineer-in-Charge.

5.0GENERAL REQUIREMENTS FOR PILING

The tenderer shall, before tendering, inspect the site and get himself acquainted with the

site conditions, access to the site, etc.

Sufficient number of hydraulic self propelled or rotary piling rigs with all accessories to

complete the entire job as per the time schedule shall be provided. The Contractor shall

also mobilize sufficient spares, cutting tools, etcto avoid any stoppage of work.

The reinforcement shall be adequately secured and held in position by metal chairs and

spacers. Ties of inter-sections shall be made with 16 SWG soft black annealed binding

wire.

The contractor must obtain the approval of the Engineer-in-Charge for the reinforcement

placed, before any concrete is placed in the forms. The reinforcement shall be free from

loose rust or scale or other coating that will destroy or reduce bond.

Concrete spacer blocks of the same strength as parent concrete shall be used to ensure

correct cover to the reinforcement. The clear cover shall be as shown on the drawings or

as per instructions of the Engineer-in-Charge.

All the reinforcing bars shall be so tied as to form a rigid cage to prevent displacement

before or during concreting.

The entire responsibility for piling as per relevant Indian Standards, Technical

specifications and as per good Engineering practices to suit the site condition shall rest

with the Contractor.

The diameter and concrete mix for the piles as envisaged in the schedule shall be kept

as it is, but the length and number of piles mentioned in the tender schedule is only

indicative and may vary as per the site conditions.

All piles shall be cast to the minimum level above cut-off as specified in IS Codes. After

stripping to cut-off level, the concrete at this level shall be dense and sound. The

tenderer shall decide the actual extra height of pile above cut-off level to achieve the

above.


Page 17 of 20

The tenderer shall take into account the extra height of concrete above cut-off level and

the rates quoted shall include the cost of this extra concrete.

No payment shall be made for rejected or defective piles due to faulty construction and

for reasons attributable to the Contractor.

The contractor‘s quoted rate should include the cost of the following;

a. Mix design for pile concrete. As long as the quality of materials does not change, an

approved mix design done earlier not prior to one year may be considered adequate

for the work.

b. Boring in all types of soils

c. Vertical reinforcement to project by length equal to development length of the rod as

specified in the drawings above pile cutoff level for embedding in the pile cap

concrete.

d. Provision of all equipment, labour, material, etc.

e. Cement cube compressive strength testing and test certificate charges to be borne by

the Contractor, not less than three samples(nine cubes) / each pile (at least two

samples for 28 days test and one for 7 days test)

f. Mechanical transportation and disposal of debris, muck, excess earth (If any) from pile

boring etc., away from the site to locations approved by the Engineer-in-charge within

the site boundary, including loading and unloading of the same shall be done by the

Contractor

g. Plasticiser / admixtures, if required may have to be used by the Contractor to achieve

required slump as approved by the Engineer in charge.

h. Casting extra length of pile above cut off level to permit removal of all laitance and

weak concrete as specified in IS 2911 part1 / Sec 2 and IS: 2911 Part -3.

i. Chipping off weak concrete to cut off level exposing the reinforcement rods and

cleaning the same.

j. Bailing out of water / liquid mud from all sources and causes.

k. Temporary casing pipes in required length as per site conditions and as per the

standards.

l. Making temporary road/ bunds for shifting materials, machineries, equipment, muck

etc. and demolishing the same after completion of work.

m. Providing sufficient protection to nearby pipe line / equipments, cables, buildings and

other structures.


Page 18 of 20

Pumping and bailing out of water, shoring, strutting, etc, if found necessary, for

successful and speedy operation of work shall be carried out by the contractor and cost

of such works shall be included in the rates quoted for piling. Extra claims whatsoever on

all subsidiary works pertaining to pilling work shall not be entertained.

All the excavated materials including debris, loose earth, muck,etc shall be carted away

and disposed off by the contractor out of the premises to any suitable place within the

site boundary asdirected by the Engineer in charge.

The Contractor shall provide all equipments, tools and plants required for the work and

rates shall include the cost of bringing the equipment etc, to site, proper maintenance

and removal of the same after completion of work.

Control of Piling Installation shall be as per the relevant IS Codes (IS 2911 (part 1 /

section2 and IS: 2911 Part – 3). Piles that are defective shall be left in places as judged

by the Engineer in charge and additional piles shall be cast to replace them at no extra

cost.

Adequate length of bars to be left over the cut-off level of the pile to develop anchorage

in the pile caps as specified.

Rig register and weekly report as per the format, approved by Client / Consultant shall be

submitted to Engineer in-charge of the project.

Reinforcement placed in the pile shall be provided with required couplings, welded joints,

spacer bars and binding wire as stipulated in the relevant specifications for

reinforcements.

All piles shall be concreted to a level above the specified pile cut off elevation as

specified in the standards. Before casting the pile cap, this excess concrete shall be cut

off up to pile cut off elevation.

Piles shall be cut off at level and elevation shown or specified in the Drawings. Care shall

be taken not to damage the reinforcement or the concrete below cut off elevation during

such stripping operations. Where stripping to be done to a level lower than the specified

cut off elevation to obtain dense and sound concrete, the Piling Contractor shall built up

the pile up to cut off elevation at his own cost.

Upon completion of the piling work, all casing equipments, construction tools, protective

covering and debris resulting from the piling operations shall be removed from the works

site to the satisfaction of Engineer in charge.


Page 19 of 20

6.0 RELEVANT STANDARDS AND CODES OF PRACTICE

I. AGGREGATES,CEMENT& CONCRETE

1. IS:456 -Code of practice for plain and reinforced concrete.

2. IS:4925 -Specification for concrete batching and mixing plant.

3. IS:2386 -Methods of test for aggregates for concrete ( Part 1 to 8 )

4. IS:516 -Method of test for strength of concrete.

5. IS:1199 -Method of sampling and analysis of concrete.

6. IS:9013 -Method of making,curing and determining compressive strength of accelerated cured

concrete test specimens.

7. IS:383 -Specification for coarse and fine aggregate from natural source for concrete.

8. IS:6461 -Glossary of terms relating to cement concrete ( Part 1 to 12 )

9. IS:5891 -Specification for Hand operated concrete Mixers.

10. IS:1200 -Method of measurement of building and civil engineering works. (Part 1 to 26 )

11. IS:2722 -Specification for portable swing weigh Batchers for concrete.

12. IS:650 -Specification of standard sand for testing of cement.

13. IS:7320 -Specification for concrete slump test apparatus.

14 IS:1489 -Specification for Portland Pozzolana cement

15. IS:1791 -Specification for batch type concrete mixers.

16. IS:5892 -Specification for concrete transit mixers and Agitators.

17. IS:3025 -Methods of sampling and test (physical and chemical) for water used in industry.

18. IS:9103 -Specification for admixtures for concrete.

19. IS:4082 -Recommendations on stacking and storage of construction materials at site

.

II. IRON AND STEEL

1. IS:2502 -Code of practice for bending and fixing of bars for concrete reinforcement.

2. IS:2751 -Recommended practice for welding of mild steel plain and deformed bars for

reinforced construction.

3. IS:1786 -Specification for High strength deformed steel bars and wires for concrete

reinforcement.

4. IS:432 -Specification for mild steel and medium tensile steel bars and hard drawn steel wire

for concrete reinforcement.


Page 20 of 20

5. IS:278 Specification for GI Barbed wire fencing

III. FOUNDATION ENGINEERING

1. IS:2911 -Code of practice for design and construction of pile foundations.(Part 1 / Section 1 )

Part.1 -Concrete piles -Section-1 -Driven cast-in-situ concrete piles.

2. IS:2911 -Code of practice for design and construction of pile foundations. ( Part 1 / Section 2 )

Part.1 - Concrete piles.-Section 2 -Bored cast-in-situ piles.

3. IS:2911 -Code of practice for design and construction of pile foundations (Part 1/ Section 3)

Part.1 -Concrete piles-Section 3 -Driven precast piles.

4. IS:2911 -Code of practice for design and construction of pile foundations.

Part.3 -Under reamed piles.

5. IS:2911 -Code of practice for design and construction of pile foundations.

Part 4 -Load test on piles.

6. IS:6427 -Glossary of terms relating to pile driving equipment.

7. IS:6426 -Specification for pile driving Hammer.

SAFETY

1. IS:5121 -Safety code for piling and other deep foundations.

***************************************

Client: M/s. BPCL-KRReport No.: R-301

Soil Investigation work for the proposed Residential Township

GRA -VEL(%)

SAND(%)

SILT(%)

CLAY(%) LL PL PI WET DRY METHOD

Ckg/cm2

ø(º)

3 0.75 SPT1 Clayey silt(Dark grey) CH 0 6 55 39 76 91 31 60

2 1.50 SPT2 Clayey silt(Dark grey) CH




5.00 UDS-1 Clayey silt(Dark grey) CH 0 4 59 37 115 122 37 85 2.43 1.38 0.64 UCS 0.06 -

6.50 VST1 Clayey silt(Dark grey) CH VST 0.09 -

SOIL DESCRIPTION

NM

C(%

)

IS27

20 (P

art2

):197

3 ATTERBERG'S LIMIT(%)IS 2720(Part-5): 1985

SHEAR PARAMETERS-IS 2720(Part-13):1986

SL (

%)

IS 2

720(

Part6

): 19

72

FSI (

%)

IS 2

720

(Par

t40)

:197

7SP

G

IS27

20(P

art-

3/se

c1):1

980

UNIT WEIGHT(gm/cc)

I.S.CLASSIFICATION

GRAIN SIZE ANALYSIS(%)IS 2720(Part5):1985

Table No.15Date of Boring Started : 10.07.13Date of Boring Completed : 13.07.13Termination Depth : 60.0m

: 95 :

BOREHOLE BH/05N DEPTH (M) SAMPLE

NAME OF WORK : SOIL INVESTIGATION WORK FOR THE PROPOSED RESIDENTIAL TOWNSHIP

LOCATION: HIGH COURT-JN,ERANAKULAM

Ground Water Level : 0.10m

T-1613

Geo Foundations and Structures Pvt Ltd Technical ManagerQuality Manager



9.50 UDS2 Clayey silt(Dark grey) CH 0 5 60 35 104 110 32 78 2.44 1.39 0.65 Triaxial 0.12 2



3 14.0 SPT8 Clayey silt(Dark grey) CH 0 4 64 32 92



9 18.5 SPT11 Sandy clayey silt(R/brown) CH 0 19 50 31 46 62 30 32




GRA -VEL(%)

SAND(%)

SILT(%)


Ckg/cm2

ø(º)

SOIL DESCRIPTION

NM

C(%

)

IS27

20 (P

art2

):197



SL (

%)

IS 2

720(

Part6

): 19

72

FSI (

%)

IS 2

720

(Par

t40)

:197

7SP

G

IS27

20(P

art-

3/se

c1):1

980

UNIT WEIGHT(gm/cc)

I.S.CLASSIFICATION







T-1613

8 20.0 SPT12 Sandy clayey silt(R/brown) CH

16 22.0 SPT13 Decayed wood(Black) OL


20 26.0 SPT15Clayey silt with decayed wood (Darkgrey) OH 0 5 59 36 41

21 28.0 SPT16 Sandy clayey silt(Grey) CI 0 39 39 22 40 44 22 22 2.45 1.86 1.33 UCS 0.71 -

23 30.0 SPT17 Sandy clayey silt(Grey) CI

25 32.0 SPT18Clayey silt with decayed wood(Black) OH 0 10 55 35

: 96 :

T-1613


25 32.0 SPT18Clayey silt with decayed wood(Black) OH 0 10 55 35

22 34.0 SPT19Sandy clayey silt with decayedwood(Black) OI

23 36.0 SPT20 Clayey silty sand (Dark grey) SC 0 58 24 18 35 39 NP

29 38.0 SPT21Sandy clayey silt with decayedwood(Dark grey) OI

48 40.0 SPT22 Silty sand(Grey) SM 0 76 24 0 32 No Limit

>100 42.0 SPT23 Silty sand(White) SM

100 44.0 SPT24 Silty sand(White) SM 0 79 21 0 20 No Limit 2.61 2.11 1.76 DST 0 39

>100 46.0 SPT25 Silty sand(White) SM

T-1613




GRA -VEL(%)

SAND(%)

SILT(%)


Ckg/cm2

ø(º)

SOIL DESCRIPTION

NM

C(%

)

IS27

20 (P

art2

):197



SL (

%)

IS 2

720(

Part6

): 19

72

FSI (

%)

IS 2

720

(Par

t40)

:197

7SP

G

IS27

20(P

art-

3/se

c1):1

980

UNIT WEIGHT(gm/cc)

I.S.CLASSIFICATION







T-1613

>100 48.0 SPT26 Silty sand with decayed wood (White) SM 0 55 45 0 16 No Limit

100 50.0 SPT27 Silty sand with decayed wood (White) SM

>100 52.0 SPT28 Silty sand(Grey) SM 0 52 48 0 18 No Limit

83 54.0 SPT29 Silty sand(Grey) SM



44 60.0 SPT32 Silty clay(Pale brown) CH 0 0 43 57 30

: 97 :

T-1613


44 60.0 SPT32 Silty clay(Pale brown) CH 0 0 43 57 30

T-1613



COMPLIANCE STATEMENT 8138-12-PS-009CS

PAGE 1 OF 1

TPS NO. 8138-12-PS-009

We state that our Quotation No. …………………………… is in full compliance with the documents issued against the Enquiry No. ………………………..except for the deviations listed below.

LIST OF DEVIATIONS

Sl. No. Description Reasons for Deviation


00F

T0

14

/94

Name of vendor:

Date Name and designation Seal & signature

tender document for design, supply ,installation ... · mbr technology stp( 120 kld ... erection...

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