technical specifications for sugauli cogen

Doc No. : GDP/EPC-BID/09-10/025, R1 Date : June 8, 2009 Assign No. : GPD/SDE/HPCL/08-09/045 Date : September 12, 2008

ENGINEERING, PROCUREMENT & CONSTRUCTION (EPC) BID DOCUMENT

20 MW Cogeneration Power Plant Village Sugauli, District East Champaran, Bihar

Technical Basis And Specifications

Prepared For

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

Petroleum House, 17, Jamshedji Tata Road, Mumbai 400 022

Prepared By

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

Pune - 411 005

June, 2009

Doc No. : GDP/EPC-BID/09-10/025, R1 Date : June 8, 2009 Assign No. : GPD/SDE/HPCL/08-09/045 Date : September 12, 2008

EPC BID DOCUMENT

20 MW Cogeneration Power Plant Village Sugauli, District East Champaran, Bihar

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Chapter No.

Chapter No. Page No.

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

1 174

1.1 Design Basis 1 1.2 Scope Of Work 172 1.3 Terminal Points 173 1.4 Building Dimensions 174 2 TECHNICAL SPECIFICATIONS FOR MECHANICAL &

ELECTRICAL EQUIPMENTS, INSTRUMENTATION & CONTROL AND ERECTION AND COMMISSIONING

175 - 464

2.1 Steam Generator &Auxiliaries 175 2.2 Steam Turbine Generator & Auxiliaries 220 2.3 EOT Crane & Hoists 280 2.4 Water Treatment Plant 291 2.5 Air Compressor & Air Dryer 299 2.6 Fuel And Ash Handling System 302 2.7 Cooling Tower & Auxiliaries 314 2.8 Fire Fighting System 322 2.9 Piping & Fittings 326 2.10 Painting 333 2.11 Electrical Evacuation System 335 2.12 Cabling 386 2.13 DCS Based Instrumentation And Control 398 2.14 Uninterrupted Power Supply 438 2.15 Erection & Commissioning 445

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Chapter No.

Chapter No. Page No.

3 CIVIL WORKS 465 - 488

3.1 Major Civil Works 465 3.2 Design Data 466 3.3 System Description & Specifications 466 3.4 Design Criteria 467 3.5 Foundations 468 3.6 Machine Foundations 469 3.7 General Design Considerations 472 3.8 Design Of Miscellaneous Items 477 3.9 Architectural Concepts And Design 478 3.10 Construction 482 4 APPROVED LIST OF VENDORS, LIST OF SPARES AND

LIST OF DRAWINGS / DOCUMENTS 489 - 514

4.1 Approved List Of Vendors 489 4.2 List Of Spares 495 4.3 List Of Drawings & Documents 503

5 DATA SHEETS 515 - 554

5.1 Steam Generator & Auxiliaries 515 5.2 Steam Turbine Generator & Auxiliaries 518 5.3 Water Treatment Plant 521 5.4 Cooling Tower 524 5.5 Fuel & Ash Handling 525 5.6 EOT Crane 533 5.7 Electrical Evacuation 535 5.8 DCS 551 5.9 Building Dimensions 552 5.10 Performance Guarantee 552 5.11 List of Technical Deviations 554

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LIST OF APPENDICES

APPENDIX

NO. APPENDICES

I SITE LOCATION MAP

II PROXIMATE & ULTIMATE ANALYSIS OF BIOMASS FUELS

III TYPICAL TG HALL LAYOUT

IV PROPOSED MASTER PLAN DEMARCATING COGEN

AREA AND PROVIDING SCHEMATIC OF FUEL

HANDLING SYSTEM

V TYPICAL SCHEMATIC PLANT STEAM SYSTEM

VI TYPICAL SCHEMATIC FOR HP HEATER

VII TYPICAL SCHEMATICS COOLING WATER SYSTEM

VIII TYPICAL SCHEMATICS PLANT WATER SYSTEM

IX TYPICAL BOM, FIRE FIGHTING

X TYPICAL SCHEMATICS SYSTEM CONFIGURATION, PLANT DCS

XI TYPICAL SINGLE LINE DIAGRAM, ELECTRICAL

EVACUATION & DISTRIBUTION SYSTEM

XII PIPING MATERIAL SPECIFICATIONS

XIII CODES & STANDARDS

XIV TYPICAL PAINTING SUMMARY

XV ELECTRICAL SYSTEM REQUIREMENTS FOR MOTOR

SELECTION

XVI RAW WATER ANALYSIS

XVII HEAT & MASS BALANCE DIAGRAM

XVIII TERMS & CONDITIONS FOR ERECTION &

COMMISSIONING

Technical EPC Bid Document for Cogen Power Plant at Sugauli, Dist. East Champaran, Bihar 1

CHAPTER 1

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

1.1 DESIGN BASIS 1.1.1 General

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

The auxiliary steam consumption for the cogen power plant will be for soot blowing and other auxiliary consumptions like Steam Jet Air Ejector (SJAE) & Gland Steam Condenser (GSC) at high pressure, for twin type HP heater at medium pressure and for de-aerator at low pressure. The auxiliary power consumption for the power plant will be about 8.5% of generation during season and 9% of generation during off-season periods.

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


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

Boiler capacity, TPH : 1 x 100

Pressure, kg/cm2 110.00

Temperature, C 540

Turbine capacity, MW 20.00

Turbine type Bleed cum double extraction cum condensing

Season operation, days 130

Off season operation, days : 170

Fuels used for season operation : Mill bagasse

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

Boiler efficiency, %

- On bagasse / bio-mass / cane trash

: 70.00, 2

Feed water temperature, C : 210

Captive power consumption, % of generation

: 8.5 during season & 9 during off-season

1.1.2 Key performance parameters

The key performance parameters for the cogen power plant are given below: Sr. No.

Description Value

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

2 Steam to Fuel Ratio, kg bagasse / kg

: 2.65


3 Average Steam to Power Ratio, kg / kW Season Off-Season

: :

5.08 3.80

4 Auxiliary Power consumption, MW (%) Season Off-Season

: :

1.70 (8.5) 1.80 (9)

Note: The estimated HMBD is provided in Appendix XVII. However, the

Tenderer can optimise the same to maximise power generation at the required steam flows to process.

1.1.3 Ambient Conditions

Plant Elevation above Mean Sea Level (MSL) : 61 meters Temperatures: (a) Maximum Temperature : 46 Deg. C (b) Minimum Temperature : 5 Deg. C (c) Plant Design Temperature : 36 Deg. C (Performance design) (d) Plant Design Wet Bulb Temperature : 27.0 Deg. C (e) Plant Design Temperature for Electrical : 50 Deg. C Equipment

Precipitation: (a) Average Annual Rainfall : 1241 mm Wind: (a) Wind Direction : South - West (May Sept) North - East (Oct - Apr) (b) Design Wind Velocity : As per IS 875 Seismic Coefficient : As per IS: 1893-2002 Seismic Zone : Zone 4


Soil Bearing Capacity* : 12 ton/m at 2 m

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

1.1.4 Fuels

a) Design & Guarantee Fuels During sugar season, the principle fuel will be bagasse and the steam generator will be designed for 100% MCR on bagasse. During sugar off-season, the boiler will operate on stored / procured bagasse and other biomass.

The estimated fuel balance will be as follows :

Value Sr.

No.

Item

Season Off season

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

TPH 49.58 -

3. Bagacillo / handling loss at 1.0% on cane, TPH

1.46 -

4. Bagasse available as fuel at 33% on cane, TPH

48.13 -

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

2.08 2.08

6. Total equivalent bagasse available, TPH (MT)

50.21 (156655)

0.00

6. Bagasse consumed by new boilers, TPH (MT)

37.74 (117748)

26.60

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

12.47 (38904)

9.54 (38904)

8. Biomass requirement, equivalent bagasse, TPH (MT)

- 17.43 (71114)


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

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

The Following gives the Ash Analysis for Bagasse: SiO2 : 50-60% Al2O3 : 10-13% Fe2O3 : 10-12% CaO : 3-5% MgO : 3-4% TiO2 : 2-4% P2O5 : 1-2% Na2O : 0.5-1.5% K2O : 4.5-6.0% SO3 : Nil b) Other Fuels

The Cogeneration plant will also be designed to operate with other fuels like sugarcane trash, rice husk and maize cobs in combination with bagasse. The operation of the plant during the seasonal operation will be basically with bagasse and during off season with saved bagasse and biomass. However during off season bio-mass fuel sugarcane trash, rice husk and maize cobs are envisaged to be used depending upon the availability. Ultimate and Proximate analysis of the other fuels like sugarcane trash, , rice husk and maize cobs are given in Appendix II


1.1.5 Plant Design Criteria The estimated cogen plant design criteria is as follows :

Sr. No.

Item Value

Season Operation (130 days)

1. Cane crushing, TCH 146 2. No. of season days, nos. 130 3. No. of hrs / day 24 4. Cane crushing / season, lakh MT / season. 4.55 5. Bagasse generation, % cane (TPH) 34.00 (49.58) 6. Bagacillo / handling loss,% cane (TPH) 1.0 (1.46) 7. Bagasse available for boiler, % cane (TPH) 48.13 (98.60) 8. Bio-gas available from distillery as fuel

(equivalent bagasse) 2.08

8. Total equivalent bagasse available for boiler, TPH

50.21

9. Total fuel available as fuel, (MT) 156655 10. Bagasse consumption during season, TPH

(MT) @ 2.65 T/MT of bagasse 37.74

(117749) 11. Bagasse saved for off season operation TPH

(MT) (9-10) 12.47

(38904) 12. Steam generation, TPH (@ 2.65kg steam / kg

bagasse 100.00

13. Steam consumption, TPH 13.1 HP steam @ 110 & 25 kg/cm2 - Gland Steam Condenser & Steam Jet Air

Ejector (SJAE) 1.00

- HP heater I 7.00 13.2 MP steam @ 8 kg/cm2 - Ethanol process 20.00 - HP heater II 8.00 - De-superheating water addition (0.56) - Total MP steam 27.44

13.3 LP steam @ 2.5 kg/cm2 - Sugar process @ 22% on cane 32.08 - De-aerator 4.60


Sr. No.

Item Value

- De-superheating water addition (0.73) - Total LP steam 35.95

13.4 Condensing steam @ 0.1 kg/cm2 28.61 13.5 Total steam consumption 100.00 14. Power generation, MW (@ 5.08 kg/kW avg.) 19.69 15. Power consumption, MW - Sugar process @ 20 kWh/TCH 2.92 - Ethanol 1.00 - Cogen auxiliaries 1.70 - Colony 0.15 - Total 5.77 16. Power export, MW (14-15) 13.92 17. Power export, MUs 43.43 Off Season Operation (170 days)

18. No. of off season days 170 19. Steam generation, TPH 76.00 20. Steam consumption, TPH 20.1 HP steam @ 110 kg/cm2 for GSC 0.76 HP steam @ 25 kg/cm2 for HP Heater I 5.32

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

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

20.4 Condensing steam @ 0.1 kg/cm2 48.33 20.5 Total steam consumption 76.00 21. Power generation, MW (@ 3.80 kg/KW avg.) 20.00 22. Power consumption, MW - Colony & Sugar Complex 0.30 - Ethanol Plant 0.90 - Cogen auxiliaries 1.80 - Total 3.00


Sr. No.

Item Value

23. Power export, MW 17.00 24. Power export, MUs 69.36 25. Total power export, MUs 112.79 26. Fuel consumption Equivalent bagasse

requirement for off-season, TPH (MT) 28.68

(117014) 27. Biogas available from distillery for off-season

(equivalent bagasse), TPH 2.08

28. Net off-season biomass fuel requirement (equivalent to bagasse), TPH (MT)

26.60 (110023)

29. Bagasse saved during off season , MT 38904 30. Net biomass required, for off-season

operation, MT 50005

31 Boiler size & configuration 1 x 110 TPH, 110 kg/cm, 540C

32 Turbine size & configuration 1x20 MW, 105 kg/cm, 535C

1.1.6 Main Plant And Equipments

1.1.6.1 Steam Generator & Auxiliaries

The steam generating system for the Cogeneration plant will consist of one bagasse and biomass fired boiler with a Maximum Continuous Rating (MCR) of 110 TPH. The outlet steam parameters of the boiler shall be 110 kg/cm2 and 540 deg C. The tolerance on the super-heater outlet temperature shall be a + 5 Deg. C. The combustion system of the boiler shall be travelling grate with spreader stoker. The boiler efficiency, firing 100 % bagasse, shall be a minimum of 70 % on the GCV basis. The flue gas temperature leaving the boiler to stack shall be chosen such that maximum economically possible efficiency is achieved but the temperature shall be sufficiently higher than the dew point considering the fuel characteristics. However, at 100% MCR the same shall not be higher than 140 deg C. An ESP is envisaged to control outlet emission to 100 mg/Nm3.


1.1.6.2 Turbo-generator & Auxiliaries

Triple extraction cum condensing steam turbine generator & auxiliaries is envisaged. The high pressure bleed will be at about 25 kg/cm, medium pressure bleed at 8 kg/cm and low pressure controlled extraction at 2.5 kg/cm will cater to the sugar mill process needs and cogeneration power plant auxiliaries. Balance of steam will be passed through condenser to generate the rated capacity. Feed water will be de-aerated in a pressurized de-aerator and further heated in HP heaters.

The Turbo - Generator and the Auxiliary Equipment covered under this specification shall be designed to achieve maximum power generation as per normal steam flow rates from the triple extraction cum condensing set.

Part of the generated power will be supplied to the sugar factory complex and the rest will be exported to the grid, after stepping up the voltage to EHV and transporting the power through transmission lines to the nearby sub-station of the BSEB. The extractions from the turbine provide the sources for the medium and low pressure steam for the use in the sugar complex & power plant auxiliaries.

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

Basic Design Parameters for the design:

Water Cooled Condenser Operating Pressure (ata)

0.1 (in off-season)

Temperature rise for cooling water (Deg. C)

8

Power Factor (lagging) 0.8


Generation Voltage (kV) 11.0, 3 phase Ambient Temperature for Electrical Equipment Design (Deg. C)

50

Parallel operation with grid Required with BSEB grid Grid Voltage 132 kV, 3 phase Duty Requirements Continuous 8000 hours System Frequency 50 + 5% Turbine Type Triple Extraction cum

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

off-season Extraction parameters, No of Extractions, Steam Flow

3 extractions at 25 kg/cm, 8 kg/cm and at 2.5 kg/cm. Bleed at about 25 kg/cm is only for HP heater no. 2. Bleed at 8 kg/cm is for HP heater no.1 and to supply 20 TPH to ethanol in season. Extraction at 2.5 kg/cm is for deaerator and supply of 32 TPH steam to sugar process in season. Appendix XVII provides the HBDs

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


The prime mover control system shall be selected and programmed to satisfy the following conditions under parallel mode of operation with the grid:

a. Load set point shall remain unaffected for the variation

of frequency between 47.5 Hz and 52.5 Hz. b. The turbine inlet steam pressure shall be maintained at

the set value by controlling the power export to the grid.

The Turbine extraction which provides the Medium Pressure Process Steam shall be selected such that the pressure at the battery limit will be maintained between the turbine inlet steam flows of 60% to 100% of the MCR flow. This is required mainly from the point of view of energy efficiency, where in even under less than the capacity crushing of the sugar plant, the MP process steam is taken through the turbine instead of taking the steam through the PRDS.

1.1.6.3 Fuel & Ash Handling

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

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


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

Bagasse from sugar mill elevator & yard, biomass from yard Ash from Boiler bed, Economiser, ESP Hoppers of Boiler & Bagasse from yard & mill

1 Material Handled

Ash from furnace through submerged ash conveyor will be normally wet when it is discharged on to the belt. Bagasse : 150 Kg/ Cu M 2 Bulk Density Bagasse Ash: 180 Kg/ Cu. M

3 Material Temperature

180 Deg. C for the fly ash and 40 Deg .C for the bagasse

4 Nature of Ash Material

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

5 Bagasse Ash analysis (% ) SiO2 50 - 60 Al2O3 10 - 13 Fe2O3 10 - 12 CaO 3 - 5 MgO 3 - 4 TiO2 2 - 4 P2 O5 1 - 2 Na2O 0.5 -1.5 K2O 4.5 - 6.0

1.1.6.4 Cooling Tower & Pumps

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

The cooling tower to be designed for continuous duty. The design of the tower shall be as per the enclosed specification and Data Sheet.


The equipment offered shall be capable of cooling the rated capacity of water through the specified range at the design wet bulb temperature.

The specified design wet bulb temperature of 27.50C includes the necessary recirculation allowance. Hence, Tenderer shall design his cooling tower based on this design wet bulb temperature without considering further recirculation allowance.

While arriving at the air flow through the tower, due consideration shall be given to heat carried away by evaporation and enthalpy correction of altitudes. Tenderer shall furnish detailed heat balance calculation in support of the air flow through the tower. Tenderer shall also furnish the basis of the enthalpy values indicated.

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

1.1.6.5 Water Treatment System

Raw water will be drawn by the Tenderer from the delivery header of the raw water transfer pumps at the ground water reservoir. Appendix IV provides the plant layout. Tenderer will also provide borewells at locations provided by the Owner / Consultant and connect the same to the day reservoir before the water treatment plant. The total capacity of the borewells should be 3000 m3/day.

Schematic of plant water system is given in Appendix VIII

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


Secondary system comprises of Multi grade Filters, Activated Carbon Filters, Filter Water pumps, Chlorine dosing and acid dosing, anti-scalant dosing systems, SMBS system related tanks and pumps, ultra-filtration unit, DM plant, Degasser, Degasser Tank, Blowers, degassed water pumps, mixed bed units, related acid and alkali dosing tanks, ejectors, morpholine dosing systems, all auxiliaries, including pumps and piping. Plant instrumentation including pH, conductivity meters, flow metering devices and totalliser.

Basis for Design

Water Treatment Plant Source of water Gandak River. In case of

exigencies, borewell water will be required to be used for process and boiler. Hence the water treatment plant should be designed accordingly.

Total outflow of water DM plant : 1000 m/day, OBR Pre-treatment plant : 1250 m/day. OBR

No. of Regeneration per day One per stream

1.1.6.6 Compressed Air System

Two (2) instrument air compressors will supply the requirement of compressed air for instruments and the control systems of the proposed cogeneration plant with one (1) working and the other standby. Each of the compressors shall be of 7 kg/cm pressure. The air compressor shall be provided with accessories like Intercooler, after cooler, Moisture separators, Air driers, Air receivers and control panel.


The air compressor shall be oil free two (2) stage reciprocating non-lubricating type with belt drive. The design of the reciprocating compressor will be opposed piston dynamically balanced according to the standard. The heat exchangers (inter and after coolers) shall be designed as per TEMA-C and coolers shall be mounted horizontally. The cooling water flow shall be through tubes and the tubes shall be of copper. The internal surfaces of the cooler shall be galvanized. The coolers shall be fitted with moisture separators and all necessary accessories.

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

The air receiver capacity shall be fabricated from SA 515 Gr. 70 or IS:2002 material. The internal surface shall be galvanized. The air receiver shall be fitted with all accessories including safety valves, moisture separators etc. The control system of pressure switches, solenoid valves, regulators for automatic loading of compressors shall be mounted on a local control panel. All air piping shall be internally galvanized. The service air requirement of the Cogeneration plant, being very low will also be met by the instrument air compressors. However the service air will be directly tapped off from the air receiver by passing the dryer units.


The compressors are to be opposed, belt pulley driven, non-lubricating type reciprocating air compressors complete with drive guards, AC electric motors, LPBS, air receiver, intercooler, after cooler, moisture separators, air dryer, moisture traps, all interconnecting pipe work & fittings, control panel, etc. The heat exchangers shall be designed as per TEMA-C and coolers shall be mounted horizontally. The air receiver shall be fabricated from SA 515 Gr. 70 or IS : 2002 material. The internal surface shall be galvanised.

Control air will be supplied to boiler and its auxiliaries, turbo generator and its auxiliaries and common plant auxiliaries like water treatment plant, fuel handling plant, ash, pump house etc. Compressed air will meet the requirements as stated below :

Capacity : 200 m3/hr or higher as per plant needs Nos.: : 2 nos. (1 operating & 1 standby) Pressure at receiver outlet : 7 kg/cm2 (g) Dew point temperature at Atmospheric conditions : (-) 400C Particulate material size (max.) : 1 micron Contaminants : No corrosive, hazardous, toxic Or flammable material Oil Content : 100% Oil Free

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


1.1.6.7 Tanks & Vessels

The tanks shall be designed, manufactured and tested in accordance with the requirements of the ASME Boiler and Pressure vessel Code Section VIII. Other equivalent standards are also acceptable. All vessels for steam application shall be designed for full vacuum.

The cogeneration plant tanks will have storage capacities as

required by design of the systems. Tanks will be of the closed top type. Tanks will be fabricated in accordance with guidelines established by API or AWWA, as determined by the service. A corrosion allowance of 3 mm shall be provided.

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

Maintenance drain connections shall be provided of an adequate size to facilitate drainage of tanks is within a reasonable time. Manholes where provided on tanks and pressure vessels shall be of size NB 500. The manhole covers shall be provided with davits. Ladders and cleanout doors will be provided on large tanks. DM water tank shall be internally lined with natural rubber or painted with three coats of Epoxy Coating. DM water and make up water tank shall be provided with interconnection platforms and staircase.

The saddles and reinforcement pads welded on to the vessels and tanks shall be of the same material as that of the vessel/tank shell or head. Insulated vessels shall be provided with insulation cleats for applying the insulation.


1.1.6.8 Piping

All cogeneration plant piping will be as per applicable IBR / IS standards. All piping will be aesthetically and neatly laid on pipe racks with approved colour coding. The cogeneration plant piping will inter-alia include raw water intake, water treatment plant, cooling water circulation, auxiliary cooling water circulation, plant service water, plant potable water, plant sanitation, compressed air ring, drain piping, treated effluent piping, steam piping from boiler to turbine, steam piping from HP line via PRDSH stations to LP & MP headers, HP / MP / LP steam piping to all cogeneration auxiliaries, steam piping from LP & MP headers to sugar plant headers.

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

All piping required for effectively connecting the steam generator with the steam, feed water, and other systems shall be provided. The piping provided shall be complete in all respects including valves, fittings, supports etc. as required. Necessary supporting materials, towers and trestles to support and anchor the pipelines at regular intervals shall be supplied. Suitable expansion loops and hangers shall be provided wherever necessary.

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


a) The flow velocities in pipes shall be limited to the following values:

Super-heated Steam. 30-60m/sec depending on pipe size

Saturated Steam. 20 to 35 m/sec Cooling Water. Up to 3 m/sec

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

c) Al local instruments shall be located on pipelines so as to render them observable from the nearest available platform.

d) Oil drains shall be sized to run no more than half full when flowing at a velocity of 0.3 m / sec, and shall be arranged to ensure good drainage.

Material Of Fabrication Of Equipments And Piping Wherever Applicable

01 Clarifloculator Rotating Bridge Type 02 Inlet well RCC 03 Alum Dosing Tank HDPE / FRP / MSRL 04 NaOCl dosing tank HDPE / FRP / MSRL 05 Polymer Dosing Tank HDPE / FRP / MSRL 06 Lime Dosing Tank HDPE / FRP / MSRL 07 Mixing channels RCC (Through flow pipe) 08 Clarifier RCC 09 Clarified water storage tank RCC 10 Multi grade filter MSEP 11 ACF MSEP 12 Acid Measuring Tank HDPE / MSRL 13 Caustic Measuring Tank MS / MSRL 14 Anti Scalant Tank HDPE 15 Fast Flush Tank HDPE 16 Backwash Tank HDPE / FRP 17 Degasser Tower MSRL 18 Degassed Water Tank MSRL


19 Degassed Blower SS 316 internals 20 Degassed water pumps SS 316 21 MB Unit MSRL 22 ETP Pump SS 316 23 Acid and Caustic Lye Pumps PP 24 Neutralisation pit RCC with acid proof tile

lining 25 Softener MSEP 26 Brine Preparation Tank RCC Bitumen 27 Brine Dosing Tank MSEP / Bitumen 28 Sludge Sump RCC 29 Sludge Pumps SS 304 30 DM water piping MSRL 31 Soft water piping MS 32 UFRO Unit SS / PVC / MSRR 33 Effluent / Sludge Slurry PVC 34 DM water tank MSRL 35 Soft water tank MSEP 36 Filtered water storage tank MSEP 37 All dosing pumps SS 316 internals 38 Raw water pumps CI 39 Filtered water and clarified

water pumps CI with SS 316 internals

1.1.6.9 Insulation

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


Glass wool materials is used should confirm to I.S. 3690 - 1974 type 2 mineral wool shall confirm to I.S. 5696 - 1970. The thickness should be to suit the diameter and temperature of pipes. The wire mesh should be of galvanized wire and lugs/pins used should be galvanized.

1.1.6.10 Fire Fighting System

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

Pressurized fire hydrant system will consist of a pipe network and hydrants positioned around the station in sufficient numbers and so located that all buildings and risks are readily protected. Necessary number of loops will be formed around various risks.

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

The hydrant network will be sized and analysed to ensure that about 3.5 kg/cm2 pressure is available at the hydraulically remotest point in the system with the hydrant pump discharging at rated head and capacity. The velocity in the hydrant main will not exceed 2 m/sec.

The fire alarm system shall consist of smoke detectors, heat detectors, fire alarm panel, hooter, manual call point etc. The detectors shall be located in all the electrical panel rooms, control room and battery room. The manual call point and hooters shall be located throughout the entire TG building. The detectors will sense the fire automatically and will generate fire alarm through Fire alarm panel.

The portable fire extinguishers shall consists of dry chemical powder type, carbon-di-oxide type, foam type fire extinguishers. The extinguishers shall be located strategically inside the TG building.


Raw water will be will be taken from the raw water pumps header at ground water reservoir to the fire water reservoir in the cogen plant. Raw water will be used for fire fighting. Typical BOM for fire fighting is provided in Appendix IX

1.1.6.11 Crane for the Turbo-generator Building

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

The crane shall be electrically operated, bridge type and shall be designed and equipped for indoor operation complete with all accessories. The crane bridge shall consist of bridge girders each one carrying a rail on which a wheeled trolley is to run. The bridge trucks and trolley frames shall be fabricated from structural steel. Access walkways with safe hand railing are required along the full span length on either side of the bridge girders.

Bridge and trolley trucks shall be of cast steel or fabricated struc-tural steel sections. Wheel trucks of cast or welded construction shall be stress relieved as per accepted standards. Spring buffers shall be provided on the trolley and bridge structural frames at suitable places to absorb the shock of impact without transferring to the structural frame.

1.1.6.12 Electrical System

The power generated will be evacuated to the sugar mill at the given terminal points. All the cogeneration power plant auxiliaries will operate on the power supplied from the cogeneration power plant. Balance of power generated after meeting the sugar and auxiliary load will be exported to the grid after stepping up to 132 kV. DG set will be provided for emergency power. All other power sources including DC power, UPS, control power, lighting, etc. will be derived from the cogeneration panels. Required earthing will be provided to ensure safety.


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

All equipment shall be designed to withstand the maximum fault levels provided in this tender document. The successful tenderer shall carry out complete system study for the electrical systems to ascertain the selection of fault levels of the switchgears are within limit, power (active and reactive) flow, system losses and power factor at various MCCs, voltage level in various level of voltage, motor starting analysis and stability study of the plant with BSEB grid.

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

Following lighting sources are considered,

Plant areas HPMV Lamp in Industrial type High Bay

fixtures or in integrated Well Glass luminaries, Industrial type Fl. Lamp fixtures with Vitreous enamelled reflectors

Electrical Room - Mirror Optic Fl. Lamps or CFL

Outdoor Lighting in transformer yard HPMV flood light fittings Battery operated Critical Lighting provided at strategic locations such as stair cases, control rooms and escape routes in the plant area - CFL lamps


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

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

b. Provision of earth mat as per IEEE 80. c. Provision of lightning conductor over 33KV switchyard. d. Provision of earthing grid conductor as per fault level considered.

e. Chimney Lightning protection and Lightning protection of other buildings

The switchgear shall be free floor standing, totally enclosed, dust and vermin proof with draw out type circuit breakers. Vertical units shall be assembled to form a continuous line Up of uniform height and depth The panel structure shall house the components contributing to the major weight of the equipment such as circuit breaker, main horizontal bus bars and other components are adequately supported without deformation or loss of alignment during transit or during operation. Each unit of the switchgear shall have necessary internal sheet metal barrier to form separate compartments for buses, instruments, relays, cable connections etc.

Adequate barriers shall permit personnel work safely within an empty compartment with the bus bars energised. Checking and removal of components shall be possible without disturbing the feeder.

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


All doors and opening shall be fitted with dust excluding neoprene gaskets with fasteners designed to ensure proper compression of the gaskets.

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

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

System Fault Level : 40 kA for 1 Sec. for 132kV system : 40 kA for 1 Sec. for 11kV system : 50 kA for 1 Sec. for 415V System : 9 kA for 1 Sec. for Lighting Circuits

a) Power Supply:

132 kV + 10%, 50Hz + 5 %, 3 Phase for Grid Connection 11 kV + 10%, 50Hz + 5 %, 3 Phase for Generation and Power Supply to 11KV Eqpts.

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

Control Voltage 110V AC, 50Hz for MCCs and PCCs Power Supply for Space Heaters, Plug Sockets, Lighting : 230 V,50 Hz, 1Ph.

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


b) Power Distribution :

a) Power will be generated at 11KV, 3Ph, 50Hz with Steam Turbine. Power will be stepped up to 132KV for Grid Connection and Evacuation to BSEB.

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

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

d) 230 V Single phase power supply shall be derived through Phase & Neutral for single phase power consumer.

c) Design Criteria In Equipments / Power Distribution :

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

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

Squirrel Cage Motors up to 15 KW shall have automatic DOL Starter suitable - for operating from MCC, DCS and PB Station near Motors.

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

Motor rating above 200KW shall be operated with Soft Starter suitable for operating from starter, DCS and PB Station near Motors. Starter Shall have bypass contactor with AC3 rating.

VFD shall be provided as per the functional requirement. Following spare feeders shall be considered in Power Distribution

o In 11KV Switchboard - 1 No. Transformer feeder


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

MCC shall be floor mounted self supporting, dust and vermin proof , fixed type construction.

Power Control Center (PCC) shall have Switch Disconnector Fuse up to 630A and above 800A these shall have Manually operated Draw Out (MDO) type ACB.ON indication shall be provided on outgoing feeders.

Motor Control Center (MCC) shall have Switch Disconnector Fuse unit, Contactor and Bimetallic Over Load (O/L) relay for starters. Starters on MCCs shall have ON & TRIP indication. The selection of switchgear components shall be minimum with one stage higher than Type II co ordination as per IS 13947

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

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

Flameproof equipments such as Push Button Stations, junction boxes, Lighting Switches, L lighting Fixtures etc shall be considered with hazardous area classification in Ethanol plant.

Push Button Station with Shrouded type actuator for ON push button, Lockable Mushroom type actuator for OFF Push button with Aluminum die cast enclosure shall be provided. Push Button Station for Motors above 15KW rating shall be provided with suppressed scale Ammeter. Push Button Station for VFD shall have Speed Setting Potentiometer and speed indicator in addition to Push Buttons and Ammeter


d) Power And Distribution Transformer

The following criteria shall be applicable for the sizing of Transformer 1) Total Connected Load shall be calculated based on Motor

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

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

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

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

5) Equipment Efficiency shall be considered 90% as average. 6) On such Calculated load + 20% Margin shall be considered. 7) If necessary percentage impedance shall be increased more

than the impedance indicated in IS to limit 415 V side Fault Level to 50KA for 1 sec.

e) Power Factor Improvement

01) Plant PF shall be required to improve above 0.95 02) This is achieved by providing:

Capacitors across HV Motors as per recommendation of manufacturer. Provide Automatic Power Correction Panel with required no. of APP type capacitor banks in 415V PCC in Cogen Plant.


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

f) LV Power Control Centre (PCC)

The following points shall be considered while designing and selection of components. I) TYPE OF FEEDERS: Incomers : D.O. 3-Pole ACB Emergency Power Supply

Feeder : D.O. 4-Pole ACB

Outgoing Feeders : SDF up to 630 A : MDO Type ACB Above 800A

II) BUSBARS Color Coded Sleeved

Aluminum Bus bar Size shall be selected as per following norms: Continuous current carrying capacity as per the Rated Current of Incomer Temperature Rise Limit Short Circuit Withstand Capacity


g) Motor Control Centre (MCC) :

The following points shall be considered while designing & selecting components. I) Incomer Feeder - MDO ACB above 800 A up to 2000

A Fixed Switch Fuse Disconnector up to 630 A

II) Outgoing Starter

Feeder Feeders shall be comprising of: Switch Fuse Disconnector Contactors Thermal Overload Relay Timer in case of Star Delta Starters Push Buttons Indicating Lamps

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

from MCC, DCS located at Central Control Room or locally from Push Button Station near motor. 02) It will be possible to start the Motor locally through enable command from PLC. 03) P.F. and KW parameter of Incomer shall be communicated to PLC. 05) ON/ OFF Status of the Motor shall be communicated to PLC.

V) Provision of Spare feeders

In MCC total 10% spare feeders shall be provided, depending on feeder ratings in MCC following feeders shall be provided.


h) LV Bus Ducting

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

i) Battery And Battery Charger

01) BATTERY: 1) VRLA Maintenance Free 2) Capacity shall be determined by total operating load and 20% margin. 3) AH shall be determined for 8 hour backup time.

02) BATTARY CHARGER

1) Float and Float cum Boost with 20% capacity

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

j) Grounding / Earthing System) & Lightening Protection

01) Earthing shall be done according to IS 3043 1987. 02) Earthing shall be carried out by G.I. Strips & Wires. Earth Electrodes shall be G.I. Plate type & Pipe type as per requirement. However, Transformer Neutral will be connected to G.I. Earth Electrode through Copper Strip. 03) Total Resistance of Earthing system shall be Less than one ohm. 04) Plant shall be protected against lightning according to IS 2309-1989.


k) Cables

The following consideration shall be given for Cable Sizing and Selection on Nominal Current Capacity

Ambient Temperature in Air/Ground Continuous Load Current Short Circuit Withstand Capacity Voltage Drop at the Starting of Motor limited to 15% & 5% at Steady state up to motor terminals.

Deration Factor due to type of Laying & Grouping. Generally Power and Control cables shall be stranded. XLPE insulated cables upto & including 4 sq.mm shall be with stranded copper conductors. Cables of 6 sq.mm & above size shall be with Al. conductor

Generally Cable trays shall be prefabricated Hot Dip Galvanized Iron. Cable Trays shall be run in Vertical formation as far as possible. HV & LV Power Cables shall have separating distance of 300mm. Separating distance between Power and Control cable shall be 300mm. Instrument cables & screened shall run on perforated cable tray having 300 mm separating distance of 300 mm. The Lux Level in various indoor areas shall be as per IS. In plant areas, the lighting shall be provided as per functional requirement. HPMV Well Glass with integral control gear box fittings (IP55) shall be provided in plant areas. Industrial FL. Lamp fittings will be provided in sub station and other indoor areas. Mirror Optic fixtures shall be provided in CCR. In outdoor areas HPSV Lamp fixtures (IP 55) shall be provided. The lighting shall be catered by Main Lighting DB. LDB & SLDB connected by Al. conductor cables. The Emergency power supply from 415V DG set will be made available to lighting transformer in case of failure of power


1.1.6.13 Instrumentation & Control System

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

The integration of all the inputs / signals for continuous monitoring, operation, data logging, data analysis, alarms, safety interlocks, annunciations etc. will be achieved through the DCS.

The DCS will include the DCS control station, related licensed software & hardware, instrument & control cabling from the marshalling cabinet receiving signals from junction boxes of all cogeneration equipment, all MCCs and software links with Turbo-visory panel, Woodward Governor and turbine temperature scanner.

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

Basic Control Design should be as below:

a. Generator, gearbox, turbine bearing temperature monitoring

shall be through the temperature scanner. b. Critical AI/AO/DI/DO signals will be redundant while

non-critical & DAS points will be non-redundant. All controllers for critical controls will be redundant. The field inputs for critical inputs will be1/2 logics. 25% of the I/Os to be considered as critical.

c. Sequence of event recorder will be provided d. Required Annunciation windows shall be included e. 25% spare I/Os to be considered. f. TG governing will be by Woodward 505E. However the

critical parameters will be monitored by providing serial Modus Interface


g. All I/Os will be potential free

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

1.1.6.14 In-Plant Communication System

The cogeneration power plant will have an EPBAX system with intercoms at all operating locations, admin building and security points. The EPBAX will have expandability and junction box to be interconnected to the EPBAX systems of the sugar, ethanol and non-plant buildings. The system will have minimum 20 extensions. The Tenderer will provide a wireless handheld walkie talkie system of Motorola / Philips make for intercommunication of all plant personnel with minimum of 15 instruments. The required battery, battery charger, centralized transmission system, etc. to be included. The system will have a frequency which will not disturb any other public or radio system. The tenderer will be responsible for obtaining the in-principle and operating license and the frequency allocation. Statutory fees, if any, will be paid by the Owner.

1.1.6.15 Civil & Structural

a) Construction Specification For Rough Grading

This specification covers furnishing all labour, materials and equipment, and performing the necessary work to complete the clearing, grubbing and excavating, filling, rough grading, consolidation and compacting

i Clearing And Grubbing :-

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


ii Excavation :-

Excavation will include earth, weathered rock and hard rock. Whenever finishing grade is referred to, it shall mean to elevations indicated on the drawings plus or minus thirty millimeters. For descriptive purposes, excavation shall be classified as follows :-

Earth excavation shall be defined as unconsolidated, or consolidated material which can be broken with a pick.

Weathered rock shall be defined as consolidated or cemented material which can be broken with a pointed pry bar or pick.

Hard rock shall be defined as competent consolidated material with few fractures that cannot be broken with a pointed pry bar and must be blasted.

Ditch or channel excavation shall be defined as that excavation between the invert of the channel and the point at which the channel side slope intersects natural or finish grade, whichever is lower

iii Filling :-

Filling shall consist of performing all operations necessary to place the fill to the line and grade. Filling shall be placed in layers that are not over 150 mm thick before compaction, then watered and compacted as hereinafter specified.


In platforms for structures, roadbeds, the top 150mm shall not contain lumps or rock of 60mm size or larger. When filling is to be placed against hillsides or existing fill, the material consists of large rock material or hard lumps which cannot be readily broken, such material shall be well distributed throughout the fill, and sufficient earth or other fine material as it is deposited, so as to fill the interstices and produce a dense compact fill.

iv Watering :-

Watering for compacting backfill material and water required for laying dust caused by grading operations shall be applied as directed by the Owner. The water shall be applied so as to obtain the optimum moisture content for compaction. The application of water will be by a distributor equipped with a spray system that will ensure a uniform application of water. At the direction of the Owner, water may be applied to the excavation area from which the fill is obtained.

v Compaction :-

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

All areas within the bench area of buildings marked, compaction of all roads, shall be compacted by tamping rollers and / or road rollers. The layer excluding the top layer shall be compacted by not less than four passes with the tamping roller. Before the last layer is placed the road roller shall make one pass over the area. The last layer shall then be placed and compacted with the road roller by making not less than four passes. The balance of the fill may be compacted by using air operated or hand rammers, as directed by the Owner.


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

Road roller shall be three wheeled and weight not less than 12 tonnes and shall produce a compression on the rear wheel of not less than 325 pounds per liner inch (60 kg per liner cm) of wheel width.

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

vi Weed Killer :-

All roadway base shall be treated with a commercial weed killer applied according to the manufacturers recommendations.

vii Civil Works Requirements

Scope of Work

The scope of permanent works includes the

construction of all earthworks associated with site levelling and embankments, mass and reinforced concrete foundations to machinery and buildings incorporating all holding down bolts and all site roads, hard-standing and drainage for the structures


Materials

Materials used in the works shall be new and as

per approved list or relevant IS standards. The Owners Representative shall have the right to reject any material that is damaged or has deteriorated and such materials shall be removed from site immediately.

Branded materials shall be handled, stored and

used, and processes shall be carried out strictly in accordance with the manufacturer's instructions and recommendations.

The Owners Representative may require the

Tenderer to obtain at his own expense a certificate in respect of any material stating that it is in accordance with the relevant Indian Standard Specification.

Elevations and Benchmarks

Except where otherwise specified, all elevations

will be in meters above mean sea level with an accuracy of two decimals. The data for all levels will be based on Benchmarks. The Tenderer, on his own responsibility, shall ensure that the Works are constructed in relation to this data. Benchmarks and other points of reference in the vicinity of the Site may be indicated on the Drawings.


viii Demolition And Site Clearance

Removal of Termite Hills

All termite hills shall be demolished and the

surplus material removed to tip. The cavity formed by the removal of the termite hill shall be treated with the solution specified below in "TERMITE PROOFING" and then filled with approved material in the specified manner for in-filling trenches.

Termite Proofing

Termite Proofing shall be undertaken over the

whole area of the buildings and aprons and shall consist of the application of a solution of 5 parts pentachlorophenol and 95 parts of furnace oil (by weight) well mixed together and applied by means of watering cans with fish tail spouts at a rate of 5 liters per m2. Before treatment the surface must be cleared of all rubbish and in particular scrap timber. The treatment shall be on the ground after removal of the top soil and/or soft layer before making up levels.

Site Clearance

The site of the works shall be cleared of all trees,

bushes and vegetation. Trees and bushes shall be uprooted and raked into windrows and burnt. Holes left by stumps and roots shall be filled with suitable material and compacted as specified.


Mature trees required to be preserved for

landscaping purposes will be indicated and marked by the Owners Representative before site clearance commences. The Tenderer shall take all necessary precautions to protect such trees from damage during all phases of the works.

ix Earthworks

The excavation and fillings shall be carried out in

such manner and order as the Owners Representative may direct.

The following definitions of the earthworks materials

shall apply to this tender in which reference is made to the defined materials:

'Top Soil' shall mean the top layer of soil containing more than 5% by weight of organic matter.

'Unsuitable material' shall mean other than suitable material and shall include:

(i) material from swamps, marshes or bogs;

(ii) peat, logs, stumps and perishable material;

(iii) material susceptible to spontaneous

combustion;

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


'Rock' shall mean material which in the opinion of the Owners Representative requires the use of wedges, pneumatic tools or blasting to enable the excavation to be completed, but specifically excludes isolated volumes of rock or other hard material of up to one cubic meter in content.

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

'Ordinary ground' shall mean material which in the opinion of the Owners Representative can be excavated by normal excavation machinery.

b) Construction Specification For Structural Excavation And Fine Grade

The work covered by this specification includes furnishing all labour, materials, equipment and performing the operations necessary to complete the excavation and filling required, for all buildings; structures and foundations and the fine grading.

i Excavation:-

The Tenderer shall perform all excavation required for the various structures and foundations. All excavation shall be to line and grade required for the proper installation and removal of the forms and to facilitate the construction. Excavation for all foundations shall be carried one meter below the floor slab for interior footing or one meter below the finished grade for wall footings and exterior footings.


ii Back- Filling :-

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

iii Compaction :-

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

iv Shoring And Bracing :-

The Tenderer shall furnish and install all shoring, bracing and sheeting as required to adequately support the excavation and to provide safety for the personnel. This shoring shall be removed as the backfilling takes place.

v Fine Grade :-

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

vi Earthworks

Where the excavation reveals a combination of

suitable and unsuitable materials the Tenderer shall, unless otherwise agreed by the Owners Representative, carry out the excavation in such a manner that suitable materials are excavated separately for use in the Works without contamination by the unsuitable materials.


The Tenderer shall dispose of excavated materials in such a manner and, at such time, as instructions provided by the Owner

vii Limits Of Excavation

The excavation shall be carried out to the required

lines, levels, widths and depths.

Before commencing any excavation the Tenderer must satisfy himself as to the accuracy of the levels shown and bring to the notice of the Owners Representative any discrepancies.

Excavations shall be suitably trimmed and leveled

before oversite concrete is placed. In locations where the material is subject to softening, a bottom layer of soil approximately 75 mm thick shall be left in and removed immediately before the placing of concrete.

In the event of over-excavation, the area shall be filled

with selected excavated material or Grade 10 concrete.

viii Protection Of Excavations

The faces of excavations shall be retained with

sheeting, timbering, strutting and shoring as necessary to protect the workmen and to prevent damage to adjacent services and structures.

If, in the opinion of the Owners Representative,

sufficient support of the excavation is not being provided and the work is dangerous to workmen or property or to permanent work, the Owners Representative may suspend operations until sufficient timbering or sheeting is provided.


The Tenderer must take every precaution against

slips or falls and should any occur he shall remove the surplus as required by the Owners Representative.

All necessary temporary drains and culverts shall be

constructed to keep the site free of water. Trenches and excavations shall be kept free of surface water by pumping or other means.

ix Approval Of Bottoms Of Excavation

The Tenderer shall report to the Owners

Representative, at least 24 hours before concreting is required, when suitable bottoms to the excavations have been reached. Any further work executed before the excavations have been inspected and approved shall, if required by the Owners Representative, be removed and new work substituted after the excavations have been approved, at the Tenderer's expense.

x Infilling Of Channels, Trenches And Pipes

When no longer required, all temporary channels,

trenches or pipes which it may have been necessary to construct in or under the permanent work shall be filled with suitable material, approved by the Owners Representative. Infilling shall be performed in layers not exceeding 300 mm thick and each layer thoroughly compacted to the satisfaction of the Owners Representative.

xi Blasting

The Tenderer shall store explosives, if required, in a

store or magazine provided with separate compartments for detonators. Explosives shall be handled by experienced and competent shot firers.


The Tenderer shall ensure that there is no unauthorized issue or improper use of explosives brought on the Site.

Explosives shall be used in the quantities and manner

recommended by manufacturers. The written permission of the Owners Representative shall be obtained for each location or series of locations where the Tenderer wishes to use explosives.

xii Filling By Embankments

Suitable material arising from excavations shall be

used where possible for filling on the Site, unless otherwise specified or required by the Owners Representative.

Where insufficient suitable material is available from

excavations approved suitable material from borrow areas may be used.

Borrow areas within the Site will be those areas

specifically designated as such by the Owners Representative.

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

naturally occurring sand, or sand prepared by crushing natural stone.

The compaction achieved in filling will be measured

by the following tests, carried out in accordance with Indian Standards 'Methods of Testing Soil for Civil Engineering Purposes'.

Density-Moisture Tests

Density Tests


The moisture content of the fill materials shall be adjusted as necessary to achieve the required compaction.

The minimum relative compaction to be achieved in

the compacted areas shall be 100% of maximum dry density as measured above. Any material which, after repeated compaction, does not achieve this figure will be removed.

Filling in areas on which no roads, structures or

services are to be constructed shall be spread in layers not thicker than 100 mm and subjected to as much traffic as possible during construction.

At the end of each day, the surface shall not be left

with areas that can retain water and, if necessary, ditches shall be cut to ensure that this object is attained.

When the state of the weather is such that, in the

opinion of the Owners Representative, it would adversely affect the placing of compacted fill, all such work shall be stopped.

All filling material, whether placed and/or

compacted or awaiting placing and/or compaction which, in the opinion of the Owners Representative, does not comply with the specification or has been damaged by weather or in any other way.

xiii Frequency Of Compaction Test

Each layer shall be compacted satisfactorily before

proceeding with the next layer, with a maximum thickness of 200 mm per layer.


xiv Surplus Excavated Material

The disposal of excavated material shall be carried

out as required by the Owners Representative.

All surplus excavated material, where so required, shall be removed and transported to a tip.

The location of such tip will be specifically designated

by the Owners Representative, within the overall Site or without.

xv Hard Core

Hard core shall be sound approved uniformly graded

stone of maximum size 150 mm.

xvi Clay For Lining

Clay used for impervious lining shall be excavated from borrow pits on site as required by the Owners Representative. The location of borrow pits will be determined by the Owners Representative on site during the progress of work. The maximum haul distance from borrow pits to areas requiring lining shall not exceed 4,000 meters.

xvii Compaction Of Clay For Lining

Materials for impervious linings shall be deposited in

uniform layers, not exceeding 150 mm. The material shall be compacted so that it is homogeneous and free from lenses, pockets, streaks or other imperfections. Each layer shall be compacted using a 'sheepsfoot' roller of sufficient weight for proper compaction, by hand or power tampers or by other means and equipment approved by the Owners Representative.


The dry density of the soil fraction in the compacted material shall not be less than 95 per cent of the laboratory standard maximum soil density (dry) as determined by Test as specified.

If the water content is less than that required for

optimum compaction, water shall be added either at the site of excavation or at site of compaction as necessary.

If the water content is more than that required for

optimum compaction the material shall be rejected for use or compaction shall be delayed until such time as the material has dried out to the optimum water content.

xviii Stone Pitching

Stone pitching shall be of sound, durable, crushed

rock or natural stone as approved by the Owners Representative and shall be uniformly sized between 100 mm minimum dimension to 150 mm maximum dimension.

The stone shall be hand placed in a single layer and

bedded on a uniform surface of approved excavated material to give a uniform finished surface with maximum opening between contiguous stones of 25 mm.

Stone pitching shall be pointed with a mortar of 3

parts sand to 1 part cement.

xix Rip-Rap

Rip-rap shall be of sound, durable, crushed rock or natural stone as approved by the Owners Representative and shall be uniformly sized at 200 mm nominal maximum dimension.


The stone shall be placed and spread to produce the minimum finished thickness with a uniform finished surface.

xx Seeding

The ground shall first be rotovated to a depth of 300

mm, leveled and raked free of stones. Prior to sowing, the ground shall be well watered and seed then spread at the rate of 1 kilogram per 20 square meters. Seed will be covered by raking and the ground consolidated with a light roller.

The area will be watered daily by the Tenderer until the site has been accepted by the Owners Representative.

c) Construction Specification For Concrete

The work covered by this specification includes furnishing all labour, materials, equipment and performing the operations necessary to complete the concrete work. The Tenderer has to prepare the working drawing alongwith the bar bending schedule in detail alongwith the form drawings from the R.C.C. drawing and shall get approved the same, prior taking up the actual work activities at site.

i Applicable Publications :-

All work shall be in accordance with the latest revision of the Indian Standard except where specifically noted otherwise : -

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


Sampling I.S. 1199 Compaction I.S. 2505 I.S. 2506 Rapid Hardening Cement I.S. 8041 Admixtures I.S. 9103 I.S. 2645

ii Materials :-

Cement Cement shall be ordinary portland cement conforming to I.S.269. All cement used in exposed concrete faces of the structure shall be of the same manufacturer. All cement shall be suitably protected from exposure to moisture until used. Special cement, if any, shall be used only after the approval of the Owner/Architect.

Coarse Aggregate Coarse Aggregate shall consist of approved sound crushed rock or gravel. It shall be free of organic matter or other deleterious material. Adequate supplies of coarse aggregate shall be stockpiled sufficiently in advance of construction to permit sampling and testing before use.

Fine Aggregate Fine Aggregate shall consist of approved natural sand, or crushed stone screenings combination of both;and shall be hard and durable. It shall be free of organic matter or other deleterious material. Adequate supplies of aggregate shall be stockpiled sufficiently in advance of construction to permit sampling and testing before use.


Water Water shall be clean, fresh and free from organic or deleterious matter in solution or in suspension, and shall be added in such amount that may not impair the strength of concrete as specified. Water, for mixing concrete, shall be supplied by the Owner, if available at site, otherwise Tenderer has to make his own arrangement for the construction water requirement. For all purpose, the Tenderer shall arrange his own supply, storage and necessary pumping and conveyance system.

Forms Forms shall be of wood or metal, approved by the Owner/Architect.

Admixtures The use of admixtures is encouraged where a sound technical reason justifies it, but with the approval of the Architect/Owner.

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


Expansion joint filler Expansion joint filler material shall consist of formed strips of a durable resilient compound. Where stiffness is lacking in proformed expansion joint filler, the strips shall be encased in saturated felt, asphalt impregnated cotton webbing or other satisfactory material. Any material used for encasement shall be firmly sealed to the body of the joint filler and shall not become detached there-from after immersion in water for a period of 48 hours. Expansion joint filler material shall be manufactured in a workman-like manner and when 10 percent or more of any lot or shipment is of non-uniform or improper construction, the entire lot or shipment may be rejected.

iii Concrete Design Mix And Strength :-

Unless otherwise noted on the drawings, all concrete shall be proportioned so as to obtain a twenty eight (28) days cube compressive design strength of 200 kg/cm2 at preliminary test. The grade of concrete shall be M:15 (1:2:4 approximately) / M:20 (1:11/2:3) or as specified. The design mix shall be prepared by an established testing laboratory and submitted by the Tenderer to the Architect / Owner for approval before use.

iv Grading Of Aggregates :-

Aggregate shall be furnished in primary sizes specified herein and shall be stored in separate batching. Bins and batched as required to confirm to the combined grading requirements. The proportioning of the fine and coarse aggregate may be varied as directed by the Engineer to produce a workable mixture.


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

Location Maximum Size

Coarse Aggregate

Massive Foundations 2 inch (63mm) Typical Foundations 1 inch (38mm) Columns, Beams and Girders 1 inch (25mm) Walls 8 inch (200mm) and thicker 1 inch (38mm) Walls 6 inch (150mm) and thinner inch (18mm) Slab at grade thicker than 4 inch (100mm)

1 inch (25mm)

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

The grading of aggregates shall be as follows :

PERCENTAGE PASSING SIEVES SIEVES Primary Aggregate Size Combined Aggregate Sizes 2 Inch 1 Inch Inch Fine 2 max 1 max max 3 100 100 2 90-100 95-100 2 35-100 100 80-85 100 1 0-15 95-100 65-85 95-100 1 0-10 55-85 100 50-75 50-80 100 0-5 35-70 90-100 45-65 45-75 90-100 3/8 10-30 20-55 100 35-55 35-60 60-80 No.4 0-5 0-10 95-100 30-45 30-45 40-60 No.8 0-5 80-85 20-35 20-35 30-45 No.16 50-85 15-30 15-30 20-35 No.30 25-60 10-15 10-15 10-25 No.50 10-30 5-10 5-10 5-15 No.100 2-10 0-3 0-3 0-5 No.200 0-2 0-2 0-2 0-2


v Storage Of Aggregates :-

Aggregates shall be stored or stockpiled in such a manner that separation of coarse and fine particles of each size will be avoided and also that various sizes will not become intermixed before proportioning. Aggregate in storage shall be adequately protected from dust or other foreign matter and all aggregates, which have become coated with dust or foreign material to such an extent as the Engineer may determine, has impaired the quality of the aggregates, shall be washed or rejected as the Engineer may decide

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

vi Mixing Of Concrete :-

Machine Mixing :

All concrete shall be mixed in batch mixers of approved type except where hand mixing is specifically approved by the Engineer. The capacity of the mixer shall be considered to be rated capacity as given in the manufacturer's catalogue, provided that a quantity equal to the rated capacity can be thoroughly mixed in the prescribed time period and further, provided there is no loss of ingredients during the mixing. Each batch shall be mixed not less than two minutes after all the ingredients are in the mixer and until the mass is uniform and homogeneous. The mixer shall be completely discharged before being recharged. The peripheral speed of the concrete mixer drum shall be approximately 60 m/minute.


Hand Mixing :

Where specifically approved by the Engineer, hand mixed concrete may be made in batches of not more than one cement bag and shall be mixed in a watertight mixing boat placed in a level position. The coarse aggregate shall be placed in the boat and the fine aggregate shall be sprayed on this layer, the two layers together not being more than 300 mm in depth. On this mixture shall be placed the cement and the whole mass turned not less than two times dry; then the whole mass shall be sprinkled with sufficient water evenly distributed, and again turned not less than three times or until uniform consistency is obtained.

vii Amount Of Water And Slump Tests :-

The amount of water added at the mixer shall be in accordance with the design mix and shall be regulated in accordance with the free water in the aggregates and the requirements for workability within the limits of slump test forth. The amount of water, including the free-water in the aggregates, shall not exceed 25 litres per sack of Cement. The equipment for measuring and supplying the water to the mixer shall be so constructed and arranged that the amount of water to be added to the mixture can be measured positively, and the predetermined quantity of water required can be discharged rapidly in one operation. The equipment shall be so designed that water from the source of supply cannot enter the measuring tank while the water is being discharged from the measuring tank into the mixer.


Location Of Concrete Slump Heavy sections & foundations 2-3 inches

(50mm to 75mm) Thin sections 8" and under. 3 inches (75mm) Slabs at grade 3-4 inches

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

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

viii Form :-

The forms shall be smooth, true to line and grade and of sufficient strength to resist any appreciable springing out of shape during the placing of concrete. All dirt, chips, saw dust, tie wire, or other foreign matter shall be removed from the forms before any concrete is placed therein. Before concrete is deposited in the forms, all inside surfaces of the forms shall be coated with an approved form oil. The form oil shall be of high penetrating quality leaving no film on the surface of the forms that can be absorbed by the concrete.

All sharp corners above grade shall be chamfered with 1"x1" (25mm x 25mm) triangular fillets. The fillets or chamfer strips shall be surfaced on all sides.

Forms shall be of sufficient strength to carry the lean weight of the concrete as a liquid without any deflection. Forms for beams, girders and slabs shall be cambered such amount as may be directed.


Form ties shall be approved form clamps or bolts to fasten the forms. The use of twiste