BOKARO POWER SUPPLY COMPANY LTD BOKARO STEEL …bpscl.com/tenders/doc/t_148_4.pdf · MW back...

BOKARO POWER SUPPLY COMPANY LTD

BOKARO STEEL CITY

“REFURBISHMENT OF SHEETS AND GLASS PANES OF

TURBINE HALL“

TENDER SPECIFICATION

FOR

REFURBISHMENT OF SHEETS AND GLASS PANES OF

TURBINE HALL

STEEL AUTHORITY OF INDIA LIMITED CENTRE FOR ENGINEERING & TECHNOLOGY

RANCHI - 834002

NOV, 2018 CET/23/BK/4492/TS/CE/01/R=1

BPSCL CONTENTS

REFURBISHMENT OF SHEETS AND

GLASS PANES OF TURBINE HALL

PAGE 1 OF 4 CET/23/BK/4492/TS/CE/01/R=1

CONTENTS – CHAPTERS

Chapter No. Description Page No.

1 Introduction 1.1 – 1.4

2 Scope of Work 2.1 – 2.6

3 Technical Specification 3.1 – 3.18

4. Defect Rectification 4.1

Sketch

Annexure

Schedules

TASK FORCE LEADER(TFL) HOD

Rajiv Ranjan

Deputy Manager

Sri Rajeev Kumar

General Manager

BPSCL CONTENTS




CONTENTS – SKETCH

SL

NO.

SKETCH NO. DESCRIPTION

1

4492/001

Plan of existing TG building with proposed work

BPSCL CONTENTS




CONTENTS – ANNEXURES

Annexure No. Description No. of Pages

1.1.6-1 Existing drawings of TG room of

TPP(Thermal power plant)

01

2.1.7.2-1 Implementation Schedule 01

BPSCL CONTENTS




CONTENTS – SCHEDULES

Schedule No. Description Page No.

1.7-1 Declaration of site visit 1

1.7-2 List of exclusions 1

1.7-3 List of deviations 1

1.7-4 List of erection equipment for facade

installation

1

1.7-5 List of special tools and tackles

1.7-6 Details of authorised person of bidder during

tender evaluation

1

1.7-7 Requirement of construction water & power 1

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PAGE 1.1 CET/23/BK/4492/TS/CE/01/R=1

1 INTRODUCTION

1.1 GENERAL:

1.1.1 Bokaro Steel Plant is the fourth integrated steel plant in the Public sector

Steel Authority of India Limited (SAIL) and came up in 1972 at Bokaro

Steel City, near Dhanbad, in the heart of coal belt region of Jharkhand.

The plant is located on the southern bank of Damodar River on Dhanbad-

Ranchi highway. It is about 50 km from Dhanbad which is on the main

Howrah-Delhi line of Eastern railway.

1.1.2 BPSCL Power Plant is located in the premises of Bokaro Steel Plant (BSL)

and has an aggregate installed capacity to generate 338 MW of power

besides 2180 tonne per hour (TPH) of steam.

1.1.3 The Plant has 9 boilers (5 boilers each of 220 TPH ,3 boilers each of 260

TPH capacity and 1 boiler of 300 TPH) and 7 turbine generators (one 12

MW back Pressure Turbine Generator (TG), 2 TGs each of 55MW capacity

, 3 TGs each of 60 MW capacity and one 36 MW back pressure TG.

1.1.4 The 6 nos. (Six) turbo generators of TPP & CPP are housed in 2(two) nos.

of TG buildings of TPP (Thermal Power Plant) and CPP (Captive Power

Plant).

1.1.5 One TG (36 MW) is housed in a separate building attached with boiler

no.9.

1.1.6 The TG buildings (TPP & CPP) are having plan area of tentatively 10500

Sq. M and height varying from approximately 25.5m to 43m from (+/-)

0.00 levels, which correspondence to absolute MSL of 230.60M.

1.1.7 The TG building of TPP is having concrete fins supported on MS structural

support in direction of 132kV old switch yard area.CPP building has no

fins. The structural arrangement of CPP is similar to that of TPP. Existing

drawings of TPP are provided in Annexure 1.1.6-1 for ready reference.

1.1.8 The existing TG buildings (TPP & CPP) are having glass facade installation

on three sides. No facade installation is there in boiler area. The existing

glass facades are framed in MS frame in which small glass panes of 3mm

thickness have been provided. These glasses are fixed in structural frame

with the help of putty.

1.1.9 The existing installation is prone to regular maintenance as glasses of

small sizes break regularly due to wind forces etc.. Regular application of

glass putty for stability of glass panes makes the work cumbersome and

hectic. Since the buildings are of considerable height, regular

maintenance to replace glass panes is difficult.

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PAGE 1.2 CET/23/BK/4492/TS/CE/01/R=1

1.1.10 The façade in the present TG buildings are installed more than 45 years

ago. No major modification or up-gradation has been carried out since

then. This system requires regular upkeep and maintenance.

1.1.11 The present TS cover the scope of work envisaged for ”refurbishment of

sheets and glass panes of turbine hall” with the help of new coloured

galvalume/zincalume sheets with translucent sheets in MS frame in the

existing main structural frame of the building on turnkey basis. Some of

the area of TG building shall be of toughened glass in aluminium frame.

1.2 IMPLEMENTATION STRATEGY

1.2.1 The complete job of Refurbishment of sheets and glass panes of turbine

hall of BPSCL is envisaged to be executed through single package.

1.2.2 This tender specification pertains to ‘’ refurbishment of sheets and glass

panes of turbine hall” to be executed on turnkey basis which includes

dismantling of existing glass facade, design and engineering of side

sheeting, supply and erection of complete side sheeting, design, supply

and erection of complete scaffolding system, supply of all necessary

items, modification in the steel structural frame, dismantling of complete

fins of TPP, design and installation of louver in sheeting to serve the

ventilation as per design, toughened glass in aluminium frame etc.

1.2.3 The complete job of façade replacement shall be executed in phase wise

manner such that the activities of the TG building will not get disturbed

and protection of major machinery should be ensured.

1.2.3.1 Details of activities and their duration shall be mentioned by the bidder

in their offer and also to be shown in the implementation schedule.

1.2.4 Other site related details

1.2.4.1 Details of over ground existing facilities at erection site which may need

diversion and special handling equipment to be deployed at site, if any,

are to be clearly brought out by the bidder in their offer.

1.3 INTENT OF SPECIFICATION

1.3.1 The intent of this tender specification is to furnish required details for

enabling the bidder to submit their best offers (technical & commercial)

as per the scope of work mentioned at chapter 2.0, technical

specifications at chapter 3.0, and defect rectification at chapter 4.0.

1.3.2 This tender specification shall be read in conjunction with other

documents enclosed with the NIT.

1.4 SITE VISIT AND OTHER REQUIREMENTS

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PAGE 1.3 CET/23/BK/4492/TS/CE/01/R=1

1.4.1 The bidder shall visit the site, study drawings/ documents and discuss

with the employer/ consultant, if required, regarding any technical

clarification and get himself acquainted with respect to the nature and

extent of work involved. The bidder shall also obtain first-hand

information regarding location, work terrain, climate condition, railways,

roads, airports and communication etc. before offering the bid for the

job.

1.4.2 All materials/ equipment/ machinery/ fabricated items used in the project

shall be according to the specification given herein and any deviation

should be clearly brought-out in schedules of exclusions and deviations

attached with this TS. No mention of exclusions and deviations will mean

that the bidder has accepted the scope and specification given herein.

1.5 DRAWINGS AND TECHNICAL DOCUMENTS TO BE SUBMITTED WITH

THE OFFER

1.5.1 The Bidder shall submit along with the bid, drawings / documents / data

as per the following details:

1) General layout showing disposition of equipment with the existing

facilities such as roads, railway tracks, utility and power lines etc.

2) Dismantling scheme of the existing façade.

3) Complete details of materials used for side sheeting.

4) Connection details of new installation with existing ones.

5) Details of installation material and structural items.

6) Erection Methodologies.

7) Detailed erection activities with procedure.

8) Manufacturers’ catalogues/ brief technical descriptions.

9) Schedule of quantities of materials used in façade installation.

10) Implementation schedule (Bar chart/PERT Network).

11) Scaffolding scheme.

12) Weight and mounting arrangement of each section to be erected.

13) Details of major construction equipment required for carrying out

the job within the stipulated time which they possess, with location

and details of construction equipment, which they would hire to

facilitate the dismantling, and construction/erection activities.

1.6 Drawings & documents listed are minimum requirement only. The Bidder

shall ensure that all other necessary write-ups, and information, required

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PAGE 1.4 CET/23/BK/4492/TS/CE/01/R=1

to fully describe the equipment and system used for completion of

dismantling and erection jobs, are to be submitted with their offer.

1.7 SCHEDULES TO BE DULY FILLED AND SUBMITTED WITH THE OFFER

1.7-1 Declaration of site visit

1.7-2 List of exclusions

1.7-3 List of deviations

1.7-4 List of erection equipment for façade installation

1.7-5 List of special tools and tackles

1.7-6 Details of authorised person of bidder during

tender evaluation

1.7-7 Requirement of construction water & power

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PAGE 2.1 CET/23/BK/4492/TS/CE/01/R=1

2 SCOPE OF WORK

2.1 GENERAL

2.1.1 The bidder shall be responsible for execution of the jobs envisaged for

“Refurbishment of sheets and glass panes of turbine hall “on Turnkey basis.

2.1.2 The scope of work shall cover design, engineering, procurement,

fabrication, supply, transportation, insurance, storage, handling,

dismantling & removal of debris, construction, erection, testing, defect

rectification to the satisfaction of the employer. All material supply shall be

new and best of its kind.

2.1.3 Execution of the project shall have provisions for easy and safe movement

of operation/ maintenance personnel for operation/ inspection of the

running plant. Adequate space should be created for dismantling/ removal

of equipment/ parts.

2.1.4 All the manufacturing/ fabrication works shall be carried out only on the

basis of approved drawings and schemes or as directed by the employer.

Approval given by the employer shall not relieve the bidder of any

obligations under the contract.

2.1.5 Any equipment/ work/ service, which may not have been specifically

mentioned in this document but is necessary for completeness of the work,

shall be clearly brought out in the offer and included in their scope of work.

2.1.6 Scope of Services

1) Receiving of all necessary items for dismantling and facade fixing of

TG building from bidder’s stores/ employer’s stores and transportation

to site.

2) Unloading of equipment at site, unpacking, cleaning up, and checking

for completeness and transportation to site for erection.

3) Transferring of centre lines and levels from standard benchmark(s),

including geodetic survey.

4) Supply of all erection consumables.

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PAGE 2.2 CET/23/BK/4492/TS/CE/01/R=1

5) Arranging tools, tackles, construction & erection machineries, cranes

and other handling & testing equipment, scaffolding, temporary

platforms, erection fixtures, skilled/semi-skilled/unskilled personnel

etc

6) Submission of QAP/test certificates and data sheet from government

approved third party testing laboratory or manufacturer.

7) Arranging and rendering equipment and personnel to employer for

checking the correctness of the work in progress.

8) Arranging inspection of materials at manufacturer’s workshop or

wherever required as per approved QAP.

9) All equipment shall conform to the relevant provisions of Statutory

and other Regulations in force such as Indian explosives Act, Indian

Factories Act, State Factories Act, Indian Electricity Rules, Central

Pollution Control Board, Indian Weights & Measures Act as applicable.

The bidder shall provide all necessary assistance to the employer to

get all the installations within the scope of supply approved by the

concerned legal authorities.

10) Any rectification / modification of existing facilities required during

erection of equipment.

11) The bidder shall be responsible for protection and / or diversion of

underground and all existing over-ground services, wherever required

and / or diversion of the underground and over ground services which

are indicated in the drawing made available to the bidder. In case there

are under-ground services which need to be protected and / or

diverted but are not shown in the drawing, the bidder shall be

responsible to execute the same.

12) Sundry works such as making of holes, grouting, chiselling of holes/

opening through walls, ceiling, floors, steel structures, etc. including

providing inserts as per requirement, cleaning of site periodically and

at the time of final handing over.

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PAGE 2.3 CET/23/BK/4492/TS/CE/01/R=1

13) Periodic transportation including loading, unloading and spreading

the unserviceable material, debris & surplus excavated earth with all

lift and lead within plant premises unless otherwise specified.

14) All instructions in the manuals for assembly, erection, testing and

commissioning of the equipment shall be in English.

2.1.7 Implementation Schedule

2.1.7.1 The project shall be implemented within a period of 09 (Nine) months from

the effective date of contract up to completion. Effective date of contract is

the date of signing of contract or 30 days from date of letter of acceptance

(LOA), whichever is earlier.

2.1.7.2 An indicative implementation schedule is shown at Annexure 2.1.7.2-1.

However, the bidder may improve upon the same and submit a schedule

with their offer, showing all major activities, with respective duration

proposed.

2.1.8 Discipline wise scope of work has been elaborated in the subsequent

clauses of this Chapter.

2.2 CIVIL , STRUCTURAL & SHEETING WORK

2.2.1 Broad scope of work :_

i. Complete design, engineering, preparation & supply of working

drawings of Architectural, Civil, Structural and Ventilation drawings

complete in all respect for the works mentioned in the tender

specification.

ii. Preparation of complete dismantling scheme & supply of working

drawings for dismantling of existing façade of TG building in TPP and

CPP complete in all respect.

iii. Dismantling of entire facade of TG building of TPP and CPP

Dismantling of facade of TG building of TPP: -

Front side (132 kV switch yard side) from axis 1 to 21

Façade facing TG hall entrance area.

Glass panes with frame in stair hall area

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PAGE 2.4 CET/23/BK/4492/TS/CE/01/R=1

Dismantling of facade of TG building of CPP

Front side (132 kV switch yard side) from axis 1 to 21

Facade facing boiler unit 9 side.

iv. Disposal of dismantled item:- As per the direction of Engineer in

Charge (Within 5 Km radius)

Site cleaning, preparation, transfer of benchmarks & geodetic

lines, checking & fixing, aligning of structures, final cleaning

of site after completion of the work shall be under the scope

of the bidder. No separate payment shall be made towards

these and the cost, if any, shall be deemed to be included in

the contract price

v. Erection of colored coated gavalume/zincalume sheets (thickness

shall be as per design but not less than 0.6mm TCT) with the supports

of existing runners and new runners/wall framework in MS(Mild

steel) in the area from where glass panes/sheets shall be dismantled

from TG building of TPP and CPP. Toughened glass (thickness as per

design but not less than 5mm) will be provided. Specification of the

same is provided in chapter 3 of this document.

vi. Erection of glass panels in aluminium frame (Approximately

1000mmx1000mm panels or as per design) in the staircase hall area

.Specification of the same is provided in chapter 3 of this document

vii. Plaster in brickwork wherever required and its painting (including

Primer).

viii. Painting on the existing steel structural frame (column and horizontal

runner) within the battery limit of TG Building.

ix. Painting of all new steel structures.

x. Provision of new rain water pipes and valley gutters of the building

(both CPP and TPP)

xi. Minor civil works shall be considered in this project. Chipping,

modification in brick/concrete work.

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PAGE 2.5 CET/23/BK/4492/TS/CE/01/R=1

xii. Minor PCC and RCC works has been considered.

xiii. Design of ventilation system by providing louver. The output of the

same shall be used in erection of side sheeting along with framework.

xiv. Proper scaffolding work for dismantling and erection activities are

covered under the scope of work.

xv. No work has been envisaged in TG building associated with boiler

no.9.

2.2.1.1 Format of bidder drawing list shall have minimum following fields:-

1) Sl. No.

2) Employer drawing No

3) Bidder drawing No

4) Area

5) Drawing/Document Name

6) Category (Approval/Reference)

7) Discipline

8) Stage (BE/DE)

9) Schedule date of submission

10) Remarks

2.2.1.2 Drawing list shall be in excel format. In case the drawing has more than one

sheet, employer drawing shall include the sheet number as part of drawing

number.

2.2.1.3 Editable format soft copies (3 sets) on CD/DVD of all “As-Built” drawings

(full set of drawings as per the approved drawing list) and assembly

drawings /fixing details

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PAGE 2.6 CET/23/BK/4492/TS/CE/01/R=1

2.3 VENTILATION SYSTEM

I. The scope of work covers design, engineering, documentation,

manufacture, shop testing, painting, packaging, transportation,

supply, installation including associated work of fixed type Louver for

natural ventilation which shall be fitted at suitable locations on

windward & leeward sides of wall frame in TG Hall

II. The purpose of louvers will be to facilitate adequate air flow inside

the shop premises so that ambient condition inside the shop remains

comfortable for working personnel and ingress of rain, dust etc. is

prevented.

III. Design of louvers shall be in line with requirements delineated

in IS: 3103-1975 (INDUSTRIAL VENTILATION OF BUILDING) &

IS:3362-1977 (NATURAL VENTILATION RESIDENTIAL BUILDING)

or any other relevant IS/International standards.

2.4 EMPLOYER’S OBLIGATION

Construction water and power shall be provided to the bidder as per

standard practice of Bokaro Power Supply Company Limited (BPSCL).

2.5 HAZARD IDENTIFICATION & RISK ASSESSMENT

The bidder will identify any hazard / risks which may result in fatal accidents

/severe damage to human health and safety, damage to equipment and

material resulting in loss of time and having cost implication. The bidder will

carry out the above assessment and formulate appropriate action plan to

prevent such incidents. This action plan shall be submitted to the Employer

before start of the work.

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PAGE 3.1 CET/23/BK/4492/TS/CE/01/R=1

3 TECHNICAL SPECIFICATION

3.1 GENERAL

3.2.1 The following climatic conditions prevails at the site of work

Average elevation (Mean Sea

Level)

- 229 m

Barometric Pressure - 980 mbar

Absolute maximum - 46.10C

Absolute minimum - 1.80C

Highest of mean monthly - 43.80C

Lowest of mean monthly - 8.10C

Relative Humidity (Maximum) - 100%

Climate - Tropical humid

Maximum wind speed - 108 km/h

Rain fall:

Annual Average - 1197.3 mm

Heaviest in 24 hr. - 272.0 mm

3.2.1.1 Power Supply

LT Power Supply

Parameter LT

Power Supply 415 V, 3 phase, 50 Hz, 4 wire

Voltage variations (+ 10%, - 15%)

Frequency variation (+ 6%, - 6%)

Combined V&F variation +10%

System neutral solidly grounded

System short circuit level 50 Ka rms. At 415 V for 1 second

3.2.1.2 Any other voltage level required for the installation shall be derived by

the bidder from the above level using his own equipment. All electrical

equipment shall be de-rated for 550C

3.2.1.3 All equipment shall be suitable for continuous operation delivering rated

output without affecting system performance under such variation in

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PAGE 3.2 CET/23/BK/4492/TS/CE/01/R=1

power supply as stated above. The Bidder shall develop all other voltages

AC & DC as required for his system from the above power supply.

3.3 DISMANTLING WORK

3.3.1 Dismantling of glass panes and GI sheets framed in structural steel.

3.3.1.1 Dismantling of glass panes shall be done with utmost care. Proper

scaffolding shall be made as per codal provisions (IS: 4014-1967).Bidder

shall be responsible for safe cutting of structural frames and removal of

glass panes shall be done in proper way, such that day to day activities of

power plant should not get disturbed. Working at height with safety must

be ensured. Proper regulations and standard operational practices of the

power plant must be adhered with. Handling and placing of glass panes

with structural frame should be carried out in phase wise manner. A

proper dismantling scheme should be submitted by the bidder prior to

start of the dismantling jobs of glass panes and structural GI sheeting.

3.3.2 Dismantling of Concrete fins of TPP(Thermal Power plant)

3.3.2.1 Concrete fins were provided in TPP building only. These should be taken

out of the building. Dismantling of concrete in fins etc up to height

approximately 43m from existing ground level should be done by jack

hammer/panel cutting or by any other mechanized means including

cutting of reinforcements, Inserts, jigs. Fixtures, steel supports, supports

grouted in concrete, anchor bolts or any other material (steel & concrete

both) and disposal, levelling etc. of the same within a distance of 5 km or

as directed by Engineer-in charge.

3.3.2.2 The TG buildings of BPSCL are surrounded by switch yard, steam and

utility pipelines, HT lines, live wires etc Proper protocol should be made

before start of dismantling and erection activities. It is the responsibility

of the bidder to follow safety norms of the power plant to ensure safe

working.

3.4 CIVIL,STRUCTURAL AND SHEETING WORKS

3.4.1 Civil Works

3.4.1.1 This specification covers the design criteria for Civil Engineering work. The

term ‘Design Criteria’ includes loading standards, permissible stresses,

functional requirements and quality standards to be adopted as a basis

for preparation of designs and drawings by the bidder. These designs and

drawings will cover buildings for production and non-production

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PAGE 3.3 CET/23/BK/4492/TS/CE/01/R=1

facilities, auxiliary facilities, ancillary buildings and structures, other

miscellaneous civil engineering items of work.

3.4.2 The designs prepared by the bidder will not only provide for the

requirements indicated in this specification but also consider the overall

process requirements, and service conditions. The new facilities shall be

planned in such a manner that the existing structures in the vicinity shall

not be affected. The designs shall be compatible with the existing and

proposed structures.

3.4.3 Standards

3.4.3.1 The design criteria for civil engineering work will be in accordance with

this specification. Detailed instructions on such aspects as are not

indicated herein will be as per the latest standards, codes. In the absence

of suitable IS specification and codes of practices, other recognized

international standards and codes may be followed with the prior

approval from employer.

3.4.3.2 This specification covers design of Civil Engineering items of work. Other

items of work will be designed according to the relevant standards,

recommendations and stipulations referred above.

3.4.3.3 In case anything mentioned in this specification is at variance with IS or

other codes of specification mentioned herein, the provisions of this

specification will prevail.

3.4.4 Setting out and Levelling

The bidder shall set out and level the work and shall be responsible for

the accuracy of the same. He has to provide all instruments and

qualified staffs with labour for getting his work checked by Engineer-in-

Charge, if so desired by the employer. Such checking, if any, shall not,

however, relieve the Bidder in anyway, of his responsibility for correct

setting out.

3.4.5 SAFETY

The bidder shall take adequate precautions to ensure complete safety

and prevention of accidents at site and shall be responsible for

the same. The safety precautions shall conform to the safety

regulations prescribed by the safety code for constructions and

relevant Indian Standard Codes, some of which are listed below:

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PAGE 3.4 CET/23/BK/4492/TS/CE/01/R=1

IS: 3764-1992 : Safety code for excavation work.

IS: 4014-1967 : Safety regulations for scaffolding work.

IS: 4081-1986 : Safety code for drilling and blasting

operations.

IS: 4138-1977 : Safety code for working with compressed air.

IS: 7923-1985 : Safety code for working with construction

machinery.

3.4.6 Keeping Work Free from Water

The bidder shall provide and maintain at his cost, pumps and other

equipment to keep the works free from water and shall continue to do

so until the handing over of the works.

3.4.7 Cleaning of site

The bidder shall keep the site clear on a continuous basis, from muck,

rubbish etc., which may arise out of the work executed by him and

dispose them suitably in allotted areas.

3.4.8 Bench Marks, Reference Pillars etc.

The bidder shall protect all benchmarks, and reference pillars /lines

including ground water gauges from damage during working. In case of

any damage the Bidder shall have to restore the same to its original

condition at his own cost.

3.4.9 Concrete and Reinforced Concrete for Structures and Foundations

Design of all reinforced concrete structures shall be as per IS: 456

– 2000

For reinforced cement concrete, the minimum grade of concrete

shall be M-25 C (with 20 mm and downgraded aggregates) and

for plain cement concrete shall be M-10 B (with 40 mm and

downgraded aggregates).

3.4.10 Load Condition

Supporting structures which may cause vibration shall be designed

for the dynamic effect of equipment together with the direct loads.

The dynamic loads and other relevant data required for analysing

the dynamic effect shall be taken as per manufacturer’s

recommendations.

3.4.11 Material & Workmanship

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PAGE 3.5 CET/23/BK/4492/TS/CE/01/R=1

Following codes may be referred for material and workmanship

Item Relevant codes

Cement IS: 269-2015,IS:8112-2013, IS:455-

2015

Aggregates IS:-383-2016

Reinforcement IS:1786-2008

Structural steel in Shuttering IS: 2062-2011

Admixtures and Chemicals As per standard manufacturer’s

recommendation

Workmanship IS: 2502-1963.

Brickwork IS: 1077-1992, IS 12894-2002.

Safety IS 4014:1967, IS 7923:1985

Grouts As per standard manufacturer’s

recommendation.

Plaster and finishes IS: 1661-1972

Painting Water based emulsion paints with

primer

3.4.12 STRUCTURAL

3.4.12.1 Design & Engineering

The bidder shall carry out the complete design and engineering of the

structural steelwork required for structures as per provisions of IS: 800-

1984.

3.4.12.2 Type of Structures

Generally steel structures shall be of welded beam column type

construction. Steel structures shall generally be fabricated at shop

according to the assembly requirements. Splices in structures required for

transportation, assembly and erection facilities should be developed by

cover plates/angles.

3.4.12.3 Loading

Load shall generally conform to IS: 875 (relevant parts) - 1987 in absence

of any load indicated by the manufacturer of the equipment. Seismic

forces shall generally confirm to IS: 1893, Part I, 2002.

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PAGE 3.6 CET/23/BK/4492/TS/CE/01/R=1

3.4.12.4 Stability and Rigidity

The support structures shall be designed for adequate rigidity and

stability in both the directions.

3.4.12.5 Inspection

All steel structures shall be subjected to inspection by the Employer and

Bidder shall provide all facilities for inspection. All welds shall be checked

visually or by other testing methods.

Unless directed otherwise, inspection shall be made at the place of

fabrication prior to dispatch. Should any structure found not to comply

with any of the provisions of this specification, it shall be liable for

rejection. No structure or a part of it, once rejected shall be resubmitted

for inspection /tests.

3.4.12.6 Material for Steel Structures

All structural steel shall conform to following standards or as

specified in the drawings. Mild steel shall conform to IS 2062:2011

for rolled sections & plates.

The Bidder shall furnish the test certificates conforming to

appropriate standards of all steel materials used for fabrication.

All structural steel shall be free from rust, scales, lamination,

cracks, fissures and other surface defects.

Steel tubes for structural purpose shall conform to IS 1161: 1998

(of Grade Yst. 240).

MS gutters and down pipes shall be manufactured from 5mm &

6mm thick mild steel plates respectively coated with bituminous

paint conforming to IS: 2062-2011.

Steel chequered plates shall be as per IS 3502:2009

Side & roof covering with colored galvalume/zincalume steel

sheets, glazing & translucent sheets.

General :

This specification covers the detailing, supply and erection of

galvanized colour coated sheets with all necessary flashing, fixing

for sides and gables of buildings & as per IS: 14246: 1995

Materials for sheeting

I. Colour coated Galvalume/Zincalume sheets of total

coated thickness (TCT) as per design but not less than

0.6mm with base metal yield strength of 550 MPa shall

be used for side sheeting.

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II. Ridging, Flashing: Colour coated Galvalume / Zincalume

sheets thickness (TCT) as per design but not less than

0.6mm with base metal yield strength of 550 MPa shall

be used.

III. Zincalume/Galvalume coating will be 150 gsm (class AZ-

150), total on both sides.

IV. Final colour of the sheets will be intimated to the bidder

after award of the contract.

V. Flashing, capping, gable and corner trimming shall be

made of coloured sheet as mentioned in the drawing .

Fixing

Fixing of galvanized colour coated sheet shall be as per

manufacturer specification.

Glazing

Toughened glass minimum 5mm thickness shall be used for

glazing. The glass should be got tested according to the

provisions mentioned in IS: 2553-1990(Part-1).

Translucent Sheet

Translucent sheet of minimum thickness 1.10 mm shall be

provided after every seven sheet on the side walls as per IS

12866: 1989.

Gutters & Down Pipes

Fixing of rainwater gutters and down pipes shall be as per IS:

2527-1984.

Bolts and Nuts

All bolts and nuts shall conform to IS: 1363-(Part 1 to

3): 2002, or IS:1364- (Part 1 to 3): 2002, Part 4 (2003),

Part 5 (2002), Part 6 (2002) as applicable and unless

specified otherwise shall be hexagonal. All nuts shall

conform to property class compatible to the property class

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PAGE 3.8 CET/23/BK/4492/TS/CE/01/R=1

of the bolt used. The bidder shall submit test certificates

when called for.

Washers

Plain washers shall be made of mild steel conforming to IS:

5369-1975 unless otherwise specified. One washer shall be

supplied with each bolt and in case of special types of

bolts more than one washer as needed for the purpose

shall be supplied. Tapered washers conforming to IS:

5372-1975 and IS: 5374-1975 shall be used for rolled

channels and beams respectively.

3.4.12.7 Splices in Structures

Shop Splice

Where shop splices in plates are necessary due to non-

availability of members in required lengths, full penetration

defect free sound butt welds shall be made.

Site Splice

Site splice for members required due to transportation, assembly

and erection facilities shall be developed by fillet welds and

cover plates and angles. In case, butt welding in plates is

employed for site splice, the same shall be sound, defect free

and of full penetration.

3.4.12.8 Fabrication

Standard

All fabrication of structural steel works shall be in accordance

with IS:800-1984 and as per the drawings unless otherwise

specified. The tolerances of fabrication of steel structures shall be

in accordance with IS: 7215-1974 unless otherwise specified.

Type of Construction

The steel structures shall generally be of shop welded

construction. Site connections shall generally be provided by

1) Welding with erection bolts.

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PAGE 3.9 CET/23/BK/4492/TS/CE/01/R=1

2) Bolting with black bolts.

Workmanship

Greatest accuracy shall be observed in the manufacture of every

part of the work and all similar parts shall be strictly

interchangeable.

Straightening

All materials shall be straight and if necessary before being

worked shall be straightened and/or flattened by pressure

unless required to be of curvilinear form and shall be free from

twists.

Shearing, flame cutting and planning

Shearing or flame cutting may be used at the Bidder's option

provided that a mechanically controlled cutting torch shall be

used for the flame cutting and that the resulting edge

shall be reasonably clean and straight.

Unless clean, square and true to shape, all flame-cut edges shall

be planed.

Holing:

Holes for bolts shall be drilled to conform to clause 10 of

IS:7215 (1974). All holes, except as stated hereunder, shall be

drilled to the required size. All punching shall be clean and

accurate and all drilling shall be free from burrs. No holes shall

be made by gas cutting process.

3.4.12.9 Assembly:

- All parts assembled for bolting shall be in close contact over

the whole surface and all bearing stiffeners shall bear tightly

at both top and bottom without being drawn or caulked.

- All parts of bolted and welded members shall be held firmly

in position by means of jigs or clamps while bolting or

welding. No drifting of holes shall be permitted except to

draw the parts together and no drift used shall be

larger than the nominal diameter of bolt. Drifting done

during assembling shall not distort the metal or enlarge the

holes.

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PAGE 3.10 CET/23/BK/4492/TS/CE/01/R=1

- Trial assemblies shall be carried out at the fabrication stage

to ensure accuracy of workmanship.

3.4.12.10 Welding

- The welding and the welded work shall generally

conform to IS 816:1969 and 9595-1996 unless otherwise

specified. As much work as possible shall be welded in shops

and the layout and sequence of operations shall be so

arranged as to eliminate distortion and shrinkage stresses.

Electrodes shall conform to IS 814:2004. The Bidder shall submit

manufacturer’s test certificates as and when called for.

- All electrodes shall be kept under dry conditions. Any

electrodes damaged by moisture shall not be used. Any

electrode which has part of its flux coating broken away or is

otherwise damaged, shall be rejected. Any electrode older than

six (6) months from the date of manufacture shall not be used.

Bidder shall submit batch certificate for electrode.

- The edges of plates shall be prepared with an automatically

controlled flame-cutting torch correctly to the shape, size

and dimensions shown in the design and fabrication drawings.

- The welding surfaces shall be smooth, uniform and free from

notches, loose scale, slag, rust, grease, moisture or any other

foreign material.

- The welding procedure shall be arranged by the bidder to

suit the details of the joints as indicated on the drawings

and the position at which welding has to be carried out.

Welding procedure shall cover the following: type and size

of electrodes, current and (for automatic welding) arc

voltage, length of run per electrode or (for automatic

welding) speed of travel, number and arrangement of runs in

multi run welds, position of welding, preparation and set

up of parts welding sequence, pre or post heating, any other

relevant information. The welding procedure shall be so

arranged that the distortion and shrinkage stresses are

reduced to a minimum and that the welds meet the specified

requirement of quality. The Bidder shall employ a competent

welding supervisor to ensure that the standard of

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PAGE 3.11 CET/23/BK/4492/TS/CE/01/R=1

workmanship and the quality of the materials comply

with the requirements laid down in this specification.

- Any weld found defective shall be cut by using either chipping

hammer or gouging torch in such a manner that adjacent

material is not injured in any way. Fusion faces and the

surrounding surfaces within 50mm of welds shall be free

from all mill scale and free from oil, paint or any substance,

which might affect the quality of the welds or impede

the quality/ progress of welding. They shall be free from

irregularities, which would interfere with the deposition of

the specified size of weld or be the cause of defects. All

mill scale within 50mm of welds shall be removed prior to

welding by thorough power wire brushing or by other approved

methods.

- Parts to be welded shall be properly assembled and held

firmly in position by means of jigs and clamps or suitable

arrangements prior to and during welding.

- After making each run of welding all slag shall be thoroughly

removed and the surface cleaned.

- Welded joints should satisfy the following requirements

Strength-quality with parent metal.

- Absence of defects.

Corrosion resistance of the weld shall not be less than that

of parent material in aggressive environment.

3.4.12.11 Criteria for test of weld:

- Visual examination: 100% of the welded joints for fillet welds

and butt welds.

- Ultrasonic method: 100% for all butt-welded joints.

Radiography examination: 2% length of butt welds made by

manual or semi-automatic machine 1% of length of butt welds

if made by automatic welding machine.

- The Bidder shall engage a reputed or any Government test

agency having Level II Ultrasonic and Radiography

examination certificate holder inspector to carry out the

Ultrasonic or X- ray examination tests. The third party shall

carry out tests, interpret test results and recommend

necessary rectification measures, if any. Bidder shall carry

BPSCL



PAGE 3.12 CET/23/BK/4492/TS/CE/01/R=1

out the rectification work as recommended by the test

agency, if any to ensure defect free welding.

- Bidder shall obtain certificates from the testing agency

certifying defect free welds and submit to the employer.

- Tests:

Visual Examination

The Bidder shall conduct visual examination and

measurement of the external dimensions of the weld for all

joints. Before examining the welded joints, areas close to

it on both sides of the weld for a width not less than 20

mm shall be cleaned of slag and other impurities.

Examination shall be done by a magnifying glass which has a

magnification power of ten (10) and measuring instrument,

which has an accuracy of ± 0.1 mm or by weld gauges.

Welded joints shall be examined from both sides.

- The Bidder shall examine the following during the visual

checks:

Correctness and shape of the welded joints, incomplete

penetration of weld metal, influx, burns, un welded craters,

under cuts, cracks in welded spots and heat affected zones,

porosity in welds and spot welds, compression in welded

joints as a result of electrode impact while carrying out

contact welding, displacement of welded element. All

defects observed shall be made good.

The Bidder shall document all data as per standard practices

and submit it to the employer.

3.4.12.12 Shop Assembly

The steel work shall be temporarily shop assembled so that accuracy of

fit may be checked before dispatch.

3.4.12.13 Erection marking

Each fabricated member whether assembled prior to dispatch or

not, shall bear an erection mark, which shall help to identify the

member and its position in respect of the whole structure, to facilitate

erection at site.

3.4.12.14 Controls in the fabrication and assembly of structures

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PAGE 3.13 CET/23/BK/4492/TS/CE/01/R=1

To ensure good quality of workmanship the bidder shall control the

fabrication and assembly of structures. All welds shall be visually examined

and measured for external dimensions by appropriate gauges.

3.4.12.15 Inspection and Testing of Fabricated Structures

- Steel structures shall be inspected at the discretion of the

Employer. The Employer and/ or his authorized representative shall have

free access at all reasonable times to the bidder’s works where the

fabrication work is carried out and shall be afforded all

reasonable facilities by the bidder for satisfying himself that the

fabrication is being undertaken according to the provisions of the

drawings and specifications.

- The bidder shall continuously inform the Employer of the progress in

fabrication work and as to when the individual pieces are ready for

inspection.

- Unless directed otherwise, inspection shall be done at the place of

manufacture prior to dispatch should any structure found not to

comply with any of the provisions of this specification, it shall be

liable for rejection. No structure or part of the structure once

rejected shall be re-submitted for inspection/test, except in cases

where the Employer considers the defect as rectifiable.

- Defects which may appear during fabrication shall be made good

with the consent of and according to the procedure laid down

by the Employer.

3.4.12.16 Measurement

- Measurement for structural steel work shall be made on the

calculated weights of steel work as determined from the

dimensions given on the drawings or any approved amendments thereto.

In the case of mild steel plates, the calculated weights shall be based on

78.50 kg per sq.m. of metal 1 cm thick and in the case of mild steel

standard rolled sections and rods the weight shall be calculated on

the basis of weight per meter run specified in IS 808:1989.

- The weights of all plates and sheets shall be calculated using the actual

dimensions shown in the drawings with deductions for skew cuts and

BPSCL



PAGE 3.14 CET/23/BK/4492/TS/CE/01/R=1

openings irrespective of their size. However, no deductions

shall be made for skew cuts for gussets, rolled sections and holes for

bolts. The weight for gussets shall be calculated from its overall

dimensions.

- Additional weight for weld metal deposited shall be allowed in the

measurements. No deduction shall be made for bolt holes. No

measurement shall, however be made for erection bolts and nuts.

- The cost of all oiling, painting, temporary erection cleats, marking,

packing and delivery to site shall be included in the rates quoted in

the bill of quantities.

- The weights, to which the rates quoted shall be applicable, shall be as

shown on the approved /accepted materials lists and no allowance

for wastage shall be permitted.

3.4.12.17 Erection

General

Erection of structural steel work shall be carried out in accordance with

IS: 800 (1984) and in an expeditious manner in conformity with drawings

and specifications. The erection tolerances of structures shall generally

be as per IS:12843 (1989). The suitability and capacity of all plant,

equipment etc. used for erection shall be to the satisfaction of the

Employer.

3.4.12.18 Storing and Handling of Materials

- The fabricated materials on receipt at site shall be carefully

unloaded, examined for defects, checked, sorted out and stacked

securely on skids above level ground. The ground shall be kept clean

and properly drained.

- The fabricated material shall be verified with respect to markings on

the marking plan. Any material found damaged or defective shall be

stacked separately and the damaged or defective portions shall be

identified by painting in distinct colour. Such materials shall be dealt

with as ordered by the Employer.

- The handling and storing of the component parts of a structure

shall involve the use of method and appliances not likely to

produce injury by twisting, bending or otherwise deforming the

metal. No member slightly bent or twisted shall be put in place

until the defects are corrected and members seriously damaged in

handling shall be rejected.

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PAGE 3.15 CET/23/BK/4492/TS/CE/01/R=1

- All small bends or twists received by members shall be rectified before

such members are put in place, any serious bends or damage shall

be reported at once to the engineer by the bidder for instructions.

3.4.12.19 Setting Out

- The bidder shall be responsible for checking the alignment

and levels all works. These shall be checked well in advance of

starting erection work and the bidder shall be responsible

for any consequences for non-compliance thereof.

- Discrepancies or mismatch, if any, in working drawings shall

immediately be brought to the notice of the Employer for his advice.

- The bidder shall be fully responsible for the correct setting out

of all steel work and erecting it correctly as per alignment and

levels shown on the drawings and plumbing of vertical members.

3.4.12.20 Assembly and Erection

- The bidder shall be fully responsible for stability of erected parts of the

structures during all stages of erection. As the work progresses, the steel

members shall be securely fixed to take care of all dead loads, wind and

erection stresses, including those due to erection equipment or its

operation.

- The bidder shall provide adequate supervision at all stages of the work

and examine each portion of the work for accuracy. He shall also

provide facilities such as, adequate temporary access ladders, tools

and tackles, instruments etc. to the satisfaction of the Employer, for his

inspection at any stage during erection. Irrespective of any inspection

and tests made by the Employer, bidder shall be entirely responsible

for the proper execution of the work.

3.4.12.21 Field Welding

- All field assembly and welding shall be executed in accordance with the

requirements for shop fabrication excepting such as manifestly apply to

shop conditions only. Where the steel has been delivered painted, the

paint shall be removed before field welding, for a distance of at least

50 mm on either side of the joints. Erection facilities shall be developed

by fillet welds and cover plates and angles. In case, butt welding in

plates is employed for site splice, the same shall be sound, defect free

and of full penetration.

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PAGE 3.16 CET/23/BK/4492/TS/CE/01/R=1

3.4.12.22 Painting of existing shop columns and new steel structures

i. Scope of work for painting comprises of surface preparation,

material supply and required quantity of thinner as recommended

by paint manufacturer and application of recommended painting

materials on the surfaces of structural steel work.

ii. Surface Preparation

iii. Application Specification

The fabricated structures, after inspection and clearance,

are to be prepared for painting by either hand tool cleaning

or power tool cleaning corresponding to IS: 1477, Part I,

1971.

Prime coats of painting shall be with Red Oxide Zinc

Chromate primer conforming to IS: 2074 (1992). Finish

coats of paints shall be done with aluminium paint

conforming to IS: 2339 (1963).

Unless specified otherwise, a minimum of two primer coats

and two finish coats of paint shall be applied, each coat

having a dry film thickness of about 30 microns. The total

dry film thickness shall not be lower than 120 microns.

All painting work shall be got done be paint spray

machines.

iv. Limitations in Painting Work

Paint shall not be applied under the following conditions:

- When relative humidity is greater than 85% or surface is

wet.

- During rain, fog and mist.

- Where amount of moisture on surface or that likely to be

caused by subsequent condensation may have harmful

effect.

3.4.12.23 Material and workmanship

Following codes may be referred for material and workmanship

Items Relevant codes

Steel Structures IS: 2062-2011

Bolts and Nuts IS: 1363-1992 and IS: 1364-1994

Washers

IS: 5369- 1975

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PAGE 3.17 CET/23/BK/4492/TS/CE/01/R=1

Electrodes

IS: 2062-2011

Prime coats of painting As per standard manufacturer’s

recommendation

Finish coats of painting IS: 2339-1963

Testing and commissioning IS: 800-1984 and IS: 7215- 1974.

Erection and tolerance in

erection

IS: 800-1984 and IS:12843-1989

3.5 GLASS FACADE IN ALUMINIUM FRAME

Glass glazing in aluminium frame shall be done in some area of the TG

building as per the following specification:-

Structural analysis & design and preparation of drawings for the

specified design loads conforming to IS 875 part III (the system

must passed the proof test at 1.5 times design wind pressure

without any failure), including functional design of the aluminium

sections(conforming to IS: 733 -1983 and IS: 1285-2002) for fixing

glazing panels of various thicknesses, aluminium cleats, sleeves

and splice plates etc. gaskets, screws, toggles, nuts, bolts, clamps

etc., structural and weather silicone sealants, flashings, fire stop -

cum-smoke seals, microwave cured EPDM gaskets for water

tightness, pressure equalisation & drainage and protection against

fire hazard.

Fabricating and supplying serrated M.S. hot dip galvanised

/Aluminium alloy(Make INDAL,HINDALCO,JINDAL or equivalent)

of 6005 T5 brackets of required sizes, sections and profiles etc. to

accommodate 3 Dimensional movement for achieving perfect

verticality and fixing structural glazing system rigidly to the RCC/

masonry/structural steel framework of building structure using

stainless steel anchor fasteners/bolts, nylon separator to prevent

bimetallic contacts with nuts and washers etc. of stainless steel

grade 316, of the required capacity and in required numbers.

Providing and filling, two part pump filled, structural silicone (Dow

corning or equivalent) sealant and one part weather silicone

sealant compatible with the structural silicone sealant of required

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PAGE 3.18 CET/23/BK/4492/TS/CE/01/R=1

bite size in a clean and controlled factory / work shop environment,

including double sided spacer tape, setting blocks and backer rod,

all of approved grade, brand and manufacture, as per the approved

sealant design, within and all around the perimeter for holding

glass.

Making provision for drainage of moisture/ water that enters

the curtain glazing system to make it watertight, by incorporating

principles of pressure equalization, providing suitable gutter

profiles at bottom (if required), making necessary holes of

required sizes and of required numbers etc. complete. This

includes all inputs of designing, labour for fabricating and

installation of aluminium grid, installation of glazed units, T&P,

scaffolding and other incidental charges including wastages etc.,

enabling temporary structures and services, cranes or cradles etc.

as described above and as specified. The item includes the cost of

getting all the structural and functional design including shop

drawings.

Providing, assembling and supplying toughened glass as per

design but not less than 5mm (Make- Saint Gobain, Asahi,

Guardian or equivalent) with Offline Coated Substrate of Colour

as Approved by Engineer in Charge/consultant during detailed

engineering. The Glass should be Fully Tempered/Toughened with

the following properties. VLT = 30 to 40%.Exterior Reflection = 10-

20%. Interior Reflection= 5%±2%. SHGC =0.3 TO 0.4. U value =

3.6to5W/m2K.

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PAGE 4.1 CET/23/BK/4492/TS/CE/01/R=1

4 DEFECT RECTIFICATION

4.1 All the defects noticed during the construction or performance shall be

rectified free of cost by the Bidder to the satisfaction of the employer. The

work shall not be taken to be finally accepted till all the defects are

satisfactorily rectified by the Bidder. The guarantee period for the side

sheeting work of the bidder shall be 12 months

4.2 The guarantee period for the structural glazing work in Aluminium frame

with glasses shall be of 60 months.

4.3 The bidder shall guarantee for its workmanship, materials, design and

satisfactory performance in accordance with relevant specifications and

provisions of the contract. The guarantee for performance shall include

individual items.

4.4 The details of the test procedures, test schedules, test certificates, QAP

for the demonstration of performance parameters shall be submitted to

the employer which shall be mutually agreed upon.

4.5 Final acceptance shall be as per the standard norms.

BPSCL ANNEXURE 2.1.7.2-1




ANNEXURE 2.1.7.2-1

BAR CHART

(REFURBISHMENT OF SHEETS AND GLASS PANES OF TURBINE HALL)

SL.NO. MILESTONE TIME(IN MONTHS) 1 2 3 4 5 6 7 8 9

1

EFFECTIVE DATE OF CONTRACT

2

PREPARATION OF DISMANTLING SCHEME

3

DETAILED ENGINEERING & DRAWINGS

(SUBMISSION & APPROVAL)

4

DISMANTLING & DISPOSAL

5

RESOURCE MOBILISATION FOR

CONSTRUCTION

6

FABRICATION ,ERECTION OF SIDE

SHEETING,ALUMINIUM WORK,GLASS FACADE

AND MINOR CIVIL WORK

SCHEDULE – 1.7-1

BPSCL SCHEDULE – 1.7-1


GLASS PANES OF TURBINE HALL PAGE 1 OF 1 CET/23/BK/4492/TS/CE/01/R=1

DECLARATION OF SITE VISIT

(To be filled up by the Bidder)

I, hereby, declare that I have visited the site to understand the site conditions, and

acquainted myself with atmosphere prevalent therein. I have also understood the

extent of total works involved for this job.

Signature of the Bidder:

Seal of company Name:

Designation:

SCHEDULE – 1.7-2

BPSCL

SCHEDULE – 1.7-2




LIST OF EXCLUSIONS

Sl. No. Reference clause of TS Details of Exclusions Reasons

Signature of the Bidder

Seal of company Name

Designation

SCHEDULE – 1.7-3





LIST OF DEVIATIONS

Sl. No. Reference clause of TS Details of Deviations Reasons



Designation

SCHEDULE – 1.7-4





LIST OF ERECTION EQUIPMENT FOR FACADE INSTALLATION

Sl. No. Description Quantity



Designation

SCHEDULE – 1.7-5





LISTS OF SPECIAL TOOLS AND TACKLES




Designation

SCHEDULE – 1.7-6





DETAILS OF AUTHORISED PERSON OF BIDDER DURING TENDER

EVALUATION

1. Name of Project :

2. Tender No. :

3. Name & Address of Bidder :

4. Name of authorized person (TECHNICAL) :

5. Email address :

6. Mobile No. :

7. Name of alternate authorised person (TECH) :

8. Email address :

9. Mobile No. :

10. Name of authorized person (COMMERCIAL) :

11. Email address :

12. Mobile No. :

13. Name of alternate authorised person (COMM) :

14. Email address :

15. Mobile No. :

Authorised Signatory

SCHEDULE – 1.7-7





REQUIREMENT OF CONSTRUCTION WATER & POWER




Designation

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