GENERAL TECHNICAL SPECIFICATION - Engineering...

STEEL AUTHORITY OF INDIA LIMITED

BHILAI STEEL PLANT

GENERAL TECHNICAL SPECIFICATION

INSTRUCTIONS TO TENDERER (GS – 01)

MECON LIMITED RANCHI - 834002

No. MEC/S/1901/11/38/0/00/00/F1889/R2 JULY, 2007

GENERAL INSTRUCTION TO

TENDERER (CHAPTER-01)

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General Technical Specification

© 2007 MECON Limited All rights reserved

General Page 1 of 1

GS-01

CONTENTS

Sl. No.

Description Page No.

01.

Intent of Specification 1

02

General 1

03

Site Conditions and Infrastructure Facilities 1

04

General Rules and Regulations and Standard 3

05

Safety 4

06

Drawings and Documents 6

07

Progress Report 9

08 Coding Scheme

9

Enclosure

01

Annexure-I – Title Block of Drawing 10

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General Page 1 of 10

GS-01

01. INTENT OF SPECIFICATION The purpose of this general specification is to provide the Contractor with certain general

information on the location and conditions existing at site and to lay down common guidelines and specifications which the Contractor shall follow in designing of the plant and during execution of work as applicable as per his scope of work

MECON LIMITED, have been appointed by the Purchaser for rendering the detailed engineering and consultancy services for setting up the project. The General Technical Specification has been divided into the following: GS 01 : General Instruction to Tenderer GS 02 : Fluid System GS 03 : Electrics GS 04 : Steel Structures & Auxiliary Facilities GS 05 : Inspection GS 06 : Material Handing & Hoisting GS 07 : Civil GS 08 : Air Conditioning and Ventilation System GS 09 : Painting GS 10 : Fire Fighting GS 11 : Architecture GS 12 : Information Technology GS 13 : Preferred Makes

GS 14 : Hydraulics

02. GENERAL The facilities envisaged, the conditions of site, etc have been described in the Technical Specification for the package. Wherever applicable, the contractor should visit the site and satisfy himself of the site conditions and get conversant with other relevant matters.

03. SITE CONDITIONS AND INFRASTRUCTURE FACILITIES 03.01 Site Conditions 03.01.01 Location

Bhilai Steel Plant (BSP), SAIL is located at Bhilai in Durg district of the state of Chhatisgarh in the central region of India. The site lies between 21.150 North latitude and 81.220 East longitude. The nearest convenient rail head is Durg which is about 12km west of Bhilai. Bhilai/Durg stations are on the Howrah-Mumbai rail line of SEC Railway of the Indian Railways

The location of Bhilai is as follows: From New Delhi, the national capital - 1359 kms From Kolkata - 868 kms From Chennai - 1269 kms From Mumbai - 1100 kms

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The distance from State Capital Raipur to Bhilai Steel Plant is 30KM. It is well connected by rail and road network. The nearest national highways are NH 6 & NH 43 crossing through Raipur.

03.01.02 Meteorological Data In the absence of meteorological data at Bhilai/ Durg, the data of the state capital Raipur, 30kms away, are considered. The meteorological details at Raipur are given below:

Ambient Temperature Absolute maximum : 47.70 C Absolute minimum : 3.90 C Highest of mean monthly : 45.20 C Ambient Air Ambient air quality : Industrial

Relative Humidity Maximum : 100% Minimum 7% Climate : Tropical Humid Rainfall Heaviest rainfall in 24 hours : 370.3 mm Annual Average : 1288.8 mm Wind Predominant wind direction : SW to NE(Oct-Feb)and West to East (Mar-Sep) Mean wind speed : 6.8 kmph Maximum wind speed : 45 kmph Altitude Average altitude of the land is 300 m above MSL Temperature inside shop premises is generally taken as 50 C above ambient, unless

otherwise specified.

03.02 Infrastructure Facilities Outside the Plant 03.02.01 Railway

Bhilai Steel Plant is connected to Indian Railways network via Bhilai/Durg Stations of SEC Railway on the Howrah-Mumbai line. The track gauge of SEC Railways as well as of the plant tracks are standard broad gauge i.e. 1676 mm.

03.02.02 Road

The plant is well connected to the country by road. National Highways NH6 & NH43 both pass through Raipur.

03.02.03 Sea Port

The nearest sea port is Vishakhapattanam, approximately 550 Km away from the site by rail.

03.02.04 Air Traffic

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The nearest air port connected to the national network is Mana at Raipur, 30kms away.

03.03 Infrastructure Facilities Inside the Plant 03.03.01 Railway The track gauge for the entire plant corresponds to the Indian Railway standard broad

guage i.e. 1676 mm. 03.03.02 Road Main road and side roads of the Plant shall have roadways of 7.0 m and 4.0 m width

respectively and the temporary roads provided during the construction stage shall be designed to cater the needs of movement of heavy construction vehicles.

04. GENERAL RULES AND REGULATIONS AND STANDARD 04.01 General Rules and Regulations 04.01.01 All plant units with respect to their location, layout, general arrangement and design of

equipment, structural design, etc. shall be safe to the personnel and conform to the relevant statutory requirements issued by Chhatisgarh Government and the Government of India but not limited to the following.

- Chhatisgarh State Factory Rules/Acts. - Indian Electricity Rules/Acts - Electricity Regulatory Commission Act - Indian Petroleum Regulations/Acts - Indian Boiler Regulations/Acts - Indian Explosives Acts - Gas Cylinders Rules/Acts - Carbide of Calcium Rules/Acts - Static and mobile Pressure Vessels Codes (unifired) Rules/Acts - Fire Protection Manual issued by Tariff Advisory Committee (India) - Pollution Control Regulations/Acts

04.01.02 Pollution control measures shall be provided considering the latest norms and

international standards. These should satisfy the stipulations of Central Pollution Control Board and Department of Environment and Forest, Government of India.

04.02 Standard 04.02.01 Preferred Makes of Equipment & Supplies To restrict/minimise stock/inventory of spares, the Purchaser will limit the makes of

equipment & supplies to those listed in the “preferred makes of equipment and supplies” unless other-wise expressly so agreed.

04.02.02 Unit of Measurement All dimensions & weights shall be given in metric system. 04.02.03 Language All drawings, documents, etc. shall be in English language.

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05. SAFETY 05.01 Safety Regulations 05.01.01 The Contractor shall comply with the, relevant Safety Rules and Regulations but not

limited to the following:

- Chhattisgarh State Factory Rules/Acts. - Indian Electricity Rules/Acts - Electricity Regulatory Commission Acts - Indian Petroleum Regulations/Acts - Indian Boiler Regulations/Acts. - Indian Explosive Acts - Gas Cylinder Rules/Acts - Carbide of calcium Rules/Acts. - Static and Mobile Pressure Vessels codes(Unfired) Rules/Acts - Fire protection manual issued by Tariff advisory committee (India) - Pollution Control Regulations/Acts

05.01.02 Strict attention shall be paid to all statutory regulations and safety rules for prevention of

accidents. 05.01.03 The safety posters/regulations for prevention of accidents shall be displayed by the

Contractor at appropriate places. Notices and warning signs shall be displayed for all sources of dangers.

05.01.04 The Contractor is not permitted to construct any temporary road crossing on the rail

tracks for the sake of their convenience at work site. 05.01.05 When the work is carried out at night or in the obscure day light, adequate arrangements

for flood lighting in the working area shall be made by the Contractor at his own cost and got approved by the Purchaser.

05.01.06 All handling/transport and rigging equipment including lifting tools and tackles shall be

checked at regular intervals and kept in good and safe working condition. A register is to be maintained regarding the results of periodical tests/checks and other

particulars in respect of each and every such equipment.

05.01.07 The Contractor must take sufficient care in moving his construction plant and equipment from one place to another, so that those do not cause any damage to the property of the Purchaser or obstruct construction activities of other Contractors.

05.01.08 The Contractor shall depute a full time safety engineer who will exclusively look after all

the jobs pertaining to safety at site and keep close liaison with Purchaser/Consultant. He will be responsible for maintaining safe working conditions at site, promoting safety consciousness among the workmen and reporting to concerned authorities in case of accident/dangerous occurrences.

05.01.09 Before execution of work in hazardous area like

- Gas contamination - Working at height. - Storage of inflammable materials

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- Danger of electric shocks - Explosion risks - Excavations more than 2 m deep, etc.

A protocol should be prepared in association with the concerned agencies of the

Purchaser/Consultant. 05.02 Safety while Working with Explosives. 05.02.01 Explosives shall not be used on the work site by the Contractor without the written

permission of the Purchaser and that too only in the manner and to the extent to which it has been prescribed.

05.02.02 Explosives shall be stored in special premises approved by the Purchaser and at the

cost of the Contractor who shall be liable for all damages, loss or injury to any person or property and shall be responsible for complying with all statutory obligations in these respects.

05.03 Safety Appliances 05.03.01 The Contractor shall provide the safety appliances conforming to the relevant Indian

standards to all their workmen and supervisors engaged by them as well as by the sub contractors.

05.03.02 The Contractor shall ensure that all the workmen and supervisors, are using the safety

appliances regularly during work at site. 05.03.03. Any form of compensation in lieu of safety appliances shall not be permitted. Any

violation in safety provisions or failure to maintain safe working conditions will lead to serious penalty on the Contractor and finally may lead to termination of the Contract.

05.03.04 The workmen of the Contractor deployed for construction and erection in hazardous

areas shall be provided with personnel protective safety appliances of special nature suitable for hazardous working conditions.

05.04 Safety during Construction/Execution 05.04.01 The Contractor shall be responsible for the safety of his workmen and employees. The

Contractor shall ensure that safety practices are followed so as to prevent personal injury to his workmen and also to other persons working/passing by in that area.

05.04.02 The Contractor shall ensure that in case of any accidents, the same are reported without

delay to the Purchaser/Statutory Authorities as per Rules. In case of any injury/accident the Contractor shall bear all the expenditure for medical treatment and shall pay the compensation in case of permanent disability or death.

05.04.03 The Contractor shall ensure that all personnel employed do not stray into other areas.

Any injury caused due to this shall be the sole responsibility of the Contractor. 05.04.04 The Contractor shall ensure that skilled labours required for specific works have

necessary trade certificates and adequate experience of the job. This is likely to be checked by the Purchaser. The concerned operator, mechanics, electricians, fitters, riggers, etc. must be fully conversant with the hazards associated in operation/maintenance of their relevant equipment.

05.04.05 Safer Working Platforms

• Contractor shall use strong and secured planks and boards of the right sizes.

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GS-01

• These planks shall be painted at the edges brightly to warn the workers for any misuse (usually zebra paint)

• Barricades should be put-up to prevent them from falling. • Contractors shall make sure that scaffolds are erected by trained scaffolders. • Supervisors must inspect scaffolds once every week.

05.04.06 Falling Objects and Debris

� No loose materials which can fall down should be kept on the working platforms. � Overhead shelters should be provided to minimize damage from falling objects. � Strong nets to be provided to catch these objects or debris. � Nets must envelop all sides of the building.

05.04.07 Personal Safety Equipment

� Workers must wear approved safety helmets and shoes. � For those working in high places safety belts shall be provided. � The safety belts must be attached to strong anchorage points.

05.04.08 Operating Construction Machine

� Contractors shall make sure that those operating the construction machinery are well trained for their jobs.

� The keys of such machinery shall be kept with the authorized persons. � The keys shall be removed after use of the machine.

05.04.09 Safer Electrical Installations

� Contractor shall use approved types of electrical sockets and plugs. � Proper insulators for all electrical wirings shall be provided. � Wiring should not be allowed to lie on the floor or on the ground.

05.05 Safety in Designing of Equipment 05.05.01 All machinery and equipment must be equipped with safety devices. The safety

provisions shall conform to the recognised standards, safety codes and statutes. 05.05.02 All safety measures as required to be adopted as per the statutory regulations and the

safety rules of the plant shall be strictly followed by the Contractor during the execution of the Contract.

06. DRAWINGS AND DOCUMENTS 06.01 Drawings 06.01.01 The drafting standards adopted in preparation of drawings shall be such that good clean

and legible print of the drawings can be obtained. 06.01.02 For preparation of original drawings guidelines contained in Indian Standard specification

IS:10164-1985 (preparation of engineering drawings and diagrams) shall be followed. 06.01.03 The Contractor shall submit the drawings in any of the following standard sizes.

Size Code Working Space (mm)

Cut Size (mm)

Uncut Size (mm)

A0 811 x 1144 841 x 1189 880 x 1230

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A1 564 x 796 594 x 841 625 x 880 A2 390 x 549 420 x 594 450 x 625 A3 267 x 375 297 x 420 330 x 450 A4 180 x 252 210 x 297 240 x 330

However, Contractor’s standard drawings are exempted from the above size limitations.

It is desirable to keep the same size for all drawings for ease of filing, reference and record keeping.

06.01.04 All drawings shall be oriented to match the plant layout drawings and shall have a key

plan identifying the plant area to which they apply. 06.01.05 All drawings shall be made with the north arrow pointing to the top of the sheet. 06.01.06 There shall be sufficient reference notes and cross references on the drawings to permit

identification of all related drawings and documents which are required for proper understanding.

06.01.07 When a drawing is revised by the Contractor, every change made shall be identified on

the drawing by placing the revision number in a small triangle so as to be easily recognisable. In addition, a record of revisions along with the co-ordinates showing the location of revisions shall be indicated at the left hand bottom corner of the drawings as per standard practice. In case of revision of drawing, for which different number is allotted, the new drawing shall clearly indicate the number of the drawing which it supersedes.

06.01.08 Approval of drawings from the statutory authorities such as the Indian Boiler

Inspectorate, Inspectorate of Explosive, Electrical Inspector, etc. is the responsibility of the Contractor.

06.01.09 Any additional drawings not specifically mentioned by the Purchaser/Consultant but is

required for the approval of drawings, shall be submitted by the Contractor. 06.01.10 The title block of the drawing shall be as per the title block enclosed as Annexure 01. 06.02 Approval of Drawings. 06.02.01 Approval of Contractor’s drawings will generally be accorded within four (4) weeks of

receipt. 06.02.02 Approval of Contractor’s drawings means that these will be checked for conformity with

applicable specifications and general conformity with the engineering requirement for the areas covered in the scope of work. It is understood that approval by the Purchaser’s Consultant does not include checking for drafting and other errors but only reviews of basic concepts and general principles involved.

06.02.03 The Contractor shall be responsible for any discrepancy, errors and omissions in the

drawings and other information furnished by them, irrespective of whether these drawings have been approved by the Purchaser/Consultants or not. The Contractor shall bear all extra cost due to alterations necessitated by reasons of any discrepancies, errors or omissions in the drawings and particulars supplied by the Contractor.

06.02.04 Drawings furnished by the Contractor shall be certified as correct for use and shall bear

the signatures of responsible persons of the Contractor. 06.02.05 Approval of Contractor’s drawings shall not relieve the Contractor of his responsibility to

comply with the intent of the contract, manufacture/fabrication or procurement prior to approval of drawings shall be at the Contractor’s risk.

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06.02.06 The Contractor shall submit 8 sets of drawings to the Purchaser for approval by the

Purchaser/Consultant. 06.02.07 If the drawing is “Approved” then one print shall be returned back to the Contractor duly

stamped “Approved” by the Consultant. 06.02.08 If the drawing is “Not approved” or “Approved as Noted”, then one stamped print with

appropriate comments shall be returned back to the Contractor for incorporation of comments and re-submission of revised drawings for approval in 8 sets within 7 days.

06.02.09 After approval of drawings the Contractor shall submit 10 sets of approved drawings to

the Purchaser. The Contractor shall incorporate the following note on the drawing before taking additional prints for submission to Purchaser.

“Approved by MECON vide letter no. ………………dtd………..”

06.02.10 The drawing shall become a contract drawing after approval and there after the Contractor shall not deviate from them in any way whatsoever except with the written permission of the Purchaser/Consultant.

06.02.11 All reference and information category drawings shall be submitted in 10 sets to

Purchaser These drawings shall be submitted to Purchaser before forwarding the same to the erection Contractor at site for construction/erection activities.

06.02.12 The information category drawings shall not be approved by the Consultant. However,

information category drawings shall be stamped “For Information Only” and one set shall be returned back to the Contractor.

06.02.13 In case any discrepancy is observed on these drawings, same shall be informed to the

Contractor by marking the comments on the drawings. The Contractor shall resubmit these drawings after incorporating the comments in 10 sets to the Purchaser.

06.02.14 After receipt of stamped “For Information Only” drawings, the Contractor shall submit 10

sets of drawings to the Purchaser. The Contractor shall incorporate the following note on the tracing before taking additional prints for submission to the Purchaser.

Stamped “For Information Only” by MECON vide their letter no. ………………………….

dated. ……………………. 06.03 Submission of Drawings, CD, Reproducible and Documents

The Contractor shall submit the following drawings/documents to the Purchaser. 06.03.01 Drawings

MECON PURCHASER 1 Approval category drawings for approval

of consultants 6 Sets 2 Sets

2 Fabrication drawings for approval of consultants

6 Sets -

3 Drawings after approval along with list of drawings (for distribution)

8 Sets 2 Sets

4 Information category drawings 8 Sets 2 Sets 5 Information category drawings after

stamping “For Information Only” by consultants.

8 Sets 2 Sets

6 Erection drawings 8 Sets 2 Sets 7 As built drawings - 2 Sets 8 Spare parts drawings - 2 Sets

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9 Wearing parts drawings - 2 Sets 06.03.02 Compact Disc and Reproducibles

MECON PURCHASER

1 As built drawing of approval category - 1 Set 2 As built drawing of information category - 1 Set 3 Spare parts drawings - 1 Set 4 5

Wearing parts drawings All Manuals

- -

1 Set 1 Set

06.03.03 Documents

MECON PURCHASER

1 Erection manual 1 Set 6 Sets 2 Operating and maintenance manuals 1 Set 6 Sets 3 Storage and reconservation manuals 1 Set 6 Sets 4 Safety manuals 1 Set 6 Sets 5 List of consumables 1 Set 6 Sets 6 List of lubricants and hydraulic oil 1 Set 6 Sets 7 List of special tools and tackles 1 Set 6 Sets 8 Test certificates and inspection certificates in

bound volume 1 Set 6 Sets

07. PROGRESS REPORT 07.01 The Contractor shall submit a detailed PERT Network showing completion time which

would indicate starting and completion dates of all activities of engineering, purchasing, procurement of materials, manufacturing, inspection, dispatch, erection, testing and commissioning, etc. under his scope of work.

07.02 The Contractor shall submit the progress report in such details as may be required by

the Purchaser so as to enable them to monitor the progress of work. 07.03 The Contractor shall submit the progress report every month in the proforma mutually

discussed and agreed upon with Purchaser/Contractor. 07.04 The Contractor shall submit 8 sets of progress report every month as on 20th of the

month so as to reach the Purchaser by 25th of month. 08. CODING SCHEME All drawings/ documents/ equipment/ spare parts/ shipments shall have a coded number

which shall be finalized with the successful tenderer.

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Title Block of Drawing ANNEXURE - I

STEEL AUTHORITY OF INDIA LIMITED BHILAI STEEL PLANT

PROJ. DRG. NO.

CONSULTANT

MECON LIMITED

SUPPLIER’S FORMAT

SUBMITTED FOR

APPROVAL

INFORMATION

REFERENCE

RECORD

CONSTRUCTION

STEEL AUTHORITY OF INDIA LIMITED��

BHILAI STEEL PLANT

GENERAL SPECIFICATION FOR

FLUID SYSTEM (GS – 02)

MECON LIMITED RANCHI – 834002

No. MEC/S/1901/11/38/0/00/00/F1889/R2 JULY, 2007

FLUID SYSTEM

(CHAPTER-02)

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Fluid System Page 1 of 2

GS-02

CONTENTS

Sl. No. Description Page No.

01. WATER SYSTEM 1

01.01 SOURCE 1

01.02 DESIGN CRITERIA FOR PUMP HOUSE 3

01.03 DESIGN CRITERIA FOR PIPE WORK 8

01.04 DESIGN CRITERIA FOR PUMPS 18

01.05 DESIGN CRITERIA FOR COOLING TOWERS 34

01.06 DESIGN CRITERIA FOR PLATE HEAT EXCHANGER 39

01.07 DESIGN CRITERIA FOR SOFT WATER PLANT 43

01.08 DESIGN CRITERIA FOR DM WATER PLANT 50

01.09 DESIGN CRITERIA FOR WATER BASED FIRE FIGHTING SYSTEM 72

01.10 DESIGN CRITERIA FOR VALVES 74

01.11 DESIGN CRITERIA FOR FILTER 81

01.12 DESIGN CRITERIA FOR STAINLESS STEEL FLEXIBLE HOUSES 85

01.13 DESIGN CRITERIA FOR RUBBER EXPANSION JOINTS 85

01.14 DESIGN CRITERIA FOR SLUICE GATES 86

01.15 DESIGN CRITERIA FOR RAW WATER TREATMENT PLANT 87

01.16 DESIGN CRITERIA FOR EFFLUENT TREATMENT PLANT 104

01.17 DESIGN CRITERIA FOR OIL SKIMMER 112

01.18 DESIGN CRITERIA FOR SCALE REMOVAL FILTER 114

01.19 DESIGN CRITERIA FOR SLUDGE SCRAPPER ASSEMBLY 122

01.20 DESIGN CRITERIA FOR CHEMICAL DOSING SYSTEM FOR RECIRCULATION SYSTEM

126

01.21 DESIGN CRITERIA FOR SURGE TANK 132

01.22 SPARES & CONSUMABLES 138

01.23 PRELIMINARY ACCEPTANCE 138

01.24 DATA SHEET 139-190

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Fluid System Page 2 of 2

GS-02

CONTENTS Sl. No. Description Page No.

02. GASES AND LIQUID FUELS

02.01 REGULATIONS 1

02.02 PIPING LAYOUT 1

02.03 DESIGN PARAMETERS 5

02.04 SELECTION OF PIPE SIZE 6

02.05 EXPANSION AND FLEXIBILITY. 7

02.06 VALVES AND MEASURING DEVICES 8

02.07 CONDENSATE DISPOSAL 9

02.08 STEAM TRAPS / MOISTURE TRAPS- 10

02.09 PURGING SYSTEM 10

02.10 BLEEDERS/ VENTS 11

02.11 VALVES AND ISOLATING DEVICES 12

02.12 HOSES & HOSE BOXES 15

02.13 SPECIAL CONSIDERATIONS FOR OXYGEN PIPING 15

02.14 DESIGN CONSIDERATIONS 16

02.15 PIPE SUPPORTS ANCHORS, RESTRAINTS 18

02.16 VALVES AND SPECIALITIES 20

02.17 FABRICATION AND INSTALLATION OF PIPE WORK 21

02.18 THERMAL INSULATION OF PIPELINES 22

02.19 LOAD CALCULATIONS AND FLEXIBILITY ANALYSIS 23

02.20 LOCATION OF PIPE SUPPORTS 25

02.21 FLEXIBILITY ANALYSIS 26

02.22 PIPING MATERIAL SPECIFICATION 27-51

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Water System Page 1 of 192

GS-02

01. WATER SYSTEM

01.01 SOURCE

The irrigation reservoirs in Tandula complex and in Mahanadi river Project (MRP) complex form the sources of water supply to Bhilai Steel Plant. These reservoirs and associated canal systems are owned and operated by Water Resources Department, Chhattisgarh Govt..

1.1 INDUSTRIAL WATER SUPPLY

Industrial water supply for most of the consumers is met from the recirculation system comprising Cooling Pond (Maroda - I), pump houses, supply and return water channels and the distribution network. The losses in the system are made-up from the storage reservoir, which supplies make-up water to the Cooling Pond periodically by gravity.

Separate recirculation systems having cooling towers, pump houses, clarifiers etc. have been provided for some of the units where water requires higher degree of cooling or gets physically and chemically contaminated.

. 1.2 TREATED MAKE-UP WATER SYSTEM

An intake works and treatment plant at Maroda – II will be provided for ensuring treated water including drinking water for the complete additional units.

1.3 SOURCE OF WATER FOR NEW FACILITIES

The additional requirement of make up water for the proposed expansion of Bhilai Steel Plant from 4.0 Mt/y to 7.0 Mt/y will be of the order of 5500 m3/h. In order to conserve water, it is envisaged to re-use the industrial effluents as make up water to various water recirculation systems of the plant after proper treatment.

1.4 ANALYSIS OF WATER

The average water quality report of water available in Maroda - I and Morada – II reservoir is given in Table 1.0 below:.

Table - 1.0

Average water quality report

Sl No. Parameter Unit Maroda - I Maroda - II

Physical analysis

Temperature 0C 26.5 - 35. 0 20.5 – 30.0

Turbidity NTU 8.0 5

1.

pH Value - 8.1 – 8.6 7.7 – 8.8

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Sl No. Parameter Unit Maroda - I Maroda - II

Solids

Total Solid mg/l 162-276 70 - 100

Dissolved Solids mg/l 150 - 264 66 - 94

2.

Suspended Solids mg/l 12 4 - 6

3. Chemical analysis

As CaCo3 mg/l - -

a) Total Hardness mg/l 86 - 136 42 - 62

b) Ca Hardness mg/l 46 - 76 30 - 42

c) Mg Hardness mg/l 40 - 60 12 - 20

d) M Alkalinity mg / l 74 - 68 50-70

e) P Alkalinity mg / l 0 - 6 0-5

f) Chloride mg/l 31 - 50 3 - 5

g) Iron mg/l 0.1 – 0.8 Nil

h) NH3 mg/l 0.2 – 1.0 0.1 – 0.4

i) Ca ++ mg/l 33.6 12.0-16.8

4. Special test

a) O.C.P. mg/l 0.6 – 2.2 0.2 – 1.0

b) Oil and Grease mg/l 1.0 – 2.0 -

c) I.L. mg/l +0.1 - +0.6 -0.6 - +0.4

d) B.O.D (5 day) at

37.00C mg/l 3.0 – 6.10 0.7 – 2.1

1.4.1 The Tenderer shall follow the logical sequence in submission of drawings for the Purchaser’s /Consultant’s approval. The drawings submitted shall be fully dimensioned and complete to the extent that may facilities the Purchaser’s / Consultant’s approval in conjunction with the drawing submitted earlier. Each set of drawing submitted for approval shall be accompanied by detailed bill of quantities, materials specification, unit and total weight. Submission of drawings and their approval within a stipulated period of time as agreed shall be the responsibility of the Contractor. Purchaser’s / Consultant’s approval of drawings shall be only in respect to reviewing the drawings for conformity with the general requirement of the system. However, the approval shall not relieve the Tenderer of his responsibilities/obligations with regard to adequacy of design, final fitment of various parts, assemblies and satisfactory performance and operation.

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GS-02

01.02 DESIGN CRITERIA FOR PUMP HOUSE The layout of the various equipment inside the pump house shall be designed by the tenderer keeping in view the safety of the personnel, accessibility of equipment and space for maintenance.

The Pump house shall be of civil construction, closed on all sides and shall be provided with minimum two entries. One of the entries shall be provided with rolling shutters having space provision of truck entry. Each pump house shall be provided with office room and toilet facilities with drinking water provision. Equipment layout including design load data, equipment foundation size, layout of pump house, details of electrics, cable layout etc shall be furnished by the Tenderer.

Structural platform with ladder shall be provided so that the valves can be easily accessible for operation and maintenance.

The sump/suction chamber shall be designed as per the standard of Hydraulic Institute. Sump model tests shall be conducted, if necessary. The sump/suction chamber shall be compartmentalized in a way to facilitate maintenance of any of the pumps’ suction valve while ensuring running of all working pumps along with one reserve pump ready to operate compartments with provisions to divert the entire flow from the cooling tower/ settling tank to either of the compartments when one of the compartments is under repair/maintenance. Sluice gates shall be provided for isolation of the compartments. The suction chambers / sump shall be provided with drain and overflow connections leading to the nearest storm water drain.

The pump house shall be provided with proper ventilation, electrics, illumination, instrumentation, telecommunication, wall clock and hoisting and handling equipment. The control room and office room shall be air-conditioned All the controls for the recirculation system and cooling tower shall be provided and the control panel shall depict the working condition of various units. The electrics of the pump house shall be designed as per the specification given in the relevant chapter. The capacity of the hoisting and handling equipment shall be selected in such a manner that it is able to handle the single heaviest load. Cranes/monorails with hoist shall be provided as indicated in the relevant chapter.

The pump house shall be provided with suitable ventilation facilities. The details of ventilation shall be as per the write-up of air conditioning and ventilation described in relevant chapter. The pump house shall be provided with necessary illumination facilities along with portable lamps. The details of illuminations have been given in the relevant chapter.

All pumphouses shall have a welding transformer and two (02) nos of 24V transformers for head lamps. The pumphouses shall be provided with a DN15 tapping of compressed-air for service requirements. The compressed-air shall be tapped from the existing plant network with due appurtenances viz- isolation valves at source and consumption point, strainers and moisture traps etc.

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GS-02

The scheme of make-up water supply shall ensure maintenance of normal water level in the sump and prevent wastage through overflow. Level switch shall be provided in the sump which will actuate motor/solenoid operated gate valve on make-up water line to the sump in order to maintain water level within a desired range. A bypass make-up water line with float valve shall also be provided into the sump with isolating facilities. .

The pump house shall be provided with adequate drainage facilities with necessary side slope, channels, etc. leading to drainage sump of suitable capacity. The pump house sump shall be provided with low level alarm and the pumps shall be provided with dry running protection. Total no. of pumps for a particular group shall be selected in the following manners.

Total no. of working pumps for a particular group Minimum no. of reserve pumps

for the group

1 pump 2 to 3

More than 3 but less than 6

2 2 3

Final arrangement shall be decided by the Purchaser / Consultant during detailed engineering stage on case to case basis. In case of drainage pumps, there will be one reserve pump for one working pump. All the cold water and hot water pumps shall be of horizontal, centrifugal type and shall have flooded suction. Each pump shall be complete in all respects comprising the following: Each pump shall have independent suction. The delivery line of each pump shall be connected to the main header with isolating header gate valves for isolating pumps’ delivery valves; in case of space constraints butterfly valves may be used with Purchaser’s / Consultant’s approval. The following flow velocities shall be maintained for the pump suction and delivery branches.

Pipe Diameter Suction side Delivery side

Upto DN 150 mm 0.6 to 1.0 0.9 to 1.5 m/s

DN 200 mm to 450 mm 0.8 to 1.2 m/s 1.2 to 1.5 m/s

DN 500 mm to 1200 mm 1.0 to 1.2 m/s 1.5 to 2.2 m/s

Above 1200 mm 1.5 to 2.0 m/s 2.2 to 2.5 m/s

Each pump shall be provided with a Gate Valve on the suction side and a non-return valve and Gate Valve / motorized butterfly valves on the delivery side. Butterfly valves will be employed for regulatory and auto-control usage; motorized gate valves shall be provided in automated pumping system for pumps’ suction & delivery. Each circulation system shall be connected with two nos. of delivery header from the pumphouse. The water carrying capacity of each header should be such that incase one of the headers is under maintenance the other header should be in a position to carry required quantity of water to the consumers.

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Each pump shall be provided with local indication of pressure on suction side and local indication and signaling of pressure on delivery side Each header shall be provided with suitable number of valves for isolating and maintenance purpose.

Each header shall be provided with local indication of pressure and indication, recording and signaling of flow and temperature, which shall be depicted on the panel of the control room. For drainage pumps two nos HSC, non-clog, self-priming centrifugal pumps of capacity 25 m3/h and adequate head with foot valve shall be provided. The pumps shall not be of mono-block design. The drainage pumps shall operate automatically based on water levels in the sump. The characteristics of the prime mover shall be same as described under the main pumps. For underground pumphouses one no. submersible pump of capacity 200 m3/h and suitable head for draining out the pumphouse shall be provided additionally. It will be connected to nearest storm water drainage system. All the valves of diameter 450 mm and above and the valves requiring remote control operation shall be electrically / pneumatically operated. Electrically operated valves shall be provided with limit switches as a safety measure. Electrically operated valves shall have provision for manual operation also. All Manual valves of sizes of 350 and above shall be gear operated. Frequently operated delivery valves and header valves below DN450 as specified by the Purchaser/Consultant during detailed engineering shall also be electrically operated. Dismantling / Rubber Expansion joints near the pumps on both suction and delivery lines and compensators on the main header shall be provided wherever necessary. Suitable chemical and biocide dosing facilities shall be provided in the suction chambers of the pump houses so as to prevent biological growth, scale/ corrosion if any of the circulating water system. The facilities shall consist of chemical storage tanks of suitable storage time, dosing pumps (metering type) one working and one reserve. The dosing system shall be complete in all respects with tanks, pumps, valves, supports, agitators and necessary pipe-work. Adequate space will be provided in the pumphouse for chemical storage. The pipe network and valves within the pump house shall be adequately supported so as to avoid undue stress on the pumps. Minimum clear gap to be kept between equipment to equipment / pipe should be 1000 mm , between equipment to wall should be 2000mm and between valves to wall should be1000 mm. If height of the equipment is more than 1 m minimum gap should be not less than the height of the equipment. Pump House Operation Philosophy The following interlocks shall be provided, as applicable, in the operation of all the pumps, such that for the starting of any of the pumps: • the level of the liquid in the pump house basin is higher than the low level, • all the pumps shall be tripped when the low-low level is reached.

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Wherever gravity drainage of premises is not feasible, suitable drainage pit shall be provided for collection of drain and stray effluents. Minimum two drainage pumps as specified above shall be provided for automatic operation based on the drainage pit water level. The level control equipment for automatic operation shall consist of the following : a) level indication, b) low level to stop the pump(s), c) high level to start the first pump, d) high-high level to start the second pump, e) high-high-high level for alarm annunciation. Storm Water Drainage Individual storm water drainage network shall be provided. The storm water drainage network shall be designed as a gravity network consisting of a combination of open surface drains, storm water manholes and underground storm sewers, as required. Storm water shall be collected in building apron side/ road side drain and shall be conveyed by a gravity network into the plant storm water system of the Purchaser.

2.1 HOISTING & HANDLING EQUIPMENT: The hoists shall be designed in accordance with the latest edition of IS-3938-1983 standard subject to any modifications and requirements specified hereinafter. Hoist will be operated by pendant push button station. Power to the hoists shall be given by trailing cable arrangement running on inverted T track. Inverted T track shall also be in the scope of the supplier. All trailing cables shall be clamped with PVC or non-metallic Clamps. Safety chains shall be provided to connect the trolleys & safety rope shall be provided to avoid tension of cable connected to pendant push button station. Length of trailing shall be such that loop length shall not exceed 1.5 m. in case of length of travel of the hoists will be more than 30 m intermediate sockets shall be provided to reduce the length of cable. Defects in the materials like fractures, cracks, blow holes, or laminations are not allowed. All parts of the hoist shall be thoroughly cleaned of all loose mill scales, rust or foreign matter & then painted. All parts inaccessible after assembly shall be painted before assembly & assembled while paint is still wet. INFORMATIONS TO BE FURNISHED ALONGWITH THE OFFER

ITEM NUMBER :

� Location : � Capacity : � Duty classification : � Total weight of hoist including : � electrical equipment � Make of hoist block : Speeds with safe working load (hoist, lower &CT :

-Lifting height : a) Above floor level :

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b) Below floor level : kW requirements Type of brakes

Adequate number of manually operated hoists/ electrically operated hoist/Elect. Under slung cranes / EOT cranes shall be provided in the pump house for easy maintenance at erection of equipment. For maintenance of crane there shall be a maintenance platform alongwith a walkway parallel to long travel. Hoisting and handling equipment shall be provided for lifting individual loads weighing 50 kg and over. The type of lifting device shall be selected based on amount of load to be lifted, height of lift and frequency of operation and the layout of the equipment to be lifted. In general if the load of be lifted is 1000kg or more and /or height of lift is 8m and more, electrically operated handling equipment shall be provided.

For pumphouses of ETP of GCP of BF & BOF electric hoist of adequate capacity shall be provided.

TECHNICAL SPECIFICATION OF U/S CRANE

The single girder crane shall be designed, manufactured, assembled and tested in accordance with IS:807/1990, IS:3177/1999, IS:3938/1983 and other relevant codes and practices for the cranes to be used in steel plants, steel industry (IPSS) unless otherwise stated. IPSS (wherever applicable) shall also be followed. INFORMATIONS TO BE FURNISHED ALONGWITH THE OFFER The tenderer shall furnish the following questionnaire duly filled along with the offer

i. Crane No. ii. Nos. off iii Type of crane iv. Capacity (t) v. Span (m) vi. Duty class vii. Location viii. Hoists :

a) Speed with safe working load, m/min b) No. of rope falls supporting the load and specification of rope c) Lift of hook above floor, m d) Drop of hook below floor, m e) kW of motor at specified rating f) RPM of motor g) Make, type and size of brake

ix. Cross - travel

a) Speed with safe working load, m/min b) Wheel base, mm c) No. of wheels d) kW of motor at specified speed e) RPM of motor f) Make, type and size of brake

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x. Bridge

a) Speed with safe working load, m/min b) Wheel base, mm c) No. of wheel on each end-carriage d) Diameter of wheel, mm e) Maximum wheel load, kg f) No. of motors g) kW of motor at specified rating h) RPM of motor i) Make, type and size of brake

xi. Power supply xi. Control voltage xiii. Made and type of control xiv. Total weight of crane, t xv. Total weight of hoist, t xvi. Break-up of crane weight, t a) Structural b) Mechanical c) Electrical xvii. General arrangement drawing showing details as enumerated xviii. List of deviations from the Purchaser’s / Consultant’s Specification.

DRAWINGS AND DOCUMENTS TO BE FURNISHED FOR APPROVAL (BY

SUCCESSFUL TENDERER)

a) General arrangement drawings showing to the scale plan, elevation and side view indicating lifting capacity, height of lift speeds, wheel load, wheel base, over buffer dimension hook approaches etc

b) General arrangement drawing of each hoist blocks.

2.2 OVERHEAD TANKS

Overhead tanks will be provided each at a suitable staging height for supply of emergency water to critical consumers for a short duration in the event of interruption in normal cooling water supply. The overhead tanks will be multi-compartment type, each compartment serving emergency water requirements of individual consumer. EOHT (emergency overhead tanks ) will be partitioned to facilitate maintenance. The filling of emergency water tanks for loss of water under normal operation and supply of cooling water from the tanks under emergency conditions will be under automatic control. Overhead tanks will be provided with overflow, drain and air vent connections. Overhead tanks shall be provided with chequered plate stair case for approach to the top of the tanks alongwith walkable platform all round the tank with hand railings. Overhead tanks storing soft/ DM water shall be inside epoxy painted.

01.03 DESIGN CRITERIA FOR PIPE WORK

The term pipe work referred herein generally cover pipes, fittings (such as bends, tees, reducers, plugs, nipples, sockets, unions, flanges, crosses etc.)., valves of various types

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and functions (such as gate, globe butterfly, plug, ball check, diaphragm, electrically operated, pressure reducing valves, etc.) strainers, filters, hoses, hose couplings hose clamps, hose nozzles, fire hydrant assemblies, pipe supports, corrosion protection etc. Pipe work is intended to convey fluids such as different qualities of water and industrial effluents. The pipe work shall be designed, manufactured, assembled and tested as per the latest standards, codes and recommendations of the Bureau of Indian Standards, ANSI, ASTM, AWWA, or other equivalent international standards. Pipe work shall be complete in all respects including all accessories essential for proper installation, operation and maintenance, even though such items are not specifically mentioned in the specification. Piping system shall be designed with high degree of reliability so that the systems perform the duty of fluid handling without any failure under all conditions of plant operation. Piping layout must follow good engineering practice. Proper attention shall be given to obtain full functional requirement of the piping system with a layout which provides sufficient clearance for other equipment and operating personnel, easy access for operation and maintenance, convenient supporting points and neat appearance. Complete design of piping system shall be subject to approval by the Owner/ Consultant. The design shall take into account the effect of internal/external pressure, thermal expansion, self weight of piping, support reactions, surge and water hammer, earthquake and wind effects at site, corrosion and erosion etc. and any other effects dictated by good engineering practices. Each consumer in a circulating system shall be provided with double header. Each header shall be provided with suitable number of valves for isolating and maintenance purpose. The delivery valves of the pumps should be able to be isolated for maintenance by means of header valves without affecting the availability of other pumps. The Piping systems shall not impose undue forces on equipment terminals. Mild steel / Carbon steel pipelines shall be used in general for water supply facilities and special quality pipes such as GI/ Cast Iron cement mortar lined DI for drinking and SS pipes for soft / DM water, PVC/ MS rubber lined, HDPE Pipes for other corrosive fluids. Material of pipes selected shall be indicated by the Tenderer in the offer and the same will be subject to Purchaser’s /Consultant’s approval. Pipelines shall be generally laid over ground on the structural trestles as far as possible, wherever it is not possible pipelines shall be laid in tunnels /trenches/underground in this order of preference. All openings in the piping shall be kept effectively closed until assembled in the system to avoid foreign matter entering into the system. As far as possible all the pipelines shall be laid together along the piping corridor. The piping corridor shall be parallel to and by the side of roads. The entire pipe network shall be provided with manually operated valves for isolation/controlling purpose. The pipe network shall be provided with air release valves at high points and drain valves at the lower points.

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Pipeline passing under or through equipment foundations or walls of buildings or any other inaccessible structure shall be provided with steel encasing pipes for easy insertion and removal. All the pressure pipes shall be laid with a nominal slope and the gravity network with slope of self-cleaning velocities. Continuous welding MS pipes shall be used for water supply facilities and pipe flanged at regular intervals and at bends shall be used for slurry and other corrosive fluid services. For drinking water, screwed and socketed GI pipelines shall be used up-to 150-mm diameter as per IS1239, P-1 heavy grade. For drinking water service for sizes more than DN150 and for underground laying ductile iron pipe DI K-9 grade will be used. Except where otherwise specified, all piping shall have butt welded connections with a minimum of flanged joints for connections to equipment. Branches shall in general, be formed by welding. Provision shall be made for branches for cleaning and flushing of pipelines wherever necessary. Manholes shall be provided in the gravity pipe networks and the distance between two manholes shall be 30m depending upon the pipe size. Compensators shall be provided on the over-ground pipe network to take care of thermal expansion. Compensators to be provided will conform to relevant IS/ IPSS. Wherever over-ground pipelines are crossing roads and railway tracks, they shall be laid on pipe bridges to provide the necessary clearance for the traffic movement. This should take in to account the various type of vehicles likely to move in the plant. Valves provided on the over-ground pipe network shall be provided with steel structural platforms and access ladders. Walkable platforms with necessary hand rails shall be provided by the side of overhead slime troughs and open gravity network, wherever necessary. Provision shall be made for support of piping which may be disconnected during maintenance work. All large pipes and all long pipes shall have at least two supports each arranged in such a way that any length of piping or valve may be removed without any additional supports being required. Pipe supports shall be capable of supporting the pipelines under all conditions of operation. All the buried pipelines shall be laid with a nominal slope towards the drain point.

All the buried pipelines shall be laid as far as possible at a depth of about 1200 mm, below finished ground level (i.e. the top of the pipelines shall be 1.2 m below the finished ground level). Isolation /control valves drain valves, air release valve provided on the buried pipe network shall be housed in suitably sized covered valve pit and the valve pits shall be of self draining type. The valve-pits to be provided shall be after due approval b y Purchaser/ Consultant. Air release valves shall be provided at the highest points of each

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sector of the pipeline and drainage valves shall be provided at the lowest points of each sector of the pipeline.

Wherever the buried pipelines are crossing the roads and tracks, they shall be suitably encased with mild steel pipes or reinforced concrete casing pipes and the different sizes of the encasing pipes shall be as given below:

Encased pipe diameter Encasing pipe ( For

Flanged pipe) size (mm) Encasing pipe (for welded pipe) size (mm)

Upto 100 300 250

150 400 300

200 500 400 300 600 400 350 600 500 400 700 600 500 800 700 600 900 800 700 1000 900 800 1100 1000 900 1200 1100 1000 1400 1200

In case a number of pipes are crossing road or track, these pipes shall be laid in a reinforced concrete culvert having easy access. Mechanical cleaning and anticorrosive protection of underground MS pipelines shall conform to IS: 10221 – 1982. The anticorrosive protection of pipelines shall consist of the following activities in sequence.

i) Application of one coat of coal tar primer ii) Application of one coat of coal tar enamel iii) One wrap of fiber glass tissue iv) Application of one coat of coal tar enamel v) One layer of fiberglass tissue impregnated in coal tar enamel.

vi) Application of the final coat of a water-resistant white wash.

Alternatively Coal tar based anticorrosion tape as per IS: 15337 – 2003 shall be provided for protection of underground mild steel pipelines. The thickness of tapes shall be 3 mm upto pipe diameter DN 300 mm and 4 mm above pipe diameter of DN 300 mm.

3.1 LAYING BURIED PIPELINES

All buried pipelines shall be laid with earth cover sufficient to avoid damage from pressure of vibration caused by the surface traffic. Minimum earth covering over the pipe shall be 1200 mm from the finished ground levels. For laying of buried pipelines earth work in excavation, back filling and acceptance of trenches etc. shall be as per IS: 5822-1994 and IS: 3114-1994 and IS: 12288-1987.

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The trench shall be so dug that the pipe line can be laid to the required alignment and at the required depth, proper leveling of the excavated surfaces is an essential requirement. If the depth of excavation is more, proper protection for side walls shall be provided till the pipe leveling is completed. The entire pipe trenches bottom shall be covered with local sand bed of 50 mm thick layer. After laying the pipelines, 150 mm thick layer of local sand shall be provided over the sand bed. In case stones, boulders etc. are found at the bottom of the trench which can not be removed completely, the bottom shall be leveled by sand layer for a minimum thickness of 150 mm. Precautions shall be taken at all the times to prevent damage to the coating and wrapping in the pipe lines and appurtenances as applicable by workmen or trespassers during laying or at any other time. Pipe handling slung and any blocking used in handling or storing the pipes must be well padded to avoid damage to pipe and its coating. After laying a pipeline on skids it shall be thoroughly cleaned, inspected and for any damage to the protective coating, satisfactory repair work shall be performed while the pipe is suspended above the trench. Before laying the pipelines, the trenches shall be examined by the Owner and after his approval only the pipes can be laid. After the pipes are erected and tested, the back filling of the trenches shall be done with loose soil free from stones, bricks and metallic pieces, in layers and shall be well rammed and compacted. The underground pipelines shall be provided with pipe-m arkers at regular intervals to facilitate identification. RCC manholes with removable covers shall be provided for the buried gravity network and the maximum distance between two manholes shall be 30 to 50 m depending upon the pipe size. Manholes of adequate size shall be provided at all pipe junctions.

Where the pipelines cannot be laid overhead on stockades and are crossing roads and tracks at too many points in a given area, the pipeline may be laid in walk-able tunnels. Pipelines in tunnels shall be provided with isolating valves, air release valves and drain valves, which are easily accessible for operation and maintenance. Gland type of Compensators shall be provided on these pipelines wherever necessary. Pipelines in tunnels shall be suitably ventilated and illuminated. There shall be minimum two entries for the tunnel. Each tunnel shall be provided with at-least two vertical centrifugal, non-clog type drainage pumps (one working and one standby) and these pumps shall operate automatically based on the liquid levels. Each tunnel shall be provided with at least a monorail and hoist for erection and maintenance purposes. Minimum height of the tunnel shall be of 3.0 m and suitable walkway aisles shall be provided for each tunnel.

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Spacing of Pipes in Tunnels & Trenches

Spacing (mm) Sl. No.

Nominal dia (mm) A B C D E

1 50 150 300 100 150 800 2 65 150 300 100 150 800 3 80 150 300 100 150 800 4 100 150 300 100 150 800 5 125 150 300 100 150 800 6 150 150 300 100 150 800 7 200 300 300 100 300 800 8 250 300 350 100 300 800 9 300 300 400 100 300 800 10 350 300 450 100 300 900 11 400 350 500 100 300 900 12 450 350 550 100 300 1000 13 500 350 600 100 300 1000 14 600 350 700 100 300 1200 15 700 350 800 100 300 1200 16 800 400 900 100 500 1500 17 900 400 1000 100 500 1500 18 1000 400 1100 100 500 1500

The typical cross-section of tunnel/trench showing pipe arrangement is as indicated below:

Actual pipe arrangement during detailed engineering shall be subject to Purchaser’s Consultant’s approval. Pipelines within the shop buildings shall be laid overhead supported form the building columns/side walls/cranes girder etc. wherever this is not possible, the pipelines shall be laid either in tunnel or in pipe trenches (covered with removable slabs of chequered plates).

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Wherever pipelines are crossing form one bay to another parallel bay, they shall be laid in tunnel or supported form the gable end.

3.2 PIPE SPECIFICATION

A) Black Pipes DN 15 to DN 50:

1. End condition : Bevel Ends 2. Material : ASTM.A.53 Gr:B/IS:1239 (Part-I) 1990 3. Manufacturing : Seamless 4. Thickness : As per Schedule 80. (DN15: 3.7 mm, DN20: 3.9 mm, DN25:

4.5 mm, DN32:4.9mm, DN40: 5.1 mm, DN50:5.5mm) B) Carbon Steel Pipes DN 65 to DN150 as per IS:1239-1990(R.A.-2004) : 1. End condition : Bevel Ends 2. Class : Heavy 3. Material : As per IS: 1387 / IS 1239 - 1990 (Part-I) 4. Thickness : As per Schedule 40. (DN65: 5.2 mm, DN80: 5.5 mm, DN100:

6 mm, DN125:6.6mm, DN150: 7.1 mm) C) Pipes above DN 150 as per IS:3589-2001: 1. End condition : Beveled ends for butt welding 2. Material : Carbon steel, Gr. Fe 410 3. Thickness : DN200-DN350: 9.52 mm, DN400 & above: 12 mm Pipes of size more than DN300 will be spirally welded. D) Carbon Steel G.I (Galvanised Iron) Pipes DN 15 to DN 150 as per IS: 1239-

2004: 1. End condition : Screwed up to DN 50, Beveled ends for all the sizes above

DN 50. 2. Grade : Heavy 3. Material : Carbon steel, Gr. Fe 410 E) S S Pipe & Pipe Fittings 1. As per ASTM A 312 – Pipe, seamless ANSI B36.10, Schedule 40 (size 6mm-

200mm) 2. As per ASTM A 358 – Pipe, welded, ANSI B16.9, Class 3000, Schedule 40,

Sizes more than DN250 3. SS butt welding fittings: ASTM A403 WP304, ANSI16.9 4. SS socket welding fittings: ASTM A182 WP304, ANSI16.11 F) MS pipes (without inside surface protection) handling DM/ soft water:

1. upto DN300: seam less { IS 1239, P-1 heavy grade, IS3589,t=9.52 mm) 2. DN300- DN700: 12 mm, 3. more than DN700: 16 mm.

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3.3 TABLE FOR MAXIMUM SPAN OF SUPPORTS

Nominal pipe size (mm) Maximum span for liquid services (m)

25 2.1

40 2.7

50 3.0

65 3.4

80 4.0

100 4.3

150 5.2

200 5.8

250 6.7

300 7.0

350 7.6

400 8.2

450 8.5

500 9.2

600 9.8

900 12.0

1000 15.0

Note: Vertical pipe work shall be clamped at intervals of 3.5m (approx.) and at the base of each riser. Maximum span at the place of turning shall be 0.7 times of normal span.

Dimensional Performance and End Finishes

Tolerance on outside diameter of the pipe and specified thickness shall conform to the limits laid down in IS:3589-2001. Finish pipe shall not deviate from straightness by more than 0.2% of the total length. Pipes to be butt welded shall be supplied with ends beveled to an angle of 30 degrees (+ 5 degree – 0 degree) measured from a line drawn perpendicular to the axis of the pipe. The root face shall be 1.6 ± 0.8 mm. Method of Quality Control in Welded Joints Following steps shall be taken by the Contractor, besides controlling quality in general, to make effective control in carrying out welded joints.

a) Welding procedures shall be prepared in line with IS: 7307 (Part – I) – 1974, reaffirmed in 1991 and tests shall be carried out to quality procedures. Number of procedures will depend on variables like positions of welding, thickness range etc. Once a welding procedure is qualified, strict adherence to it shall be made during actual welding.

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b) Welders employed shall be qualified as per IS: 7310 (Part – I) – 1974, reaffirmed

in 1987 after passing necessary tests.

c) Welding consumables shall be of approved type. Such consumables are, however, subject to qualifying initial check tests as per IS: 814-1991.

d) The Contractor shall strictly follow approved welding procedures during actual

welding. Besides, the following stages of inspection shall also be carried out:

i) Weld edge preparation before welding, proper fit up, position of welding, cleaning of slag between the passes, proper weld profile etc., shall be checked visually amongst others.

ii) Non-destructive tests of weld of welded joints shall be carried out as per approved procedures/ drawings.

Preparation of Joints The Contractor shall prepare the edge correctly to the shape, size and dimensions of the vee-grooves as per ANSI B-16.25 unless otherwise specified in drawings/ documents. The welding surfaces shall be smooth, uniform and free from fins, tears, notches or any other defect which may adversely affect welding and shall be free from loose scale, slag, rust, grease, paint, moisture or any other foreign material. The clean surface shall extend to about 10 mm beyond the welding faces to avoid contamination of the weld metal with foreign material and to avoid unsound weld deposit. Assembly, Alignment & Welding

The sequence of welding shall be so planned and followed that there shall be a balance of welding about the neutral axis of the fabrication. The Contractor shall employ sufficient number of welders working at the same time in diagonal quadrants of the shell using back-step method of welding. The rate of progress of each welder shall be more or less equal and quality uniform. The general direction of welding shall be towards the free end of the joint, but in a long joint as in shell fabrication, back-step technique shall be used to reduce distortion. To minimize internal locked up stresses due to welding, the vertical joints for the shell shall be welded and completed to a circular course and then the horizontal circumferential seam welded. However, before the welding of horizontal seam started, the complete circular course shall be aligned and adjusted for their correct axes. Alternatively, the Contractor shall complete each course in all respect on ground and then the pre-assembled course shall be listed and placed in position. In such a sequence and planning, the same principle of balancing of weld about the neutral axis shall be followed and the method of fabrication of each course shall be similar to fabrication of penstock pipes of transmission/ industrial pipelines of bigger diameter. Pipe and attachment shall be aligned properly by accurate and permanent methods prior to welding. If tack welds are used, the tack shall be either fused into the first layer or weld or else chipped out. Tests on welded joints (a) Visual examination

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The Contractor shall conduct visual examination and measurement of 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 that 20 mm shall be cleared of slag and other impurities. Examination shall be done by magnifying glass which has a magnification power of ten (10) and measuring instrument which has an accuracy of ± 0.1 mm of by weld gauges. Welded joints shall be examined from both sides. The Contractor shall examine the following during the Visual examination: - i) Check the correctness of shape and size of the welded joints ii) Incomplete penetration of weld metal iii) Influx iv) Burns v) Under cuts vi) Un-welded crates vii) Cracks in welded spots and heat affected zones viii) Porosity in welds and spot welds ix) Compression in welded joints as a result of electrode impact while carrying out

contact welding x) Displacement of welded element. The Contractor shall carryout any or all tests as specified hereinafter to satisfy the Purchaser / Consultant about the acceptability of the welded joints, as directed by the Purchaser / Consultant.

(b) Liquid Dye-penetrant Test

Liquid dye-penetrant tests shall be carried out in accordance with IS: 3658-1981, reaffirmed in 1991 for surface/ sub-surface defects.

(c) Test by Blowing

The surface of the weld shall be covered with soap solution consisting of one (1) litre of water and hundred (100) grams of soap. Compressed air shall be blown from the opposite side at pressure of 4 to 5 kg/cm2. The distance between the tip of base and the weld shall not be more than 50 mm. Any formation of soap bubble will indicate welding defects. Portable compressor shall be arranged by the Contractor, if necessary, for this purpose.

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Tolerance Deviations for assembly of welded joints may be permitted to the following extent:

Tolerance

Sl. No.

Manual arc Automatic

a) Source butt-Joints

i) Gap between the ends of plates

+ 2.00 mm - 1.00 mm

± 1.00 mm

ii) Stepping of one plate over the other

1.00 mm 2.00 mm

b) Single Vee-groove Joints

i) Bevel angle ± 5 deg. ± 5 deg. ii) Gap between two + 2.00 mm

- 1.00 mm + 1.00 mm

iii) Stepping of one plate

over other 2.00 mm 2.00 mm

c) Lap Joint i) Overlap 5.00 mm 5.00 mm ii) Gap between the

surface 2.00 mm 1.00 mm

d) Tee-filler Joints i) Gap between the edges

of the web and the surface of the flange

2.00 mm 2.00 mm

01.04 DESIGN CRITERIA FOR PUMPS 4.01 HORIZONTAL & VERTICAL CENTRIFUGAL PUMPS

All the pumps provided in the pump house shall be horizontal centrifugal type with flooded suction. For drainage pumps HSC, non-clog, self-priming centrifugal pumps of capacity 25 m3/h and adequate head with foot valve shall be provided. The pumps shall not be of mono-block design. As far as practicable, pumps of reputed indigenous makes shall be preferred. Pumps shall be HSC SSSD type. Vertical pumps shall be provided for power plant applications, pumps’ rotational speed shall be 750 rpm (8-pole drive motor). The slurry pumps for ETP of GCP of BF & BOFs shall be ESTD pump directly coupled

with motor. The drive motor shall be 4-pole motor. The bearings shall be oil-lubricated.

The horizontal pumps shall be mounted on a common base plate with the motor and shall be directly coupled to the motor thorough a flexible coupling without any gear reducer. In case of slurry pumps use of fluid coupling may be permitted.

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The pumps (horizontal as well as vertical centrifugal) will be designed, manufactured and tested as per IS:1520-1980, IS:5120-1977 R.A.1991, IS:9137-1978 R.A.1993 or as per international standards acceptable to the Purchaser / Consultant and will be suitable for the required duty conditions and capacities. The pumps and their auxiliary equipment shall be suitable for the required duty conditions and shall be designed and constructed for continuous duty at full load. The centrifugal pumps shall be suitable for a capacity range of 25% to 125% of duty point capacity. The motor capacity shall have a margin over its BHP absorbed at the pump shaft at duty point and the margin shall be 25% for motors of rating upto 15kW, 20% for motors of rating 18.5kW to 160kW and 15% for motors of rating 200kW and above. The above margin shall be in addition to temperature derating. The pumps of kW rating more than 250 kW shall be of synchronous speed 1000 rpm/750 rpm. For pumps less than 250 kW motor rating, rpm shall not be more than 1500 (drive motor shall be 4-pole motor) unless otherwise specified. The equipment and auxiliaries shall be designed for quick and economical maintenance. The equipment shall be easily dismantable without disturbing the suction and delivery pipe connections. The equipment design shall incorporate provisions for reduction in noise level. The rotating elements of the pumps shall be checked for critical speed in bending as well as in torsion. The critical speeds shall be at least 30% away from the normal speeds for units with flexible shafts and at least 20% away from the maximum operating speed in case of stiff shafts.

All passages inside the pump casing and impellers, which may be inaccessible to machining, shall be ground to a smooth finish as far as practicable. The direction of rotation shall be clearly marked either by incorporating it on the casing or by separate metal plate arrow securely fitted to the casing.

• The head – Vs – discharge characteristics of the pump shall be continuously rising

form the duty point to the shut off point without any zone of instability. The required duty range for a pump shall be on the stable portion of its head capacity curve close to the best efficiency point. The head developed at the best efficiency point shall be close to the required differential pressure so that throttling is not required at pump discharge. The power-vs- discharge characteristics shall be non-overloading type. The shut-off head shall be minimum 20% /15 mWC (whichever is more) than the rated head of the pump.

• The pump flow rating shall have 10 % margin over the process flow value.

• Pump-motor shall be selected in such a way that tripping of a working pump will not

result in run-out condition and overloading of running pump-motor.

• The pump shall be so selected and installed that the available NPSH is not lower than the required NPSH even in the most adverse operating conditions.

• The pump shall be of proven make and design having material of construction which

is the best of its kind for the particular application and shall be manufactured using

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best engineering practices under strict quality control. Each pump shall be tested as per the standards stipulated elsewhere in this document. The test shall include hydrostatic test, static and dynamic balancing tests, performance tests material tests and motor routine tests.

• The pump shaft and bearing shall be adequately sized to take the unbalanced forced

due to mal-operation. The pump gland shall ensure proper sealing without excessive tightening of the packing. Proper cooling and flushing arrangement for the gland shall be provided wherever required.

• All moving parts of the pump shall be adequately guarded to prevent any injury to

operating personnel. • Pumps shall be designed and installed keeping in view the easy accessibility of its

parts for maintenance. All end suction pumps shall be of back-pull-out design and shall be provided with spacer coupling of adequate length.

• Mechanical seals shall be provided at all pumps envisaged for closed loop circuit as

specified by the Purchaser/Consultant during detailed engineering. . • Minimum no. of standby pump shall be provided for each group of clear water pumps

and drainage pumps as specified in the design criteria for pump house. The group of Pumps for scale water or other abrasive slurries shall be provided with at least two standby units. Special abrasion resistant material shall be used for these pumps and the design shall allow easy replacement of parts subject to wear and tear.

• An isolating valve shall be provided on the suction line of each pump and another

isolating valve together with a non-return valve shall be provided at the delivery line of each pump. Pressure gauges shall be provided at the suction and delivery flange of each pump.

• The suction pipeline shall be laid at a constant down ward slope from pump centre

line to the suction chamber. Reducers used in the line shall be eccentric type to keep the top of the suction line straight.

• Each pump shall be provided with adequate safety interlocks including overload and

dry running protection. • Dismantling joints shall be provided on the delivery side of large size pumps to

facilitate quick maintenance, wherever required. • All pumps shall be provided with suitable lifting attachments and each pump

installation shall have suitable handling facilities. • A clear minimum gap of 800 mm shall be maintained between the pump and the

adjacent piping, other equipment or structures for proper movement. In case the height of the top most part of the pump from the working floor is more than 1.0 m, the minimum clearance shall be increased to 1000 mm.

• The details of pumps should match with the drive motors throughout the working life

of these equipments and to meet operational requirement. High-speed motors of 3000 rpm shall not be used for the cooling water circuit supply/return pumps, process pumps, make-up water pumps, drinking water pumps, fire water pumps. . Working hour meter shall be provided on control panels to monitor conditions and subsequent ageing / reduced efficiency, etc.

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• Vibration readings, etc. of new installation shall be supplied. • Pumps shall be installed and commissioned as per manufacturer’s instructions. A

continuous running for 72 hours shall be required before final acceptance is given to the pumping installation.

4.01.01 Shop testing of pumps

• All materials, casting and forging shall be of tested quality. • Pump casing shall be of robust construction and hydrostatically tested at 200% of the

rated pressure or 150 % shut off pressure, whichever is higher. The test pressure shall be maintained for at least 15 minutes.

• The impellers along with any other unmachined rotating parts shall be tested for

proper balancing in order to avoid undue vibration during operation. • Performance tests shall be carried on each centrifugal pump. Performance test shall

be made to determine the following.

a) The discharge against a specified head when running at a specified speed under a specific suction head.

b) The power absorbed by the pump at the shaft (BHP) under the above-specified conditions.

c) Efficiency of the pump under the above specified conditions. d) Variation of required NPSH with discharge.

• The pump accessories like bearings, couplings etc. shall be subject to shop tests as

per manufacturer’s standards. • The materials of construction of various components of all equipment and material

covered under the scope of his specification shall be certified by the contractor with regard to their compliance to specifications laid down for them under relevant clauses of applicable standards and /or the manufacturing drawings of the contractor duly approved by the Purchaser / Consultant. Formal material test certificates to the effect shall be issued by the contractor.

• All test results and certificates including material test certificates shall be submitted

for approval to the Purchaser / Consultant before dispatch of equipment. The vertical centrifugal pump sets shall be supplied with flange mounted vertical motors, motor stool, base plate, coupling, column pipe, delivery pipe, suction strainer, companion flanges, gaskets, bolts, nuts, washers, etc. A stainless steel name plate shall be furnished and securely attached by stainless steel pins at an easily accessible point on the pump. The plate shall be stamped with the following minimum information: - - Name of Manufacturer - Model No. - Purchaser's item no. or tag No.

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- Serial number of pump

- Capacity in cubic meters per hour - Pumping head in meters of liquid column

- Specific gravity of liquid pumped - Revolutions per minute

- Pump input power, kW

- Motor rating, kW

- Design code IS/IPSS:

4.01.02 MATERIAL OF CONSTRUCTION FOR PUMPS A) HORIZONTAL CENTRIFUGAL PUMPS:

Sl. No

ITEM MATERIAL

a) Casing CI IS: 210 FG260 b) Impeller CF8M c) Shaft En8 / SS410 d) Shaft sleeve SS410 (H) e) Wearing rings CI FG 220 / CF8 f) Shims & packings Brass IS: 442 g) Neck ring CI FG 260 / CF8 h) Lantern ring CI FG 220 i) Gland CI FG 220 j) Bearing end cover CI FG 220

k) Bearing Housing CI FG 220 l) Coupling Pump & motor CI FG 260

m) ‘O’ rings Nitrile Rubber n) Sleeve nuts SS 410 o) Cowl nuts SS410 p) Base plate MS Fabricated

B) VERTICAL CENTRIFUGAL PUMPS:

Sl. No.

ITEM MATERIAL

1 IMPELLER CS ASTM A 216, CF 8M 2 CASING CAST IRON (IS 210 FG 260) 3 CASING RING CAST IRON (IS 210 FG 260) / CF8 4 SHAFT EN 8 / SS410 5 SHAFT SLEEVE SS – 410 (H) 6 GLAND CAST IRON

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Sl. No.

ITEM MATERIAL

7 BASE FRAME M.S FABRICATED 8 COMPANION FLANGES M.S 9 COLUMN PIPE M.S 10 SUCTION STRAINER M.S GALVANISED

For handling scale water and slurry water (ETP of GCP of BF & BOF) Ni hard impeller and casing with SS shaft will be used. The above MOC is for guidance, MOC of all pumps will be subjected to Purchaser’s /Consultant’s approval during detailed engineering.

4.02 VERTICAL TURBINE PUMP

Vertical Turbine Pumps along with their auxiliary equipment shall be suitable for the required duty conditions and shall be designed and manufactured for continuous duty at full load. The vertical turbine pump shall be designed, manufactured and tested as per IS: 1710 – 1989 (Reaffirmed 1999). Vertical pumps are envisaged only as supply water pumps for Power and Blowing Station (TBS & TGS), for such usage vertical pumps may be supplied with bearings submerged in water. The motor rating shall be maximum of the following requirements: - a) 15% margin over the pump shaft input power at the rated conditions. b) 5% margin over the maximum pump shaft input power required within its operating

range including the shut-off point.

The above margin shall be in addition to temperature derating. Capacity Vs discharge pressure curve for each pump shall preferably be continuously drooping from the shut-off point to the rated operation point and be suit

GENERAL TECHNICAL SPECIFICATION - Engineering...

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