DESEIN

Volume-VI: Civil, Structural & Architectural Works

INTRODUCTION

Ennore Thermal Power Station of Tamil Nadu Electricity Board (TANGEDCO) has existing generation capacity of 450 MW, which consists of 2x60 MW units and 3x110 MW units. TANGEDCO proposes to add 1x660 MW unit. Name of the project Location : : 1x660 MW ETPS ANNEXE Situated in Ernavur village, Ennore at a distance of 20 kms from Chennai City. Longitude: Latitude : Access to site by Road & Rail : 80 18 29.26 East 13 12 02.87 North
o O

The site is located 20 kms from Chennai City. Nearest Railway station is Kathivakkam station is about 2 km from the proposed site. Chennai (Meenambakkam) Ennore Ambient air temperature: Max. 41.5 C Min. 17.6 C Wet bulb temperature Annual mean humidity : : 23.9 C 74% 1215.3 mm : : 50 m/s January to March West North west Direction April to October South and south west direction Seismic zone : Zone III
o o o

Nearest Air port Nearest Sea port Meteorological data

: : :

Average annual rainfall : Basic wind speed Wind direction

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:1

DESEIN

Volume-VI: Civil, Structural & Architectural Works

1.0

CODES AND STANDARDS Following is a general listing of Codes and Standards to be used in the design of the Plant. Specific applicable codes and standards will be identified in System Design Descriptions / Technical Specifications as appropriate. The latest editions / revision of following codes and standards along with addendums / amendments, if any, shall be followed:

1.1

General a) Internationally accepted design Codes and Standards where Indian Codes are not available and which are equivalent to Indian Standards. National Building Code of India. Accepted Standards and good Practice listed in the appendix to National Building Code of India. IS:1200 : Method of measurement of Building and Civil Engineering Works. IS:1256 : Code of Practice for Building Byelaws.

b) c)

d) e) 1.2

Earthwork a) IS-1498 : Classification and identification of soils for General Engineering purpose Safety code for excavation work Safety code for working with construction machinery

b) c) 1.3

IS-3764 IS:7293

: :

Concrete a) b) IS-269 IS-383 : : Ordinary and low heat Portland cement Coarse and fine aggregate from natural sources for concrete Mild steel and medium tensile steel bars and hard drawn steel wire for concrete reinforcement Portland slag cement Code of practice for plain and reinforced concrete Test Sieves (all parts) Methods of test for strength of concrete Methods of sampling and analysis of concrete Hard drawn reinforcement steel wire fabric for concrete

c)

IS-432

d) e) f) g) h) i)

IS-455 IS-456 IS-460 IS-516 IS-1199 IS-1566

: : : : : :

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:2

DESEIN

Volume-VI: Civil, Structural & Architectural Works

j)

IS-1786

High strength deformed steel bars and wires for concrete reinforcement Hot applied sealing compounds for joints in concrete Methods of test for aggregates for concrete (all parts) Code of practice for bending and fixing of bars for concrete reinforcement Code of practice for concrete structures for storage of liquids (all parts) Code of practice for design and installation of joints in buildings Welded steel wire fabrics for general use. High alumina cement for structural use Concrete slump test apparatus Code of practice for extreme weather concreting (all parts) Rapid hardening Portland cement High strength ordinary Portland cement Recommended guidelines for concrete mix design. Ductile detailing of RCC structure subjected to seismic loads Handbook on concrete reinforcement and detailing

k) l)

IS-1834 IS-2386

: :

m)

IS:2502

n)

IS:3370

o)

IS-3414

p) q) r) s)

IS-4948 IS-6452 IS-7320 IS-7861

: : : :

t) u) v) w)

IS-8041 IS-8112 IS-10262 IS:13290

: : : :

x) 1.4

SP:34

Foundations a) IS-1904 : Code of practice for structural safety of building Shallow foundations Code of practice for design and construction of raft foundations Code of practice for design and construction of Machine foundations (all parts) Code of practice for design and construction of pile foundation Code of Practice for anti-termite measures and treatment

b)

IS-2950

c)

IS-2974

d)

IS-2911

e)

IS-6313 (Part-1 Part-2)

: &

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:3

DESEIN

Volume-VI: Civil, Structural & Architectural Works

1.5

Loading a) IS-875 : Code of practice for design loads for buildings and structures Bridge Rules of Government of India, Ministry of Railways (Railway Board)

b) 1.6 Masonry a) b) c)

IRS

IS-712 IS-1077 IS-1127

: : :

Building limes Common burnt clay building bricks Recommendations for dimensions and workmanship of natural building stones for masonry work. Methods of sampling and physical tests for refractory materials Code of practice for construction of stone masonry (all parts) Code of practice for brickwork Sand for masonry mortars Concrete masonry units. (all parts Hollow and Solid concrete blocks) Code of practice for preparation and use of masonry mortars Code of practice for construction of hollow concrete block masonry Burnt clay facing bricks Code of practice for design and installation of joints in buildings Methods of tests of burnt clay building bricks Code of practice for use of silicate type chemical resistant mortars Acid resistant bricks

d)

IS-1528

e)

IS-1597

f) g) h)

IS-2212 IS-2116 IS-2185

: : :

i)

IS-2250

j)

IS:2572

k) l)

IS-2691 IS-3414

: :

m) n)

IS-3495 IS-4441

: :

o) 1.7

IS-4860

Doors, Windows & Ventilators a) IS-399 : Classification of commercial timbers and their zonal distribution

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:4

DESEIN

Volume-VI: Civil, Structural & Architectural Works

b)

IS-883

Code of practice for design of structural timber in buildings Timber paneled and glazed shutters (all parts) Steel doors, windows and ventilators Code of practice for fixing and glazing of metal (steel and aluminium) doors, windows and ventilators Steel windows for industrial buildings Transparent sheet glass for glazing and framing purposes Aluminium doors, windows and ventilators Aluminium windows for industrial building Wooden flush door shutters (cellular and hollow core type) Wooden flush door shutters (solid core type) Code of practice for industrial ventilation Code of practice for glazing in buildings Fire check doors Timber door, windows and ventilator frames Steel door frames Metal rolling shutters and rolling grills

c) d) e)

IS-1003 IS-1038 IS-1081

: : :

f) g)

IS-1361 IS-2835

: :

h) i) j)

IS-1948 IS-1949 IS-2191

: : :

k) l) m) n) o) p) q)

IS-2202 IS-3103 IS-3548 IS-3614 IS-4021 IS-4351 IS-6248

: : : : : : :

1.8

Roof & Flooring a) IS-2204 : Code of practice for construction of reinforced concrete shell roof Criteria for the design and construction of precast concrete trusses Criteria for design of RC shell structures and folded plates Rubber flooring materials for general purposes Bitumen mastic for flooring Code of practice for laying bitumen mastic flooring

b)

IS-3201

c)

IS-2210

d) e) f)

IS-809 IS-1195 IS-1196

: : :

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:5

DESEIN

Volume-VI: Civil, Structural & Architectural Works

g)

IS-1198

Code of practice for laying, fixing and maintenance of linoleum floors Cement concrete flooring tiles Code of practice for laying and finishing of cement concrete flooring tiles Code of practice for laying in situ terrazzo floor finish Code of practice for laying in situ cement concrete flooring Code of practice for laying in situ granolithic concrete floor topping
Code of practice for laying burnt clay brick flooring

h) i)

IS-1237 IS-1443

: :

j) k)

IS-2114 IS-2571

: :

l)

IS-5491

m) n) o) 1.9

IS-5766 IS-1197 IS:2441

: : :

Code of practice for laying of rubber floors Code of practice for fixing ceiling coverings.

Waterproofing a) IS-1322 : Bitumen felts for waterproofing and damp proofing

b)

IS-1346

Code of practice for waterproofing of roofs with bitumen felts Code of practice for laying damp proof treatment using bituminous felts. Code of practice for laying lime concrete for a water proofed roof finish Bitumen mastic for use in waterproofing of roofs. Code of practice for general design, details and preparatory work for damp proofing and water proofing of buildings Bitumen primer for use in water proofing and damp proofing Code of practice for application of bitumen mastic for waterproofing of roofs.

c)

IS-1609

d)

IS-3036

e) f)

IS-3037 IS-3067

: :

g)

IS-3384

h) 1.10

IS-4365

Soil Engineering a) IS-1498 : Classification and identification of soils for general engineering purposes

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:6

DESEIN

Volume-VI: Civil, Structural & Architectural Works

b)

IS-1892

Code of practice for sub-structure investigation for foundations Method for standard penetration test for soils Methods of test for soils (all parts)

c) d) 1.11

IS-2131 IS-2720

: :

Water Supply, Drainage & Sewerage a) b) c) d) IS-404 IS-458 IS:651 IS-771 : : : : Lead pipes Concrete pipes Salt glazed stoneware pipes and fittings Glazed fire-clay sanitary appliances (all parts)

e)

IS-774

Flushing cisterns for water closets and urinals other than plasti9c cisterns Code of practice for laying of concrete piles Code of basic requirements for water supply, drainage and sanitation Asbestos cement building pipes, gutters and fittings (all parts) Code of practice for building drainage Code of practice for selection, installation and maintenance of sanitary appliances Code of practice for water supply in buildings Code of practice for installation of septic tanks (all parts) Code of practice for laying of cast iron pipes Code of practice for laying of glazed stoneware pipes Code of practice for drainage of building basement Method of measurement : Laying of water and (PartXVI) sewer lines including appurtenant items Centrifugally cast (spun) iron pressure pipes for water, gas and sewage

f) g)

IS-783 IS-1172

: :

h)

IS-1626

i) j)

IS-1742 IS-2064

: :

k) l)

IS-2065 IS-2470

: :

m) n) o) p)

IS-3114 IS-4127 IS-12251 IS-1200

: : : :

q)

IS-1536

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:7

DESEIN

Volume-VI: Civil, Structural & Architectural Works

r)

IS-1537

Vertically cast iron pressure pipe for water, gas and sewage Cast iron spigot and socket drain pipes Code of practice for sanitary pipe work above ground for buildings Low density polyethylene pipes for potable water supplies Cast iron fittings for pressure pipes for potable water supplies Cast iron rainwater pipes and fittings Sand cast iron spigot and socket soil, waste and ventilating pipes, fittings and accessories Pre-stressed concrete pipes Cast iron manhole covers and frames Cast iron grating for drainage purposes P and S traps

s) t)

IS-3486 IS-5329

: :

u)

IS-3076

v)

IS-1538

w) x)

IS-1230 IS-1729

: :

y) z) aa) bb)

IS-784 IS-1726 IS-5961 IS-5219 [Part-I) IS-772

: : : :

cc)

General requirements sanitary appliances

for

enameled

cast

iron

dd)

IS-775

Cast iron brackets and supports for wash basins and sinks Glazed earthenware wall tiles Plastic water closet seats and covers (all parts) Code of practice for fixing rainwater gutters and down pipes for roof drainage.

ee) ff) gg) 1.12

IS-777 IS-2548 IS-2527

: : :

Paving & Road Works a) b) c) IS-73 IS-702 IS:1201 : : : Paving bitumen Industrial bitumen Method of testing tar and bituminous materials thru 1220

d)

Practice followed by Indian Road Congress (all parts).

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:8

DESEIN

Volume-VI: Civil, Structural & Architectural Works

1.13

Earthquake Resistant Design a) b) IS-1893 IS-4326 : : Criteria for earthquake resistant design of structures Code of practice for earthquake resistant design and construction of buildings

1.14

Chimney a) IS-4998 : Criteria for design of R.C. Chimneys (all parts)

1.15

Structural Steel Work a) b) IS-800 IS-802 : : Code of practice for general construction in steel Code of practice for use of structural steel in overhead transmission line Part-I: Part-II: Load and permissible stresses Fabrication, galvanizing, inspection packing. and

c)

IS-806

Code of practice for use of steel tubes in general building construction Rolled steel beams, channels and angle sections Scheme for symbols for welding Covered electrodes for manual metal arc welding for carbon and carbon manganese steel Code of practice for use of metal arc welding for general construction in mild steel Code of practice for training and testing of metal arc welders Code of practice for safety and health requirements in electric and gas welding and cutting operation Code of practice for resistance spot welding for light assemblies in mild steel Recommendations for limits and fits for engineering. Code of practice for use of welding in bridges and structures subjected to dynamic loading Steel tubes for structural purposes Recommended practice for radiographic examination of fusion welded butt joints in steel plates

d) e) f)

IS-808 IS-813 IS-814

: : :

g)

IS-816

h)

IS-817

i)

IS-818

j)

IS-819

k) l)

IS-919 IS-1024

: :

m) n)

IS-1161 IS-1182

: :

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:9

DESEIN

Volume-VI: Civil, Structural & Architectural Works

o)

IS-1200 [Part-VIII] IS-1239

Method of measurement of steelwork and iron work

p)

Mild steel tubes, tubulars and other wrought steel fittings (all parts) Black hexagonal bolts, nuts and locknuts (dia. 6 to 39 mm) and black hexagon screws (dia. 6 to 24 mm) [all parts]. Precision and semi-precision hexagon bolts, screws, nuts and locknuts (dia. range 6 to 39 mm) [all parts] Slotted counter sunk head screws (dia range 1.6 to 20 mm) Technical supply conditions for threaded steel fasteners Code of practice for laying and finishing of cement concrete flooring tiles. Methods of tensile testing of steel products Dimensions for steel plate, sheet and strip for structural and general engineering purpose Dimensions for steel flats for structural and general engineering purposes Rolling and cutting tolerances for hot rolled steel products Structural steel (ordinary quality) Plain washers Steel for general structural purposes Ready mixed paint, air drying, red oxide zincchrome, priming Methods of testing uniformity of coating of zinc coated articles. Acceptance test for wire-flux combinations for submerged arc welding of structural steel Code of practice for ultrasonic pulse echo testing by contact and immersions methods High strength structural bolts High strength bolts in steel structures

q)

IS-1363

r)

IS-1364

s)

IS-1365

t)

IS-1367

u)

IS-1443

v) w)

IS-1608 IS-1730

: :

x)

IS-1731

y)

IS-1852

z) aa) bb) cc)

IS-1977 IS-2016 IS-2062 IS-2074

: : : :

dd)

IS-2633

ee)

IS-3613

ff)

IS-3664

gg) hh)

IS-3757 IS-4000

: :

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:10

DESEIN

Volume-VI: Civil, Structural & Architectural Works

ii)

IS-4759

Hot dip zinc coatings on structural steel and other allied products Code of practice for magnetic particle flaw detection of welds Tolerances for fabrication of steel structures Base-wire electrodes for submerged arc welding of structural steel Approval test for welders when welding procedure approval is not required. Structural steel micro-alloyed (medium and high strength qualities) Recommendation for metal arc welding of carbon and carbon manganese steel Structural welding code.

jj)

IS-5334

kk) ll)

IS-7215 IS-7280

: :

mm)

IS-7318 [Part-I] IS-8500

nn)

oo)

IS-9595

pp) 1.16 Painting a) b) c)

AWS D.1.1

IS-348 IS-427 IS-428

: : :

Specification for French polish Specification for distemper, dry colour as required Specification for distemper, oil emulsion, colour as required Code of practice for painting of ferrous metal in buildings Code of practice for finishing of wood and wood based materials Specification for Aluminium Paints for general purposes in dual containers Code of practice for painting concrete, masonry and plaster surface Specification for enamel, synthetic, exterior undercoating , (b) finishing (a)

d)

IS-1477 (I&II)

e)

IS-2338 (1&II) IS-2339

f)

g)

IS-2395

h)

IS-2932

i)

IS-2933

Specification for enamel, exterior (a) undercoating, (b) finishing. Specification for cement paint.

j)

IS-5410

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:11

DESEIN

Volume-VI: Civil, Structural & Architectural Works

1.17

a) b)

Indian Road Congress (IRC) Bridge codes Indian Railways Standard Bridge Rules

1.18

Environmental Protection Charter on Corporate Responsibility for Environmental Protection (CREP) published in Gazette of India dated 27.08.2003.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:12

DESEIN

Volume-VI: Civil, Structural & Architectural Works

2.0 2.1 2.1.1

SCOPE OF CIVIL & STRUCTURAL WORKS Scope of Work This specification is to cover design, preparation of general arrangement, construction as well as fabrication drawings, supply of all labour as well as materials and construction of all civil, structural as well as architectural work on EPC basis. The work to be performed under this specification consist of design, engineering as well as providing all labour, materials, consumables, equipment, temporary works, temporary labour and staff colony, constructional plant, fuel supply, transportation and all incidental items not shown or specified but reasonably implied or necessary for the completion and proper functioning of the plant, all in strict accordance with the specifications and including revisions and amendments thereto as may be required during the execution of the work. All materials including cement, reinforcement steel, structural steel etc. shall be arranged by the Contractor. The scope shall also including setting up by the Contractor a complete testing laboratory in the field to carry out all relevant tests as per BIS or other international standards required for the civil works for the project. The work shall be carried out according to the design/drawings to be developed by the Contractor and approved by the Purchaser. For all building and structures, foundations, etc. necessary layout and details are to be developed by the Contractor keeping in view the statutory & functional requirements of the plant & facilities and providing enough space & access for operation, use & maintenance. Certain minimum requirements are indicated in this specification for guidance purpose only. However, the Contractors offer shall cover the complete requirements of the plant & facilities and providing enough space & access for operation, use & maintenance. Also the Contractors offer shall cover the complete require ments as per the best prevailing practices and to the complete satisfaction of the Purchaser. Description of various items of work under this specification and nature of work in detail are given hereinafter. The complete work under this scope is referred to as CIVIL WORKS. List of various civil works covered under the scope is given below: In general the areas include 1. Turbine building foundation including Turbo-generator foundation and superstructure including service and maintenance bays. Foundation for steam generator / ESP supporting structure. Mill and bunker building including bunker structures. ESP control room. 275m single steel flue RCC chimney. Ash pipe supporting structure both for bottom ash and fly ash (100% dry collection) from plant area upto ash dyke / RCC silo respectively. Ash / mill reject handling system structures.

2.1.2

2.1.3

2.1.4

2.1.5

2.1.6

2.1.6.1

2. 3. 4. 5. 6.

7.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:13

DESEIN

Volume-VI: Civil, Structural & Architectural Works Remote fly ash silos 3 Nos. each having capacity min. 1000 m . 80T electronic weigh bridge at ash silo area to be provided. 9. Mill reject silo. Will be steel construction. Foundations to be provided for the same. The existing ash dyke area shall be provided with GI barbed wire fencing of height of 3m for an approximate length of 6 km. Sea water intake well, intake pipe & pump house Circulating water (CW) pump house and sump including forebay. Electro-chlorination building one at sea water forebay & another one at circulating water system forebay at ETPS complex. CW RCC ducts from CW pump house to Turbine building, Turbine building to cooling tower and channel from cooling tower to CW pump house forebay. Natural draft cooling tower including basin and other apparatus. Overhead Service & Potable Water Tanks as indicated in volume III & Volume VII . Service water, potable water, filter water and DMCW tanks as listed in Volume III & Volume VII. Sea water pipe line from sea water pump house to CW forebay and clarifier, MS pipeline with corrocoat or polyurethane coating inside of 1500 microns DFT / GRP. In all the cases the pipes shall encased outside in 250 mm thick RCC encasement except for GRP pipe. All the pipe lines shall be buried below the natural ground. The number of pipes and its diameter and route shall be determined by the contractor after carrying out detailed engineering. Clarified water storage tank and clarified water pump house.
3

8.

10.

11. 12. 13.

14.

15. 16.

17.

18.

19.

20. 21.

RO Stage I Permeate Tank and pumphouse Fire water reservoir, fire water pump house and fire station.

22. 23. 24.

Guard Pond & Pumphouse Foundation of various water pumps. Junction towers, underground tunnels, trestles and Conveyor galleries, stacker reclaimer, coal stockyard, dust suppression / extraction and ventilation system, switchgear room etc. for external coal handling plant (from NCTPS to ETPS) & internal coal handling system. Switchyard control building and 230 kV GIS switchyard all works. Transformer yard.

25. 26.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:14

DESEIN

Volume-VI: Civil, Structural & Architectural Works

27.

Rail track with RCC aprons connecting Transformer yard and maintenance bay. Fuel oil Day tanks, Fuel oil pump house, fuel oil tank farm area/dyke, fuel oil decanting pump house. Service building. Administrative building of minimum two (2) floors each having 1000 m area.
2

28.

29. 30.

31. 32. 33. 34. 35.

Compressor house and D.G. set room. Condensate storage tanks, DM water tank & RO Stage II Permeate Tank. Air washer building. Hydrogen generation plant (H2 Plant) Mechanical workshop with truss and sheet roof (50 m2 area) and electrical 2 workshop building of 250 m area with RCC roof including all required facilities. Paving, trenches, tunnels, channels, duct banks etc. Elevators shall be as per Volume III from Chapter 20. Necessary Civil Works to be executed including foundation, roofing, Supporting structures, etc., based on Mechanical Specification. Structural steel pipe rack and cable racks for pipes and cables for clarified water, D.M. Water, steam pipes, fuel oil pipes etc. with walkways. RCC paving from power house to chimney including Boiler area. RCC track connecting transformer yard service bay in TG building including cross track in service bay. Parking sheds for four wheelers and two wheelers a) Car park Partly covered parking total parking area 3000 Sq.M. Covered car parking with roof only and sides open shall be provided adjacent to the administrative building for minimum 20 Cars. Parking area indicated are net areas only (i.e.) excluding ramp, etc. Scooter and Cycle shed shall be provided with roof cover only. Cycle & Scooter shed - 750 Sq.M

36. 37.

38.

39. 40.

41.

b)

42.

Surface storage and RCC storm water drainage system for the entire plant as per design. Re-routing the existing storm water drain without affecting the generation of existing plant. Development of Green Belt which will be approx. 30% of the total plant area.

43.

44.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:15

DESEIN

Volume-VI: Civil, Structural & Architectural Works

45.

Landscaping of the areas around all important building e.g. service building, administration building, canteen, pump house etc. About 1000 m2 of area to be landscaped with Korean grass and latest flower plants. This area of 1000 2 m will be over and above the area of Green Belt Development to be provided as per MoEF Clearance. Security house cum time office of 100 m area. Canteen building of 200 m and single storey. Pantry will have stainless steel kitchen sink (750mm size) and platform in pantry will be of 12 mm thick polished granite top for dining as well as counters. Roof parapet wall of 750 mm height is to be provided for all buildings. Necessary steel / concrete staircase may be provided for access to roof for all buildings. All toilets shall be provided with exhaust fans. Kitchen sink wherever provided shall be of stainless steel. 10 metre high & 2 metre square at top Guard / Watch towers spaced @ 500m (max.) and placed appropriately around the boundary wall. The whole security arrangements including main gate and other vital areas including safe guarding of their construction materials during the entire construction period. Permanent bio-metric security system arrangement shall be erected at main gate after completing the construction activity to maintain the security arrangements. Two (2) Dormitories, each of 100m Sq.M area with Toilets and Changing rooms shall be provided for the security persons and the same will be constructed on the first floor of the security and time office. Temporary fencing shall be provided during construction in between the existing and proposed plant as directed by Owners engineer. Industrial type RR stone masonry compound wall of approximate length of 6 km and 4.5m height with minimum of 60 cm thickness at bottom 1.5m high, 45 cm thickness middle 1.50m and 38 cm thick of top 1.50m with anticlimbing devices with Y-frames fixed to each pillar and provided spiral spun type barbed wire including providing main entrance gates. Site shall be graded with available wet ash from ETPS / NTCPS ash dyke up to +9.00m level and the balance 50 cm depth up to +9.5m (+ 9.5 m corresponds to RL + 9.50m ) shall be filled with approved good quality gravel for the proposed site (Gravel Blanketing). The Entire area earmarked for ETPS EXPANSION within the existing ETPS compound is to be graded to the required level. In addition, the areas outside the existing ETPS Western Compound Wall where the proposed Ash Silos, Bottom Ash Silos, Ash Slurry Pump House etc. are located, along with their road approaches also, are to be graded to the above specified level Necessary dewatering pump units with required capacities shall be provided for reclaiming ash and site grading works. Necessary approach road for
2 2

46. 47.

48.

49. 50. 51.

52.

53.

54.

55.

56.

57.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:16

DESEIN

Volume-VI: Civil, Structural & Architectural Works

reclaiming the wet ash from ETPS ash pond shall be provided by the EPC contractor at his own cost. The reclaiming of ash shall be carried out without obstructing the normal discharge of ash slurry into the ash pond. Computation of ash quantity only in volume basis. Necessary security arrangement shall be provided for controlling the traffic / movement of vehicles at the EPC contractors cost. 58. Permanent stores building of min. 1000 m shall be provided with RCC roof and metal floor finish. Permanent partition wall is to be provided wherever needed. Permanent store yard area adjacent to the store building shall be paved with RCC of min. 150 mm thicknesses with necessary RR soling of 300 mm thick with proper packing of gravel blending. 40 MT electronic weigh bridge shall be provided in store complex. If the sufficient space for the stores yard and stores building is not available in the proposed project area, the existing store complex area at ETPS may be graded up to +9.5m and utilized for the same. Office building for store keeper and store controller shall be provided on the first floor of the store building. The stores building shall be provided with required number of RCC racks and steel racks with required no. of shelves. In the store building area 600 sq ft shall be air conditioned with required no. of shelves along with lock and key to stock instrumentation spares. One number rotor shed shall be provided to store heavy rotor equipments with facility to handle with gantry crane facilities. 59. Dispensary and first aid centre. First Aid Centre: It shall be RCC structure with brick cladding. This shall provide for minimum two beds, a Doctors room, Examination room, Dispensary, Waiting room, Toilet block and an ambulance porch. The First aid centre shall be fully equipped to handle emergency. The floors shall be provided with terrazzo tiles and walls with dado of white glazed tiles to a height of 2100 mm. 60. Necessary pipe racks.. No interconnection between existing PH to the proposed PH(Annex) Service water system pipelines. Rain Water Harvesting for all buildings and piping up to rain water tank. All roofs tops shall have RWH with filter arrangement. Filtered water shall be pumped to Raw Water system for its utilization. Rain Water Harvesting should be implemented as per the scheme / design approved, Central ground water Authority / Board or State ground water authority or MoEF authorized agency shall be consulted for finalization of appropriate rain water harvesting technology. The necessary consultancy
2

61. 62.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:17

DESEIN

Volume-VI: Civil, Structural & Architectural Works

charges for the above agency for preparing rain water Harvesting method / scheme for the project to be borne by the Bidder. 63. Clearing and removing the buried items if any in the whole proposed plant area and the same is to be deposited to the ETPS existing stores. The factory buildings shall have provision of dewatering sump and dewatering pump wherever there is accumulation of rain water like trenches due to elevations. Unwanted structures, building, pipe lines, sewer line, walls, power line and roads if any found in the construction area shall be cleared off. This is applicable to ECH construction also. The contractor has to fill or excavate or blast the areas to the required formation levels as indicated in the plot plan. Reinforced concrete grade floor shall be provided at ground level in the power plant area comprising of the area from transformer yard, to Boiler area upto chimney. The graded floor shall be in grade M20 concrete of minimum thickness of 200 mm, laid over PCC and compacted crushed stone base of 230 mm thickness. Grade slab shall be provided with reinforcement both ways, top and bottom with minimum 8 mm dia Tor steel at 200 mm c/s (minimum). 68. 69. Neutralization pit, effluent treatment plant & sewage treatment plant. Laboratory sink shall be of white vitreous china of size 600x400x200 mm conforming to IS: 2556 (Part 5) in laboratories and in Battery room. An Eye and Face fountain (Combined unit with receptacle) conforming to IS: 10592 shall be provided in Battery room, DM Plant and Chlorination plant. The blow down pipe line alignment will be handed over 1 year after the Handing Over of site. 20 metre high lighting towers shall be provided in Coalyard area and Switchyard area. Road Weigh Bridge and Control Room These shall be RCC framed structure with RCC roof and brick cladding. Adeqaute windows shall be provied for ventilation & lighting. Roof shall be given liquid membrane water proofing treatment. Flush welded steel doors shall be provided for personnel movement. Toilet facilities shall be provided. 74. All underground structures such as basement, sump etc. and water retaining structures shall be water proofed as per specification. For under deck insulation, Fire Resistant Under deck insulation such as Lloyd foam or equivalent PUF may considered with suitable specification.

64.

65.

66.

67.

70.

71.

72.

73.

75.

2.1.6.2

The work also includes: (a) Site surveying.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:18

DESEIN

Volume-VI: Civil, Structural & Architectural Works

(b)

Soil investigation and preparation of soil investigation report and suggestion of type of foundations including design of piles. Preparation of Architectural drawings. Design, preparation of drawings and construction of all structures. Preparation of as built drawings of all structures and facilities to reflect as built status of construction. Submission of as built drawings in Autocad in CDs. Plumbing & sanitary works. Painting. Anti-termite and anti-weed treatment in all areas / buildings as per IS: 6313. All temporary roads and approach roads necessary for construction purpose shall be of WBM for a minimum width of 4m. All permanent roads as stipulated in article 27.0 of this specification. Green belt development External compound wall and internal compound wall required based on plot plan and layout.

(c) (d) (e)

(f) (g) (h) (i) (j)

(k) (l) (m)

2.1.6.3

It is not the intent to specify herein all the works in the scope of this contract. All other buildings, structures and works necessary which are not specifically mentioned here but required for construction, operation and maintenance of the power plant are deemed to be included in the scope of the Contractor. In the event of conflict between requirement of any two clauses of this specification, or different codes / standards, the more stringent requirement as per the interpretation of Owner is to be followed by EPC contractor.

2.1.6.4

All works shall conform to the specification. The works shall conform to high standards of design, engineering and workmanship. Design and construction shall conform in every respect to all local and state regulations governing such works and to stipulations of Indian Standards unless stipulated otherwise in detail specification. Protection of existing utilities and services During construction, the contractor shall provide all protection for existing utilities and services as may be required by his construction operations. Permanent protection of certain items shall be as included under other sections or as instructed by the Owner. In addition to the requirements as specified, herein the contractor shall comply with the following requirements:a) Use all necessary precautionary and protective measures required to maintain existing utilities, services and appurtenances that must be kept in operation. In particular, the contractor shall take adequate measures to prevent undermining of utilities and services presently in services.

2.1.6.5

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:19

DESEIN

Volume-VI: Civil, Structural & Architectural Works b) Protect existing or new utilities and services where required by the contractors operations and/or as directed by the Owner. The contractor shall be responsible for bracing and supporting utilities and services to prevent settlement, displacement or damage.

3.0 3.1 3.1.1

INSTRUCTION TO BIDDERS Data to be furnished by Bidder at the time of Bid A write-up on survey to be undertaken indicating grid, intervals for taking spot levels, contour intervals, precision of surveying instruments proposed to be used, drawings that will be prepared, details to be covered by survey etc. Detail general arrangements / architectural drawings of all buildings and structures showing dimensions, levels, plans, sections, elevations, loadings, materials proposed, types of framings, wall / cladding, floors, roofs, types of finishes etc. This can be provided at the time of detailed engineering. Detail design criteria proposed to be adopted for each building, structures, foundations, facilities etc. A write-up with drawings on layout of cooling water (CW) system indicating sizes and design loads for CW conduits, seal pit, channels and proposed method of construction etc. Size, concrete grade and other design parameters and construction details etc. for 275m high RCC chimney with steel flue. The top most flue can shall be of stainless steel. Details of thermal insulation for ceiling and detail of false ceiling assumed with manufactures catalogue and areas where they propose. All deviations from bid document shall be furnished by the Bidder. List of equipment to be deployed and rates of labour assumed by the bidder and by other sub-contractors to be associated with him-in is to be furnished. List of softwares proposed to be used against various areas, for analysis, design, construction etc. their source & along with validation report for the softwares. The list of documents indicated elsewhere of this section to be submitted by the contractor to the Owner for his approval and manner in which the same need to be submitted. No construction shall commence at site without obtaining approval from the Owner on these documents. Therefore, it is necessary that bar charts for buildings / structures / area wise shall be submitted for design / drawing activity indicating. a) A Level-1 part chart showing the starting and completion date of all civil construction activities. A Level-2 part chart showing the time required for preparation of design criteria, for approval of design criteria by Owner, time required for detailed design and drawing preparation and time required for approval of design and drawing by Owner. This part shall taken into account the construction schedule (Level 1 part).

3.1.2

3.1.3

3.1.4

3.1.5

3.1.6

3.1.7 3.1.8

3.1.9

3.1.10

b)

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:20

DESEIN

Volume-VI: Civil, Structural & Architectural Works

c)

A Level-3 network for all civil works shall be submitted to Owner for monitoring of progress of works at site.

3.1.11

A detail note on quality plan both for design and construction activity proposed to be adopted for obtaining quality works. List of all sub-contractors that the bidder proposes to employ, in case the contract is awarded to him, indicating their addresses with telephone number, experience on similar jobs, name, qualification and experience of persons who shall be involved in the job on behalf of the contractor etc. shall be submitted to Owner. Only the subcontractor approved by Owner shall be engaged by the contractor on the job. Contractor has to set-up a testing laboratory equipped with the following minimum apparatus, materials and competent trained staff required for carrying out field tests: a) b) Slump cone apparatus to measure slump. Concrete cube testing machine with adequate number of moulds of (15cmx15cmx15cm) to measure compressive strength of concrete. Vicat apparatus to find initial and final setting time of cement. IS sieves with vibrating machine to determine fineness modulus of coarse and fine aggregate. Abrasion & impact testing equipment for testing coarse aggregate and apparatus to determine flakiness index of aggregates. Complete apparatus for the test of air content of concrete by pressure method as per IS:1199. Density bottle to determine sand bulkage. Hydrometer for testing pH value of water Thermometer for checking temperature Apparatus for measuring proctor density, water content of compacted soil determining CBR values. All apparatus for determining dry density and water content of sand/soil and aggregates. Any other equipment felt appropriate by the Owner for measurement of paint thickness, testing of structural members, welding etc. The testing machines shall be recalibrated periodically and as directed by Owner to detect errors. The moulds for cubes shall be checked frequently and made to conform to specifications contained in IS-516.

3.1.12

3.1.13

c) d)

e)

f)

g) h) i) j)

k)

3.2 3.2.1

Inspection of Site by Bidder Bidder shall inspect the site, examine and obtain all information required and satisfy himself regarding matters and things such as access to site, communications, transport, right of way, the type and number of equipment and facilities required for the work, availability of local labour, materials and their rates, local working conditions, weather, sub-soil conditions, natural drainage etc. Ignorance of the site conditions shall not be accepted by the Owner as basis for any claim for compensation or extension of time.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:21

DESEIN

Volume-VI: Civil, Structural & Architectural Works

3.2.2

The submission of a bid by the Bidder will be construed as evidence that such an examination was made and any later claims / disputes in regards to rates quoted shall not be entertained or considered by the Owner. The contractor shall organize his own arrangement to transport his equipment, men and materials so as to match the construction schedule.

3.3 3.3.1

Construction Tools & Materials Supplied by Contractor Contractor shall provide and maintain at the site necessary number and type of machinery and equipment including survey instruments in good working condition for proper setting out and timely completion of the various works cover under this specification. All arrangements for transporting the equipment to and from the site shall be done by the Contractor at his own expenses. No claim shall be entertained for mobilizing additional equipment and/or personnel to complete the work within the stipulated time. Contractor shall provide all fuels and lubricants required for the operation and maintenance of construction machinery and equipment as well as his transport vehicles at his own cost. The contractor shall ensure that the work shall proceed uninterrupted even in the event of power failure. As such, adequate number of diesel operated equipment shall be provided by the contractor at his own cost as an alternative arrangement, in case electrically operated equipment are proposed to be brought to site. The contractor shall ensure continuous supply of coarse and fine aggregate conforming to the specification for the duration of the contract period and extended period, if any. Adequate stocks are to be ensured before the onset of monsoon, because the approaches to the queries becomes difficult during monsoon. All materials supplied by the contractor shall be original, new and of the best quality and shall conform to the given specifications. Approval in writing shall be obtained from the Owner before any alternative or equivalent material is used other than what is specifically mentioned in the drawings. Contractor shall furnish manufacturers test certificate for all the manufactured items supplied by him. Representative specimens of the material shall also be submitted to the Owner and shall be tested at a recognized testing laboratory at Contractors cost in case Owner so desire. The Owner reserves the right to test any construction material supplied by the Contractor in an established testing laboratory at Contractors cost. The Owner reserves the right to instruct the Contractor to remove all materials, which do not meet the specification requirements.

3.3.2

3.3.3

3.3.4

3.3.5

3.3.6

3.3.7

3.4 3.4.1

Work Execution and Supervision Contractor shall have at the site accredited and qualified engineers and foremen / supervisors with adequate number of years of experience in execution of similar works and also operators of machinery and equipment, for satisfactory progress and timely completion of the work.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:22

DESEIN

Volume-VI: Civil, Structural & Architectural Works Contractors Engineer-in-charge of the work at site shall be capable of interpreting the specification and drawings and make adequate site decisions as and when required. He shall also take instructions from the Owner and be responsible for carrying out the instructions. Contractor shall be fully responsible for the correctness and accuracy of the tests performed, results obtained / tabulated, interpretation of test results and recommendations made. The work shall be executed in a professional manner, with fully understanding of the importance of work for a project of this magnitude. In the event of occurrence of any accidents at / near the site of the work or in connection with execution of the work, a report shall be made immediately to the Owner, giving full details of the accidents. He shall also report such accidents to all the competent authorities wherever such reports are required by them. All temporary electrical installation shall be supervised by a qualified electrical supervisor of the Contractor. Owner reserves the right to order in writing, from time to time, during the progress of the work, removal and re-execution of any work which in the opinion of the Owner, is not in accordance with the specification. During inclement weather, rains etc. contractor shall suspend all works for such time as the Owner may direct and shall protect from damage all works already in progress or completed just then. All such temporary protective measures shall be at contractors cost and any damage to works shall be made good by the contractor at his own expense. Should the work be suspended by reasons of strikes / riots by Contractors own employees or any other causes whatsoever save and except the force majeure condition, Contractor shall take all precautions necessary for the protection of works and make good, at his own expenses, any damage arising from any other these causes. During the course of contractors works, other works either by the Owner or by the Contractors or by both simultaneously will be in progress within the project area. Contractor shall make his best effort to work in harmony with others in the best overall interest of the project and towards its speedy completion. The Contractor shall be responsible for maintaining cleanliness of the site. The site shall be free of unwanted rubbish or filth, which is hazardous & detrimental to health, and affect safety of the work place. All material supplied shall conform to the specification. Entry of unwanted materials shall be prohibited. SUBMISSION The following documents are to be submitted for the approval of the OWNER, prior to commencement of fabrication & erection / construction. All drawings shall be of standard sizes (metric system) and shall be made on AUTOCAD. Software used for design shall be validated and established ones like STAAD Pro, NISA, and ANSYS. Hard and soft copies to be furnished to the OWNER. The list is not exhaustive but indicative only.

3.4.2

3.4.3

3.4.4

3.4.5

3.4.6

3.4.7

3.4.8

3.4.9

3.4.10

3.4.11

4.0

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:23

DESEIN

Volume-VI: Civil, Structural & Architectural Works

1)

The analysis of TG building, Mill building, ESP control room, Chlorination building, Switchyard control building, CW pump house, Raw water pump house, Ash water pump houses and Service building are to be done by developing 3D mathematical model adopting response spectra method of analysis as per IS: 1893-2002 & 2005, in addition to wind load analysis as per IS: 875 Part-3. Preparation of design drawings with maximum detailing possible and developing all possible connection / joint details for all the buildings within the scope of civil / structural works. General plant layout drawing with coordinates of roads, boundary wall, and facilities, piping / cable corridors, pipe and cable trestles, provision of landscaping and green belt development, diversion roads and drains, equipment lay down areas etc. Drawing showing underground facilities with coordinates of these facilities like buried pipes, buried cables, trenches, ducts, sewer, drains, sumps pits, culverts, foundations etc. Soil investigation report based on additional geo-technical investigation carried out by CONTRACTOR along with foundation recommendation for various buildings / structures / facilities. Site Grading and storm water drainage study furnishing levels of various terraces arrangement and details of drains, culverts etc for storm water drainage system. Study note on disposal of sewage and other effluent from the plant to satisfy the statutory requirement. Design basis memorandum for all buildings, facilities, services and structures. Drawing showing loading data at various levels for all buildings and structures. Architectural floor plans, elevations, cross sections and perspective view in colour of all buildings. For main plant building CONTRACTOR shall submit two different schemes along with a report elaborating the underlying philosophy of the proposed architectural concepts. Design calculations and drawings for foundations / substructure and superstructure of all buildings including pump houses and other structures. Design calculations including dynamic analysis and drawings for all foundations subjected to dynamic loads like foundations for TG, BFP, Mill, Fans (PA, FD, ID), Crushers etc. Design calculations and drawings for all facilities and services like roads, culverts, bridges, pavings, road / rail crossings, drainage pump house (if required), drains, sewers, sewage pump house, sewage treatment plant, water supply, water tank, sumps, tunnels, trenches, ducts etc.

2)

3)

4)

5)

6)

7)

8)

9)

10)

11)

12)

13)

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:24

DESEIN

Volume-VI: Civil, Structural & Architectural Works

14)

Drawings of all architectural works including finishing schedule, colour schemes (both internal and external), doors & windows, flooring and false ceiling, etc. Design calculations and drawings for plumbing and building drainage. Design calculations and drawings for switchyard structures, transformer yard, etc. Design calculations and drawings for structures pertaining to condenser Cooling water system. Design calculation and drawings / document for the sea water system structures is covered within the scope of the Contractor. Design calculations and drawings for civil structures / works associated with fuel oil handling system, ash handling system, coal handling system, Ash disposal system, etc. All other designs, details / drawings or any other submissions as indicated else where in this specification and as required by the Owner. Details of corrosion protection measures for all structures. Total quantity of concrete (grade wise), reinforcement steel (diameter wise) and structural steel (section wise) shall be indicated in all construction drawings. All design and drawings for the Cooling towers. All design and drawings for RCC single steel flue chimney. All design calculations and drawings for foundation of Boiler and ESP area structures. Shop fabrication drawings of al structural steel work along with design calculations Construction and erection procedure for all major structure with specific reference to main plant building, bunker structures, transfer towers, conveyor galleries, TG foundation and other machine foundations. Write up on various statutory requirements and their compliance for various buildings and facilities. Quality assurance and Quality Control procedures. Copies of all reports on investigation and studies carried out by the CONTRACTOR as per the scope. Soft copies of all design calculation and drawings shall be submitted for records after approval of the OWNER.

15) 16)

17)

18)

19)

20)

21) 22)

23) 24) 25)

26)

27)

28)

29) 30)

31)

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:25

DESEIN

Volume-VI: Civil, Structural & Architectural Works

5.0 5.1

MATERIAL Structural Steel Steel will conform to Grade-A of IS:2062 (latest) for rolled steel members or plates upto 20 mm thickness. For plates above 20 mm thickness and welded construction steel conforming to Grade-B (killed and normalized) of IS: 2062(latest) shall be used except for crane girders where Grade-C (IS: 2062) steel shall be used. Steel shall be procured from SAIL or any other approved main producers. Chequered plate shall conform to IS: 3502 (latest) and minimum thickness of chequered plate for floorings, covers etc shall be 8 mm O/P. Stainless steel liner in the coal bunkers shall be 6 mm thick of grade AISI 304; finish grade 2B (cold rolled, annealed & pickled and skin passed) and shall be provided on the inner faces of entire inclined portion of hoppers and mouth of the hoppers, without allowing any projections in coal flow path. The electrodes classification as per AWS shall be as follows:a) b) For welding of stainless steel to stainless steel : E308L For welding of stainless steel to mild steel : E309

5.2

Cement Ordinary Portland Cement (OPC) shall be used for all structures except for foundations, under ground structures & structures coming in contact with saline water where in sulphate resistant cement with C3A content limited to 5% to 8% shall be used. Grade of cement shall be 43 conforming to IS: 8113.

5.3

Reinforcement The reinforcement used shall be cold worked steel high strength deformed bars of grade Fe 415 / Fe 500 conforming to IS:1786 latest. Fusion bonded epoxy coated reinforcement steel with coating conforming to IS:13620 shall be used for the complete project.

6.0 6.1 6.1.1

DESIGN CRITERIA General The design criteria given herein is applicable for all structures and buildings including main plant buildings, control building, service building, mill and bunker building, single flue RCC chimney, coal handling plant, water treatment plant, various equipment foundations, transfer points, fuel oil handling plant, light diesel oil handling system, ash handling system, transformer yard, pump houses, CW pump house & forebay, CW channels, natural draft cooling tower, compressor house, DG set building, switchgear building, security / time office building with a weigh bridge (road) of 25 mt capacity, watch tower at designated locations etc. and other miscellaneous buildings, culverts, bridges, water retaining structures, switchyard structures, roads, drains, sewers cables & pipe trestles etc. and various other works covered under the scope of civil/structural works.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:26

DESEIN

Volume-VI: Civil, Structural & Architectural Works

6.1.2

Structures shall be designed for the most critical combinations of dead loads, imposed loads, equipment loads, crane loads, piping loads, wind loads, seismic loads and temperature loads and friction load. i) All the buildings shall have framed super structure. Type of building frame work (steel or RCC), type of cladding (masonry or metal cladding) shall be as specified under Architectural Design Concept. The main plant building, bunker building, transfer tower, conveyor galleries and trestles shall have structural steel framed super structure. CW pump house superstructure, raw water pump house superstructure will be of RCC framed structure. iii) All other buildings may have either RCC or structural steel frame work as per Owners requirements. All buildings having RCC framing shall have masonry cladding of minimum one masonry unit thickness (not less than 230 mm) on exterior case. All buildings, having structural steel frame work shall have metal cladding on exterior face above the masonry work and RCC roof over permanent metal deck shuttering. RCC cup board as per requirement. Ladies & Gents toilets shall be provided in all buildings. The cable trenches shall be provided with extra width than exactly required for future handling and maintenance. Watch Towers shall be provided with (1.5mx1.5mx3m) structural steel framing with RCC floor at elevated height of 10m shall be provided with color coated roof canopy, access ladder and searchlights mounted on it. The watch tower platform shall be provided with 900 mm high handrails on all sides.

6.1.3

ii)

iv)

v)

vi) vii) viii)

ix)

6.2 6.2.1

LOADING Dead Loads Dead loads shall include the weight of structure complete with finishes, fixtures & partitions and shall be taken as per IS: 875 (Part-I)

6.2.2

Imposed Loads Imposed loads in different areas shall include live loads, erection, operation and maintenance loads. Equipment loads (which constitute all loads of equipment to be supported on the building frame) are not included in the imposed loads furnished below and shall be considered in addition to imposed loads. For consideration of imposed loads on structures, IS:875 (Part-2) Code of practice for design loads (other than earthquake) for buildings & structure shall be followed. The following minimum imposed loads as indicated for some of the important areas shall however be considered for the design. If actual expected load is more than the specified minimum load, then actual load is to be considered.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:27

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Sl.No. A) Turbine Building i) ii)

Location

Imposed Loads (T/Sq.m)

Ground floor (general) Ground floor (Heavy equipment storage area) Actual load of storage material or 1.5 T/sq.m (min) Mezzanine Floor Operating Floor a) Rotor Removal area Rotor removal area beams shall also be checked for the rotor load at the center of beam

2.50

iii) iv)

1.50

5.00

b) v)

Equipment Laydown area

3.00 0.75

Gratings, chequered floors, walkways, platforms, stairs etc. Roof (Where no equipment are located and non-accessible) Roof (where equipment are located and accessible)

vi)

0.15

0.50

B)

Deaerator and Heater Bay i) ii) HP / LP heater floor Deaerator floor 2.0 1.5

iii)

Cable gallery

0.50 (In addition to this actual cable load shall be considered) 1.00 1.0

iv) v)

MCC & Control Building floors AHU room battery room, air washer room

C)

Mill & Bunker Bay i) ii) iii) Ground Floor Feeder Floor Tripper Floor 2.5 2.00 2.00 Beams however shall be checked for

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:28

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Sl.No.

Location

Imposed Loads (T/Sq.m) feeder/tripper concentrated load 0.15 (where no equipment are located) 0.50 (where equipment are located) 1.50

iv)

Roof

D) E)

Pump Houses operating floor

Underground Structures such as Channels, Sumps, Underground Pump House, Tanks, Trenches, Reservoirs, Cooling Water Ducts etc. In addition to earth pressure and ground water pressure, the surcharge load of 2T/sqm. shall also be considered for design of all underground structures.

F)

Road Culverts / Bridges and its allied structures including RCC Pipe Crossings & Road Crossing of Trenches. Design for class AA loading (wheeled & tracked both) and checked for class A loading as per IRC Standard.

G)

Covers for Channels / trenches

H)

Railway Supporting Structures, Rail Culverts

Trench cover at entry to building and road crossings shall be designed for live load of 100 kN at centre. Trench cover at other location shall be designed with a surcharge of 100 2 kN/m or a concentrated load of 100 kN at center which is worst. As per railway Bridge Rules 0.50

I) J)

Boiler / ESP Support Structures General (Unless Specified Otherwise) i) ii) iii) iv) v) Stairs, Landings and Balconies Toilets Chequered plates, grating floors, etc. RCC floors (General) a) Flat roofs (where no equipment

0.50 0.20 0.50 0.50 0.15

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:29

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Sl.No.

Location are located) b) Flat Roofs (where equipment are located)

Imposed Loads (T/Sq.m)

0.50

vi)

Inclined Roofs

As per IS:875 (PartII) 0.50 T/sq.m or a concentrated load of 0.3 T/m which ever is greater 0.50 1.00

vii)

Walkways (General).

viii) ix)

Walkways of conveyor galleries. Floor of control room of switchyard control building Cable and pipe trestles

x)

0.20 for walkway and in addition, friction loads as applicable.

Note: 1. Additional load for cable, piping / ducting, shall be considered as applicable.
2

2.

Hung load shall be based on minimum loading equivalents of 1 kN/ m for 2 piping and 0.5 kN/m for electrical ventilation and air conditioning. Loading resulting from concentrations of facilities in specific areas shall be substituted where listed base loadings are excluded

3.

6.3

Equipment, Piping and Associated Loads Equipment loads shall be considered over and above the imposed loads. Equipment loads shall be considered as given by equipment supplier.

6.4

Crane Loads For crane loads, an impact factor of 25% and lateral crane surge of 10% (of lifted weight + trolley weight) shall be considered in the analysis of frame according to the provisions of IS:875. The longitudinal crane surge shall be 5% of the static wheel load. Longitudinal surge and lateral surge shall not be considered to act simultaneously.

6.5

Seismic Load The project site is in Zone III as per IS:1893 Part I 2003 & IS:1893 Part II

2005
Zone factor Z Importance factor = = 0.16 1.75

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:30

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Response reduction factor = 5.0 (for MRF) AND 3.0 (for OMRF) 6.6 Wind Load Basic wind speed at project site is 50 m/sec. as per IS:875 -1987 Part-3 Probability factor,(k1 risk coefficient), terrain, height and structure size factor, k2 and topography factor, k3 shall be as per IS:875. 6.7 Damping in Structures The damping factor to be adopted shall not be more than as indicated below: Type of Structure a) b) c) Welded steel structure Bolted steel structure RCC structure Wind Load 1% 2% 1.6% Seismic Load 2% 2% 5%

6.8

Temperature Load For temperature loading, the total temperature variation shall be considered as 2/3 of the average maximum annual variation in temperature. The average maximum annual variation in temperature for this purpose shall be taken as the difference between the mean of the daily minimum ambient temperature during the coldest month of the year and mean of daily maximum ambient temperature during the hottest month of the year. The structure shall be designed to withstand stresses due to 50% of the total temperature variation. Suitable expansion joints shall be provided in the longitudinal direction wherever necessary with provision of twin columns. The maximum distance of the expansion joint shall be as per the provisions of IS:800 and IS:456 for steel and concrete structures respectively. Systems and system component design criteria which require ambient temperature extremes shall use the range from 22C to 40C for dry-bulb temperatures.

6.9

Permissible Deflections The permissible deflections of various steel members under normal loading conditions shall be as specified below. For calculation of deflections in structures and individual members dynamic effects shall not be considered, unless specified otherwise. Also, no increase in deflection limits shall be allowed when wind or seismic load are acting concurrent with normal loading conditions.

6.9.1 6.9.1.1

Vertical Deflection a) b) c) d) e) For beams supporting dynamic equipment : Span / 500 For beams supporting floors / masonry : Span / 325 For beams supporting pipes : Span / 400 For roofing and cladding components : Span / 250 For gratings and chequered plates : Span / 200 subject to a maximum of 6 mm f) Coal/ Ash conveyor gallery bridges : Span / 450

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:31

DESEIN

Volume-VI: Civil, Structural & Architectural Works

6.9.1.2

For crane gantries or any member subjected to working loads, the maximum deflection under dead load and live load excluding impact shall not exceed the following values: a) b) For manually operated cranes & monorails For electric overhead cranes i) Up to 50 t capacity ii) Over 50 t capacity : Span / 750 : Span / 1000 : Span / 500

6.9.2

Horizontal deflections The permissible horizontal deflections shall be as per following unless specified otherwise: a) b) c) d) e) f) Single storey building (without crane load ) Multistoried building (without crane load) Pipe rack columns Open Structures Crane gantry girder due to surge Building main columns at crane rail: level due to action of crane surge load only Open gantry columns at crane rail level due to action of crane surge load only Coal handling trestles : : : : : Height / 325 Height / 500 Height / 200 span/2000 limited to maximum of 15 mm Height/200

Height / 2500 limited to maximum of 10 mm

g)

: :

Height/4000 limited to maximum of 10 mm Height / 1000

h) 6.9.3

Provisions of IS: 800 and relevant IS Code shall be followed for limiting deflections of structural elements not listed above. Minimum thickness of structural steel elements Minimum Thickness The minimum thickness of various components of a structure and hot rolled sections shall be as follows. The minimum thickness of rolled shapes shall mean flange thickness regardless of web thickness. Structural steel members exposed to significantly corrosive environment shall be increased suitably in thickness or suitably protected otherwise as per good practice and sound engineering judgement in each instance. a) Trusses, purlins, girts and bracing Columns and beams Guessets

6.9.4

6mm 8mm 8mm

b) c)

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:32

DESEIN

Volume-VI: Civil, Structural & Architectural Works

d) e) e) f)

Stiffeners Base plates Chequered plates Grating flats

8mm 10mm & above 8 mm o/p & above 5 mm

Minimum thickness of structural members other than gratings directly exposed to weather and inaccessible for painting and maintenance shall be 8 mm. Minimum Sizes The flange width of purlins supporting light weight concrete slab shall not be less than 65 mm and for those supporting roof sheeting and wall cladding it shall not be less than 50 mm. Width of steel rolled section connected to other member shall be at least 50 mm. The depth of beams for platform of all structures shall not be less than 125 mm. 6.10 6.10.1 Civil Design Concepts Individual members of the frame shall be designed for the worst combination of forces such as bending moment, axial force, shear force, torsion, etc. Criticality of erection / maintenance loads shall also be checked separately in combination with other simultaneously occurring loads for possible design loadings. The different load combinations shall be taken as per IS:875 (Part-5) and other relevant IS Codes. a. b. Wind and seismic forces shall not be considered to act simultaneously. For the design of main plant structures during seismic condition, the deaerator feed water tank shall be considered full upto operating level. However, for other load combinations, deaerator feed water tank in flooded condition shall be considered. Lifted load of crane shall not be considered during seismic con dition. In case two cranes are provided and tandem operation is not envisaged, the load shall be taken as one crane fully loaded and second crane without lifted load but standing idle adjacent to first crane. In case two cranes are provided and tandem operation is envisaged for some bays, then the load shall be taken as both the cranes fully loaded and standing side for these bays. For other bays, load shall be taken as one crane fully loaded and second crane without lifted load but standing idle adjacent to first crane. Permissible stresses for different load combinations shall be taken as per relevant IS codes. For the design of pipe / cable supporting structure, the soil weight shall be considered as backfilled upto grade level for the condition of pipe running full / cables in position.

6.10.2

c. d.

e.

f.

g.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:33

DESEIN

Volume-VI: Civil, Structural & Architectural Works

h.

Frictional force between the pipes and supporting structure in longitudinal direction need not be considered along with seismic or wind forces.

6.10.3

The design of steel structures shall be done by working stress method. Design shall be as per provision of IS:800 and other relevant IS standards. For design of coal bins and loading hopper IS:9178 (Part I to III) shall be followed. Welding shall be used for fabrication and erection. Site connections shall generally be with welding. However, high Strength Structural (HSS) bolts shall be used for all important connections to be decided during detail engineering stage. In few cases, for shear connections or removable beam connections, bolted joints with MS bolts may be adopted. For HSS bolt connection, IS:4000, IS:3757, IS:6623 and IS:6649 shall be followed. IS:814, IS:816, IS:1024, IS:4353 and IS:9595 shall be followed for welding of structures. Trestles supporting coal conveyor galleries shall be so proportioned that the transverse deflection of trestles due to wind / seismic load shall not exceed trestle height / 1000 as stipulated in IS:11592. Pedestals supporting gravity take-up shall be designed to resist 100% impact. For calculation of coal load on moving conveyor, a multiplication factor of 1.2 shall be used to take care of inertia force. a) Conveyor gallery structure & trestles shall be designed considering both conveyors operating simultaneously. 1. Dynamic analysis of conveyor galleries and conveyor supporting system shall be carried out for spans greater than 25m. All structures close to railway line shall have clearances conforming to Railway norms.

6.10.4

6.10.5

6.10.6 6.10.7

2.

6.10.8

a)

Dispersion of load in any direction through soil shall be as per IS:8009 (relevant part). Dispersion of load through concrete shall be considered at an angle of 45 degrees with horizontal from the edge of contact area. Permissible deflection (unless specified otherwise in this specification) for latticed framework and beams of floors other than drive floor shall be span/325. The allowable deflection for beams directly supporting drive machinery shall be restricted to span / 500 unless specified otherwise in this specification.

b)

6.10.9

a)

b)

6.10.10

Transverse coal pressure on Bunker/ Silo / Hopper walls shall be calculated using Walkers theory and IS:9178. The Coal Bunker / Silo / Hopper shall be designed for the following conditions. i) The Bunker / Silo / Hopper is full up to its full capacity with top surface nearly horizontal. The Bunker / Silo / Hopper is partially empty with the top surface of coal at an angle of repose of 37 degrees.

ii)

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:34

DESEIN

Volume-VI: Civil, Structural & Architectural Works

6.10.11

Bunker in mill building shall be circular in plan and the complete hopper including vertical and sloped portion up to1M from the top of conical portion shall be provided with lining of atleast 6 mm thick SS plate of grade AISI 304. Design pressure on coal bunker / hopper walls shall take into account all possible flow regimes (core flow, mass flow, etc.), and different aeration regimes (radial, diametrical, radial and core, impulsive etc.) For all capacity (volume) calculation and structural design (load calculation) unit weight of coal shall be assumed as 800 kg/cum and 1050 kg/cum respectively. a) The design and construction of RCC structures shall be carried out as per IS:456-2000. Working stress method shall be adopted for the design wherever specifically mentioned in this specification. For all concrete structures, ductile detailing has to be done as per IS:13920 and IS:4326. For reinforcement detailing, IS:5525 and SP34 shall be followed. Two layers of reinforcement (on both inner and outer faces) shall be provided for RCC wall sections having thickness 150mm or more. All RCC liquid retaining / conveying structure shall be designed in accordance with IS:3370 (Part 1 to 4) by working stress method, using limited steel stress. However, water storage tanks shall be designed as an uncracked section as per IS:3370 (Part 1 to 4) by working stress method. All liquid retaining / carrying structures shall be tested for water tightness as per the provisions of IS:3370 and IS:6494 and in case of leakage, the same shall be rectified by chemical injection grouting through nozzles.

6.10.12

6.10.13

6.10.14

b)

c) d)

6.10.15

a)

b)

For design of all underground structures, foundations, CW ducts, etc. ground water table shall be assumed at the finished ground level unless specified otherwise. In addition to cater the pressure and ground water pressure etc, minimum surcharge 2 load of 2 T/M shall also be considered for design of all underground structures. 6.10.16 Earth pressure for all underground structures shall be calculated using coefficient of earth pressure at rest. Co-efficient of passive earth pressure shall be used only in design of shear keys for stability against sliding. a) Following loading conditions shall be considered in addition to the loading from super structure for the design of substructure of pump house, channels, sumps, tanks, trenches and other underground structures containing liquid. i) Water pressure from inside and no outside pressure, like earth pressure, ground water & surcharge pressure (applicable only to structures which are liable to be filled up with water or any other liquid.) Earth pressure, surcharge pressure and ground water pressure from outside and no water pressure from inside. Design shall also be checked against buoyancy due to the ground water during construction as well as after construction stages. Minimum factor of safety against buoyancy shall be ensured

6.10.17

ii)

iii)

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:35

DESEIN

Volume-VI: Civil, Structural & Architectural Works

considering empty condition inside and ignoring the superimposed loadings. Provision of pressure relief valves / flap valves, etc. may be used to counter the buoyancy. When pressure relief valves are used, 60% of the hydrostatic pressure shall be considered for design of the base slab. iv) Base slab and piers of the pump houses shall also be designed for the condition of different combination of pump sump being empty during maintenance stages with maximum ground water level.

b)

Intermediate dividing pier of pump sumps and partition wall (if applicable) in channel shall be designed considering water on one side only and other side being empty for maintenance. All pump houses and other substructures (wherever applicable) shall be checked for stability against sliding and overturning during construction as well as operating conditions for various combinations of loads. For the foundation of Turbo-generator, Boiler feed pumps, Fan (ID, FD and PA), Mills etc., detailed static and dynamic analysis shall be done. The static analysis shall include all operating conditions, load cases and abnormal loads like short circuit, loss of blade, unbalance and seismic forces. Unbalance loads for normal operating condition as given by machine manufacturer and / or VDI 2060 whichever is more conservative shall be used for calculating dynamic response. The dynamic analysis. Transient analysis shall be carried out for the short circuit condition with an appropriate force function. Frequency separation criteria and amplitude criteria as laid down in IS:2974 and / or DIN 4024 and / or VDI 2056 and / or as required by the machine manufacturer, whichever is more stringent shall be satisfied. RCC design shall be done by working stress method for all machine foundations. A fatigue factor of 2.0 shall be considered for dynamic forces. Minimum reinforcement shall be governed by IS:2974 as well as IS:456. However minimum reinforcement in bottom face of the foundation raft resting on soil or pile shall not be less than 0.2% of effective cross sectional area of the raft. The special requirements for concreting including grade, type of aggregate, use of admixture, temperature control, ultrasonic testing, etc. shall be as mentioned elsewhere in this specification.

c)

6.10.18

a)

b)

All block foundations supporting rotating equipment resting on soil or piles shall be designed using the elastic half space theory. The mass of the RCC block shall not be less than three times the mass of the machine. Dynamic analysis shall be carried out to calculate natural frequencies in all the modes including coupled modes and to calculate vibration amplitudes. Frequency and amplitude criteria as laid down in the relevant codes and / or by machine manufacturer whichever is more stringent shall be satisfied. Minimum reinforcement shall be governed by IS:2974 and IS:456. Minimum Reinforcement in base raft in either direction shall be as follows:i) At bottom face 0.2% of gross sectional area. 0.12% of gross sectional area. cross-

ii)

At top face

cross-

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:36

DESEIN

Volume-VI: Civil, Structural & Architectural Works

c)

For the foundations supporting minor rotating equipment weighing less than one tonne or if the mass of the rotating parts is less than one hundredth of the mass of the foundation, no dynamic analysis is necessary. However, if such minor equipment is to be supported on building structure, floors, etc. suitable vibration isolation shall be provided by means of springs, neoprene pads, etc. and such vibration isolation system shall be designed suitably. TG, BFP, Mill, PA, FD & ID fan foundations shall be supported on vibration isolation system. The vibration isolation system shall consist of steel helical spring units and viscous dampers supporting the RCC deck which would support the machine. The spring units shall conform to DIN 2089 and DIN 2096. GERB or equivalent manufacturers vibration isolation system shall be supplied for supporting machines like TG, BFP, Mill, PA, FD & ID fan. Isolation efficiency of at least 90% shall be provided for the Turbo generator, ID fan foundations.

d)

e)

f)

6.10.19

If RCC floor / roof is assumed to act as diaphragm transmitting lateral loads to braced bays, it shall be provided with shear connectors. However, whenever large / more number of cut-outs are provided in the floor slab, horizontal floor bracings shall be provided below slab to transfer horizontal force to columns without considering diaphragm action from slab. Roof decking sheets shall be designed as per IS:801 to carry the self load, dead load due to RCC slab and finishes and imposed load. The deflection of metal deck shall be limited as per BS:5950. In case composite action is considered in the design, suitable shear studs shall be provided as per BS: 5950. Roof Access All roofs shall be provided with access thorough a steel staircase / cage ladder. Minimum 1000 mm wide access path shall be provided with tiles to approach equipment on roof.

6.10.20

6.10.21

6.10.22

Platforms and Walkways Platforms shall be provided to all major equipment, not directly accessible from - the floors, for maintenance. Platforms and connecting walkway shall have a minimum width of 750 mm. Platforms in front of the entry shall be atleast 900 mm wide. Platforms located close to each other shall be connected with walkways. All steel platforms above grade level shall be constructed with kick plates at edge of the platform to prevent tools or materials from falling off. It shall consists of 8 mm thick steel plate projecting 100 mm above the platform surface. Kick plate shall be painted with the same type of coating as the material to which it is attached. Continuous walkway at least 750 mm (Wherever occurs) wide shall be provided along the crane girder level with handrails, on both side of the building. Approach to EOT crane shall be ensured by Cage ladder or staircase.

6.10.23

Edge Protection Wherever possible around floor openings an RCC kerb of 100 mm wide 150 mm high shall be provided. All concrete edges, where breakage of concrete corners expected shall be provided with angles of minimum size L 50x50x6 with lugs for edge protection e.g. alround the cut-outs I openings in floor slab, edges of drains

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:37

DESEIN

Volume-VI: Civil, Structural & Architectural Works

supporting grating covers, edges of. RCC cable I pipe trenches supporting covers, edges of manholes supporting covers and supporting edges of precast covers etc. 6.10.24 Anchor Bolts and Insert Plates Anchor bolts and insert plates shall be made of mild steel as per IS:800. 6.10.25 Vertical Headroom All accessible areas shall be provided with minimum clear headroom as follows, unless otherwise specified. Finished floors to ceiling (buildings) Doors, Walkways, Platforms, Stairs etc. False ceiling of office areas Above false ceiling Safety cage for ladders Access for fork lift trucks Main roads / Railway crossings & crane access Other plant roads and truck access Cable & Pipe rack (except at road and rail crossings) 6.10.26 Anti Termite Treatment Pre-constructional anti termite treatment shall be given to all vulnerable areas susceptible to termite attack and shall include column pits, wall trenches, foundations filling bellow the floors etc., as per IS: 6313 and other relevant Indian Standards. 6.10.27 Statutory Requirements All the applicable statutory rules pertaining to Indian Factories act, Factory rules of State Government, Fire safety rules of Tariff Advisory committee, Water act of Pollution Control boards, Explosives act etc., and stipulations of other relevant statutory authorities shall be taken into consideration at the time of design and construction. Provisions of safety, health and welfare according to Factories act shall be complied with at design stage. These shall include provision of continuous walkway (minimum 750 mm wide) along crane-girder at crane girder level on both sides of the building, comfortable approach to EOT crane. cabin, railings, fire escape locker room for workmen, pantry, toilets, rest rooms etc. Adequate no. of fire escapes shall be provided in a building. Fire proof doors, no. of staircase, fire separation walls, lath plastering on structural steel member (in fire prone areas) shall. be made according to the recommendation of TAC. For fire safety requirements of buildings IS: 1641 and IS: 1642 shall be followed in addition to TAC requirements. All masonry firewalls shall be minimum 345 thick and RCC firewall shall be minimum 200 mm thick. 6.10.28 Miscellaneous Requirements Doors and windows on external walls of buildings shall be provided with RCC sunshade over the openings With 300 mm, projection on either side of the opening. Projection on sunshade from the wall shall be minimum 450 nm over window openings and 750 mm over door openings. 3000 mm 2100 mm 2400 mm 1000 mm 2500 mm 2800 mm 7000 mm 5000 mm 3000 mm

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:38

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Doors and windows on the external walls of buildings with metal cladding shall be fixed by creating recesses in the cladding system. No cable trenches shall be provided in TG hall, Boiler/ESP area, fuel oil pump house, Ash pump houses etc. Duct banks consisting of MS/PVC conduits for cables shall be provided with proper sealing arrangement consisting of fire retardant sealing compound. All floor openings for cables below electrical panel shall be sealed with fire sealing compound after cables are laid. All openings in external walls provided for pipes, cables, duct etc. shall be effectively sealed to prevent water seepage, after the routing of the services are completed. Natural lighting & Ventilation The area of windows shall be a minimum 15 % of the floor area to ensure adequate natural lighting. Fans shall be provided in general office areas as per standard norms. Sewerage system shall be provided with adequate ventilation for the pipe work as well as manhole. 7.0 CONCRETE MIX The following minimum grades of concrete as per IS:456 shall generally be used for the type of structures noted against each grade. a. b. Grade M15 Mix (1:4:8) : : Fill concrete Foundation below brick wall, blinding layer below foundations, trenches and underground structures, minimum thickness of the layer shall be 75 mm. Base plate encasement, pavement around building including plinth protection work, encasement of structural steel work, grade slab & grade beams etc. TG foundation, chimney raft and all RCC members, e.g. foundation and superstructure, pedestals, roof slabs, cable and pipe trenches, water retaining structures, cooling water channel, CWPH forebay, raft & sump etc. TG top deck, chimney shell etc. and for structures coming in contact with sea water. For natural draft cooling tower.

c.

Grade M20

d.

Grade M25 & M30

e. f.

Grade M35 Grade M40 / M45

: :

For superstructure of RCC chimney and natural draft cooling towers richer mix may be used as per design requirement. However, requirement of Table-4 & 5 of IS:456 shall be satisfied as per the exposure condition. As per IS:456, exposure condition will be severe for all structures under the civil scope of work except for sea water

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:39

DESEIN

Volume-VI: Civil, Structural & Architectural Works

intake well and pump house, cooling tower, CWPH forebay & sump etc. coming in contact with sea water, where in exposure condition shall be very severe. 8.0 SPECIAL PAINTING FOR SEA WATER STRUCTURES All concrete surface coming in contact with sea water will be painted with 1.5 mm thick polyurea coating meeting ASTM D-16, Type V (two component, chemical cure). This will be applicable for sea water intake well and pump house, cooling tower and CW pump house forebay and sump, Clarified Water reservoir, Guard pond, Fire water sump, RO stage I Permeate Tank etc. In case of NDCT, inside cooling tower, polyurea coating upto 2M height above the drift eliminator is to be provided. 9.0 SPECIFICATION FOR PAINTING OF STEEL STRUCTURES/MATERIAL All fabricated steel materials, except those galvanized, would receive anti corrosive coatings as per specified below:1. For exposed steel materials, the following painting specifications would apply: a. Surface preparation of Swedish Standards 2 by shot / metal blasting. Application of Zinc silicate primer of DFT 75 microns by spray/airless spray / as per manufacturers specifications. Undercoat of 2 pack epoxy with micaceous iron oxide pigment in two coats / as per manufacturers instructions giving a total DFT of 100 microns. Finish coat of high build polyamide cured with 2 pack epoxy pigmented with fade resistant, chemical resistant, colour pigments giving a total DFT of 100 microns. Top finish coat of polyurethane paint of DFT 35 micron for UV protection. Thus for structures / surfaces exposed to atmosphere, coating with a total DFT of 305 microns would be applied.

b.

c.

d.

e.

2.

Painting would not be done in frosty or foggy weather or when humidity is such as to cause condensation on the surfaces to be painted. The surfaces of steel work to be painted are thoroughly cleaned of all loose mill scale, rust, grease, dirt and other foreign matter by metal/ shot blasting only. The surface dose would not possess a slick finish to which paint may not adhere properly. All painting works are carried out as applicable IS standards, BS 5493 and manufacturers instructions.

3.

4.

10.0 10.1

GEO-TECHNICAL INVESTIGATION M/s TANGEDCO, owner of this project has carried out preliminary soil investigation work in power block area i.e. from power house to chimney. Few boreholes and static

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:40

DESEIN

Volume-VI: Civil, Structural & Architectural Works

cone penetration tests were performed. Annexure-I of the specification.

The borelog datas are enclosed in

As per the soil consultants report main plant building structures, TG foundation, boiler foundation, mill building foundation, mill foundation, ID, FD & PA fan foundation, chimney foundation etc. pile foundation is recommended. Piles will be bored cast-in-situ. 10.2 Recommended safe load carrying capacity of Bored Piles will be as follows: S.No. Dia. of Pile Depth below cutoff (m) Vertical Compression (kN) Vertical Tension (kN) Later Load

(mm) 1. 2. 3. 4. 5. 6. 500 600 750 500 600 750 23.0 18.0 900 1200 1800 1400 1800 2500 300 400 500 700 800 900

(kN) 80 120 160 80 120 160

Above informations regarding soil investigation is only for the guidance of the bidders. Owner does not take any responsibility for the correctness and interpretation of the result. Any variation of the said information shall not constitute a valid reason in affecting the terms and condition of the bid. The bidder shall fully satisfy himself about the nature of soil expected to be encountered, including the type of foundation, bearing capacity, sub-soil water etc. prior to the submission of his bid. 10.3 Detailed geotechnical investigation shall be carried out by the Contractor on award of work. Based on the plot plan developed, the contractor shall identify proposed borehole locations and obtain the approval of Owner prior to commencing the investigation. In the power block bore holes shall be provided and spread judiciously to cover all major building as well as equipment foundations. Generally, a grid of 50 metres c/c both ways is recommended from Chimney to end of Switchyard. In the offsite areas also it shall be ensured that the bore holes are provided near all major structures. If the final geotechnical investigation report is found to be in variance with the assumptions / preliminary investigations made during bid stage, the contractor is not eligible for any extra claim or time extension. Following field tests shall be conducted: Bore holes and standard penetration tests Static plate load tests Cyclic plate load test Cross hole shear velocity test

10.4

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:41

DESEIN

Volume-VI: Civil, Structural & Architectural Works

10.5

Field permeability tests Field density tests Vane shear tests Static cone and dynamic cone penetration tests Electric resistivity tests Pressure meter tests Percolation test California bearing ratio tests

Bore holes shall be located to cover the entire area. All bore holes shall be sunk up to a depth of 40.0 m or N value greater than 100 is obtained for 4 consecutive intervals. Standard penetration test (SPT) and collection of undisturbed soil samples (UDS) shall be carried out alternatively at 1.0m intervals and at significant change of strata. The interval shall be increased to 1.5m below 5m depth of boring. UDS shall be replaced by SPT in cohesion less strata. Even in highly weathered / disintegrated rock, where core recovery is poor, SPT shall be conducted. The first SPT in any borehole shall be conducted at 1m depth. Dynamic Cone Penetration Test (DCPT) The test equipment and procedure shall meet the requirement of IS:4968 (Part II). The driving shall not be done for more than 30 cm at a time after which it shall be stopped for a minute or two. The tests shall be terminated when the blow counts exceed 35 for 100 mm. penetration when the cone is dry and 20 for 100 mm. penetration when the cone is penetrated by circulating slurry. The results shall be reported in a suitable tabular form giving below counts for every 30 cm. penetration supplemented by a graphical plot of blow count versus depth.

10.6

10.7

In rock strata, core recovery, Rock Quality Designation (RQD) and Room Mass Rating (RMR) shall be noted carefully for each run, immediately after cores are taken out of barrel. During boring, the level at which ground water is struck shall be carefully noted. Ground water samples shall be collected for chemical analysis. Boring shall be carried out without the use of water or drilling mud up to the depth of ground water table. Following laboratory tests shall be conducted: (preferably on Undisturbed soil samples and if UDS is not possible, on remoulded soil samples) i) Grain size analysis a) b) Hydrometer analysis Sieve analysis

10.8

10.9

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:42

DESEIN

Volume-VI: Civil, Structural & Architectural Works

ii) iii) iv)

Field density and moisture content. Specific gravity. Chemical analysis of soil and ground water including sulphates, chlorides, pH value etc. Chemical analysis of 2:1, water:soil extract of the samples giving SO 3 content. Consistency Index: Liquid limit, plastic limit, plasticity index, shrinkage ratio. Consolidation test giving all relevant information. Swelling pressure and free swell index for expansive soils. Unconfined compressive strength on undisturbed soil samples Direct shear test. Triaxial compressive strength tests: a) b) c) Unconsolidated undrained test Consolidated undrained test Consolidated drained test

v)

vi) vii) viii) ix) x) xi)

xii) xiii)

Moisture density relations for Standard Proctor and Modified Proctor tests. Crushing strength, specific gravity, unit weight, water absorption test of rock specimens of NX size. Permeability test.

xiv) 10.10

The Geotechnical investigation report shall necessarily include but not be limited to the following information: a) b) Recommended types of foundation. Allowable safe bearing capacities and settlement values in different strata for shallow foundations indicating relevant design criteria adopted, method of analysis adopted etc. Type of piles recommended with reasons for the same, length, diameter, allowable capacity (lateral pullout and vertical) of individual and groups of piles, negative skin friction, if any, and magnitude of estimated negative skin friction. Recommendations for values for modulus of sub grade reaction for foundation design by elastic method. Type of cement to be used for concrete substructures and in stone/ brick masonry foundations with reference to the chemical nature of subsoil and ground water.

c)

d)

e)

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:43

DESEIN

Volume-VI: Civil, Structural & Architectural Works

f)

Recommendations regarding excavations (shallow & deep), embankment, safe sides slopes for excavation and embankment, dewatering, site drainage etc. Recommended soil properties such as density, specific gravity, cohesion, angle of internal friction etc. for design.

g)

11.0

JOINTS / CONNECTIONS IN STEEL STRUCTURES: Steel structures shall be detailed and connection and joints provided as per the provisions of IS:800, IS:9595, IS:1367 and IS:9178 and as per following requirements: a. Connection of vertical bracings with connection members and diagonals of truss members shall be designed for full tensile capacity of the bracings unless actual loads are indicated on the drawings. Size of fillet weld for flange to web connection for built up section shall be as follows: i) For box section weld size shall be designed for 60% of full shear capacity or actual shear whichever is more. Where filet weld is not possible, full penetration but weld shall be provided. For built-up I section, weld size shall be designed for 80% of full shear capacity or actual shear, (if indicated in drawings) whichever is more. However, weld size shall not be less 0.5 times the web thickness. Weld shall be double fillet. All welds shall be continuous unless otherwise specifically approved. The minimum size of the fillet weld shall be 6 mm.

b.

ii)

iii)

c.

Shear connections shall be designed for 70% of section strength for rolled sections and 80% of section strength of built-up section or rolled section with cover plates. However, if actual shear load is more than above, the connection shall be designed for actual load. Moment connection between beam and column shall be designed for 100% of moment capacity of the beam section. This can achieved either by direct butt welding of the top flange of beam with column flange or by providing top moment plate with suitable notch for additional weld length. All butt welds shall be full penetration butt welds. The connection between top flange and web of crane girder shall be full penetration butt weld. Bottom flange, connection with web can be fillet weld or butt weld as directed by Purchaser. Connection of base plate and associated stiffeners with the columns shall be designed considering the total load transferred through welds. However, minimum weld size (double fillet) shall not be less than 0.6 times the thickness of stiffeners. Splicing: All work shall be full strength. Field splicing shall be done with web and flange cover plates for full strength. In exceptional cases, the field splicing shall be designed for 50% of load carried by the cover plates and

d.

e. f.

g.

h.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:44

DESEIN

Volume-VI: Civil, Structural & Architectural Works

remaining 50% load through full penetration butt weld. Shop splicing for all sections other than rolled shall be carried out by full penetration butt welds with no cover plates. Splicing for all rolled sections shall be carried out using web and flange cover plates. 12.0 12.1 ARCHITECTURALCONCEPTS AND DESIGN Architectural Concepts a) Layout of the plant area shall have definite hierarchy of road network depending upon its usage, aesthetic, visual sensibilities for creating road vistas, focal points, building back drops, building frames. General layout shall be evolved taking over the basis of landform & local climate & due consideration shall be given to orientation & wind direction. The resulting built mass shall present a definite image width in distinct vocabulary in the form of landmarks, nodes & skyline. Main Plant Building shall be architecturally treated in such a way that it retains a monumental scale, yet presents a pleasing composition of mass and void with suitable and functionally designed projections and recesses. The overall impact of the building shall be one of aesthetically unified architectural composition having a comprehendible scale, blending tonal values with the surroundings and taking full consideration of the climatic conditions, the building orientation and the existing structures nearby. All other buildings and structures shall be architecturally treated in such a way so as to be in complete harmony with the main plant, surrounding structures and environment. Local architectural characters and materials may be judiciously imbibed. The building shall be designed initiating an architectural control common to all buildings. The architectural control shall be clearly spelt out in terms of scale, man & form. Overall colour scheme and finish schedule of the plant and other buildings shall be designed judiciously and in a comprehensive manner taking into a account the mass and void of buildings, its faade, equipments, exposed structural elements, piping, trestles, bus ducts and other service elements. Overall emphasis shall be on developing an eco-friendly architecture, merging with the nature with its own sustainable energy management systems. The scheme shall be conceptually finalized in totality including that of equipments so that the proper coordination with other agencies can be taken up at appropriate time. 12.2 Architectural Design i) Natural light shall be used to the maximum extent specially in the form of north light / sky light. For adequate light & ventilation, National Building code recommendations shall be followed. Entrance canopies, chajjas (projections, recesses) over openable windows and door openings on exterior facades shall be provided. All the buildings shall be architecturally designed to meet the National Building Code (SP:7) norms and local building bye laws, wherever applicable.

b)

c)

d)

e)

ii)

iii)

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:45

DESEIN

Volume-VI: Civil, Structural & Architectural Works

iv)

Architectural design and detailing aspects of all the buildings shall be rendered through professional services of an Architect. Statutory requirements and any clearances from local authority may be required to be met with, wherever essential. The Architect Consultant shall be of National / International repute having experience in similar kind of works. The consultant shall evolve the design philosophy based on Employers guidelines and shall present it in the form of presentation drawings, Prospective views, 3-D Models & detail drawings.

13.0 13.1

TURBINE GENERATOR BUILDING Turbine building (TG bay and heater bay) framing shall be of structural steel with moment connected framing in the transverse direction and bracing in the longitudinal direction. Service and maintenance bays shall not have any intermediate floors, however a 1500 mm wide observation gallery with handrails shall be given along the wall at the operating floor level to observe the TG erection operation. Intermediate floors shall preferably be provided at 8.50 m and operating floor at 17.0m. Floor at 8.50m and operating level shall be RCC floors over steel framing, where as the floor at any other level as required may have chequered plate / gratings supported on structural steel frame work. Crane capacity and crane rail level shall be fixed based on the equipment to be lifted and the method of lifting generator stator. At crane girder top flange level a crane walkway shall be provided in line with factory rules. Access shall be provided to crane walkway through staircase from operating floor in addition to cage ladder at two ends. Bottom level of roof framing shall be decided by the crane clearance required duly taking into account clearance required for mounting light fixtures. Roofing shall consist of in-situ RCC slab of minimum 150 mm thickness laid to a slope of 1 in 100, constructed over permanently colour coated galvanized MS troughed metal sheet of approved profile supported on steel purlins and trusses. Silicon modified polyester paint shall be used for permanent coating on exposed surface. The galvanization shall be 275 qm/sqm and DFT of permanent colour coating shall be 20 micron (approx). Primer coat shall be provided on inner side. Roof of heater bay shall be of RCC slab over the steel roof beams. TG bay roof shall be provided with exhaust system. All external sides shall generally be cladded with permanent colour coated sandwiched insulated metal cladding system (refer cl. 40.0 in Part-B) from 3m (approx) above ground floor up to roof. Brickwork shall generally be provided from ground floor to 3m (approx) height. Wall in front of transformers shall be of adequate thickness to satisfy fire rating as per TAC regulations. On the heater bay side the brick wall shall be provided upto 1m above deaerator floor level. Cladding beyond the above level shall of permanent colour coated sandwiched insulated metal cladding system. Windows shall be side-hung steel glazed using 6mm thick wired glass generally. However in areas where cladding is of sheeting fixed glazing in anodized aluminium framework and in accessible areas sliding windows in anodized aluminium framework using 6mm thick wired glass shall be provided. All the doors on external walls shall be of double plate flush steel doors. For equipment entry into the service bay specially designed steel sliding cum / folding / rolling shutters shall be provided with appropriate operating mechanism. Rolling shutter shall also be provided in front of condenser to facilitate tube removal.

13.2

13.3

13.4

13.5

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:46

DESEIN

Volume-VI: Civil, Structural & Architectural Works

13.6

Staircase protected on all sides with fireproof enclosure shall be provided to satisfy LPA regulations. All the doors leading to the inside of the power house from staircase shall be automatically closing fire proof door satisfying LPA regulations. Access cage ladders shall be given to TG building roof. A roof shall be provided with roof water proofing treatment using high solid content liquid applied elastomeric water proofing membrane with separate wearing course as per ASTM-C-836 & 898. Thickness of the membrane shall be 1.5mm (min.). This treatment shall include application of polymerized mastic over the roof to achieve smooth surface and primer coat. Wearing course on the top of membrane shall consist of 25 mm thick PCC (1:2:4) cast in panels of maximum 1.2x1.2m size and reinforced with 0.56mm dia galvanized chicken wire mesh and sealing of joints using sealing compound/ elastomeric water proofing membrane. However, chequered concrete tile flooring 22mm (min.) thick of approved colour and shade conforming to IS:13801 shall be provided for path way of 1m width for access of personnel and handling of equipment and for the entire area of the roof where equipment like A/C ventilation plant, cooling towers, etc. are provided in place of PCC wearing course. Equipment shall be installed on raised pedestal of minimum 30 cm height from the finished roof to facilitate maintenance of roof treatment in future. HDPE rain water pipe of min. 150 dia OD conforming to IS:4984 shall be provided to drain off the rainwater from roof. They shall be suitably concealed from the faade. Thickness of structural RCC floor shall be minimum 150 mm above the steel floor beams for the intermediate floors with an additional 50 mm floor finish, which shall be provided later. All the intermediate floors shall be provided with proper drainage. Catch pit with CI grills shall be provided near the internal column in a regular pattern and the floor shall be sloped towards the catch pit by varying the thickness of the bedding concrete for the floor finish. Catch pits shall be at the same co-ordinate for all floor levels. 80 NB galvanized MS pipes conforming to IS:1239 shall be provided to carry the drainage down. The pipes shall be clamped on to the intermediate column. Sumps shall be provided in ground floor to receive the water. Proper drainage arrangement shall be provided in the ground floor by means of RCC gravity channels with MS grills on top. The drainage shall be led to sumps from where the water shall be pumped to plant drainage, concrete kerb shall be provided to isolate the area and water shall be led through sump and channels to the floor drainage system. Oil water separator should be provided as required to isolate oil from the drainage water where the water is mixed with oil.

13.7

13.8

13.9

In operating floor the design live load shall be painted on the floors prominently showing the extent of the area where such loading is permitted. Wherever openings are provided in the floor for handling of equipment using EOT cranes such openings shall be covered with gratings provided over removable steel beams. Expansion joint shall be provided in the building to satisfy the requirements of IS:800 and IS:3414. For casting of RCC roof of high raise building like CWPH, TG building etc. permanent profile phosphate coated deck is to be provided. CONTROL ROOM / ELECTRICAL BAY STRUCTURE The building framing shall be structural steel with moment connection in the transverse direction and bracing in longitudinal direction located by the side of turbine building. It shall be ensured that in front of control room no cross bracing is provided.

13.10

13.11 13.12 14.0 14.1

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:47

DESEIN

Volume-VI: Civil, Structural & Architectural Works

14.2

A minimum headroom of 2200 mm shall be given in the cable vaults. In control room false ceiling level shall be kept 3500 mm above floor level All floors shall be of in-situ RCC slab provided over structural steel beams with permanently laid MS sheet shuttering. Minimum thickness of structural concrete shall be 150 mm with an additional 50 mm provided for finish. Roof shall also be of in-situ concrete with permanently laid MS sheet shuttering; but the concrete shall be given a slope of minimum 1 in 100 to effect proper drainage. No openings will be permitted on the roof of control room excepting possibly opening for A/C duct to exercise proper control on air conditioning. No openings will be permitted on the roof also, as this will interfere with effective water proofing Cladding shall be of brick walls. Windows from switchgear room and control room / electronic cubicle room will not normally be allowed on the Boiler side to avoid coal dust nuisance. Walls shall normally be supported on wall/floor beams. If wall beams cannot be avoided they shall preferably be given at the level of floor beams and shall be encased in concrete. Portion of the structural steel column projecting into the room shall be encased with brick masonry to shield it from fire hazards. Cable vault in ground and second floor shall be provided with minimum 2 doors per unit. The doors shall be flush steel doors. No windows shall be provided on the turbine bay side

14.3

14.4

14.5

14.6

Switchgear room shall be provided with minimum two steel doors to satisfy statutory requirement. In addition a two leaf sliding doors of slush welded steel construction shall be provided to move the switchgears into the room making use of equipment lifting hatch provided in turbine building. Main entrance to control room shall be provided with air locked lobby with automatic closing sliding glass doors. Lobby shall be formed of anodized aluminium framing with toughened sheet glass 6 mm thick. Partition between control room and adjoining rooms shall be of glazed aluminium partition with 300 mm high brick wall at bottom for toe protection. All the doors shall be single lead glazed aluminium doors for all cabins. For movements of panels suitably sized double leaf aluminium glazed doors shall be provided. Control room wall upto the false ceiling level shall be of aluminium glazed partition on either side of air lock. In other area cladding shall be of brick wall. UPS room shall be provided with brick cladding all-round to reduce sound nuisance. Battery room shall be provided with PVC doors in PVC framing. For Air washer room steel doors shall be used which shall be airtight. No window shall be provided in air washer room.

14.7

14.8

Staircase properly enclosed to satisfy LPA regulations shall be provided at either ends of each unit. All doors leading to staircase shall be automatic closing fireproof door. Staircase shall not be provided around the passenger lift. Staircase shall extend upto roof. Toilets shall be provided at the switchgear room level and control room level. Toilet floors shall be sunk and shaft shall be provided to route the soil pipe. Sunken floor shall be provided with damp proofing treatment. Control room and electronic cubicle room is to be provided with false ceiling. False ceiling shall be designed aesthetically properly arranging, supply air diffuser, return air grill, fire protection sprinklers and light fittings. Aluminium ceiling system shall be provided. Under deck insulation shall be provided on the ceiling, on the walls and

14.9

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:48

DESEIN

Volume-VI: Civil, Structural & Architectural Works

beams above false ceiling. Under deck insulation shall be provided for air washer room also. 14.10 Floor above control room where APRDS and other pipes are located as well as floor below the deaerator area shall be provided with proper drains to prevent any accumulation of water. This is very important to prevent seepage of water into the control room. All openings in floor for switchgear and other panels shall be sealed with fireproof material after cables are connected. Adequately designed RCC storm water drains shall be provided to lead the roof drainage on to the plant drainage system. These drains shall have pre-cast RCC slotted cover. Plinth protection shall be given on the side of the drain up to the brick wall. MILL AND BUNKER BAY BUILDING The framing shall be of structural steel. This shall be designed as a moment connected framing in the transverse direction and braced in the longitudinal direction. These structures primarily support coalbunkers, coal feeders and tripper arrangement to feed the coal into coal bunker. The bunker shall be circular in plan and shall have the capacity as per the requirement of steam generator. A mill maintenance platform shall be provided at appropriate elevation to attend to routine maintenance. This shall be a platform with chequered plate or gratings over steel framing with handrail all around. Above this floor a framing shall be provided to support under slung crane used for handling mill maintenance work. The crane runway girders shall extend to the full length of mill bay to enable approach to the service bay also. Framework for supporting the circular bunker are provided above the feeder floor based on geometry of the hopper. Bunker shall be provided with a top steel cover with slit openings for entry of coal. On sides of the bunker necessary openings shall have to be provided for bunker ventilation / dust extraction. Tripper floor is immediately above the bunker. This floor is of RCC supported on structural steel framework. Tripper roof shall be of RCC supported on structural steel framework. A fall of about 300 mm is given for the roof framing to effect proper drainage. Tripper roof supports bunker ventilation / dust supporting structure. An RCC parapet or steel handrail shall be provided for the tripper roof. A access stair/ladder shall be provided from tripper floor to roof in each unit. In addition to the above, framing arrangement for structural steel platform at various levels around the bunker shall be provided with proper access ladder, for poking, striking and attending to air canons Tripper floor and roof shall be given access through boiler staircase / elevators. Bunker supporting structure is normally left uncladded up to the bottom of tripper floor. For tripper floor upto 3000 mm above finished tripper floor level, brick wall shall be provided. Above this level permanent colour coated galvanized trough sheet

14.11

15.0 15.1

15.2

15.3

15.4

15.5

15.6

15.7

15.8

15.9 15.10

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:49

DESEIN

Volume-VI: Civil, Structural & Architectural Works

cladding shall be provided. Fixed steel windows with 6mm thick wired glass shall be provided in the tripper house as per requirements for conveyor gallery 15.11 Roof slab will be sloped to one side to permit easy drainage. Liquid membrane water proofing treatment is to be provided. As the roof is accessible and maintenance crew is likely to work on this floor, the entire roof shall be provided with min. 50 thick screed over the water proofing treatment. Rainwater down take pipes of HDPE shall be provided. One number goods cum passenger elevator, and two nos. of staircase shall provide access to all floor/platforms extending upto the roof level. These structures primarily support coal bunkers, coal feeders and tripper arrangement to feed the coal into coal bunker. Requisite nos. of corridor as per operational requirements shall be provided to access steam generator building from Mill building. The Mill building and steam generator building shall have expansion gap and corridor shall be connected with sliding supports. Stainless steel liners shall be provided in bunkers for the conical, hyperbolic hoppers and 1 m from top of Bunker for vertical portion. 16.0 16.1 STEAM GENERATOR AREA PAVING Entire steam generator area upto the end of chimney shall be provided with RCC paving over rubble stone soling (for the details of RCC paving refer clause 41.7 of Volume-VI, Part-B). Paving shall be carefully planned such that maintenance access roads of minimum 4m wide to all major equipment are available. This area shall be designed for heavy loads similar to design of roads. Such approach road shall be provided to the SG elevator also to enable handling of equipment at higher level during maintenance. Such roadways shall be clearly identified with kerbs / painting. All drain / trench covers in these areas shall be designed to withstand truck loading. The drainage of the entire SG area shall be properly planned. Network of RCC drains with RCC cover with slotted holes or MS grills shall be provided covering the entire area which lead the storm as well as process leakage water to the peripheral drains, which in turn will lead to plant drainage system. Where open drains are not permitted under ground pipes may be provided in which case at all junctions and ends proper manholes shall be provided to permit periodic cleaning of the pipes. All structural steel columns in the area shall be provided with encasing to a height of minimum 200 mm above paving level and in addition the bases also need encasing if base plates are below paving level. For periodical cleaning of manholes suitable screens or baskets shall be provided for easy cleaning from time to time. TRANSFORMER YARD Generator transformer, station transformer, unit auxiliary transformer and service transformer are located in front of the turbine building. Transformers shall be installed on RCC foundations with rails on the top and oil soak pits filled with hard stone aggregate. Burnt oil pits are provided to collect leaked oil from the soak pit through salt glazed, pipes laid to slope. RCC blast wall / RCC frame with brick wall of adequate thickness and height to satisfy TAC regulations shall be provided in between transformers as fire barrier wall.

15.12 15.13

16.2

16.3

17.0 17.1

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:50

DESEIN

Volume-VI: Civil, Structural & Architectural Works

17.2

RCC foundations shall be provided with rail to transport transformers out of transformer yard during maintenance. Entire area shall be surrounded with 3m high chain link fencing with gates. Where rails cross the fencing, fencing shall be made of removable type to facilitate transport of transformer. Floors shall be paved with plain cement concrete and shall be sloped towards peripheral drains, which shall lead to a sump from which the drainage is led through an oil water separator. The clear water shall be led to plant drainage. ESP Control Room ESP panel control room buildings shall be RCC framed building with brick walls plastered on both faces, complete with drains, space conditioning, and building lighting. The building shall have a separate air-conditioned area; and a separate non air-conditioned area except as required for the contained equipment. The contractor ascertains the building size according to the design requirements.

17.3

18.0 18.1

REINFORCED CONCRETE CHIMNEY Scope This specification covers the general requirements for design and construction of reinforced concrete single flue chimney of circular cross section including RCC shell, steel flue, internal platforms, staircase, appurtenances, fixtures, fittings, conduit and other embedments, lift (inside windshield), natural ventilation etc. complete.

18.2

Codes and Standards a) b) IS:456-2000 IS:4998 (Part-1-1975 & 1992) IS:875 (Part-3-1987) : : Code of practice and reinforced concrete Criteria for design of reinforced concrete chimneys

c)

Code of Practice for Wind Load

d)

IS:1893-2002 (Part-1) Fifth revision

Criteria for earthquake resistant design of criteria

e) f)

IS:432 (Part 1): Mild steel and medium steel bars IS:1786 : Cold twisted steel bars for concrete reinforcement : : Code of Practice for general building construction steel Ready mixed paint, brushing, bituminous, black. Lead free, acid, alkali and heat resisting Mild steel tubes, tubulars and other wrought steel fittings, Part-1 Mild steel tubes Code of practice for design and construction of foundations in soils : General requirements

g) h)

IS:800 IS:158

i)

IS:1239

j)

IS:1904

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:51

DESEIN

Volume-VI: Civil, Structural & Architectural Works

k) l) m)

IS:2062 IS:3043 IS:3346

: : :

Steel for general structural purpose Code of practice for earthing Method for the determination of thermal conductivity of thermal insulation materials (two slab guarded hot plate method) Un-bonded rock and slag wool for thermal insulation. Design and construction of steel chimney liners. Task committee on steel chimney liners, Fossil Power Committee, Power Division, ASCE.

n) o)

IS:3677 ASCE-1975

: :

p)

Vickery, B.J Wind Induced Loads on Reinforced Concrete Chimneys Paper presented at National Seminar on Tall Reinforced Concrete Chimneys, 25-27 April, 1985, New Delhi. Vickery, B.J. and Base, The response of reinforced concrete chimneys to vortex shedding, R I Journal of Engineering Structures, 1984, Volume -6. Reference may also be made to ACI:307-1979 Specification for design and construction of RC Chimney, if some items are not covered in India Codes. Manohar S.N. Tall Chimneys Design and Construction, Tata McGraw Hill Publication. Pinfold G.M, Reinforced Concrete Chimneys and Towers, View Point Publication.

q)

r)

s)

18.3 18.3.1

Design Parameters and Requirements General a) General parameters of the chimney: 1) Total height of the chimney above grade level Single flue RCC wind shield (shell) for one 500 MW Boiler No. of boilers Exit velocity of gas at top Density of gases Volume of gases Temperature of flue gases Inlet duct center line elevation : : 275 M

2)

3) 4) 5) 6) 7) 8)

: : : : :

One (1) 30 m/sec 0.8825 kg/m

802.8 M /Sec 127 C

As per Boiler manufacturers drg.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:52

DESEIN

Volume-VI: Civil, Structural & Architectural Works

9)

Inlet duct opening dimensions

As per Boiler manufacturers drg. 41.5 C 17.3 C 27 M

10) 11) 12)

Maximum ambient temperature : Minimum ambient temperature : External diameter of windshield : at top of raft (min.) Minimum top shell thickness :

13) 14) 15)

400 mm 900 mm Circular annular raft on bored pile 120 mm WC

Minimum bottom shell thickness : Chimney foundation :

16)

Flue gas pressure at chimney entry level

18.3.2

Design Requirements RCC 275M chimney shall be of single steel flue. Flue shall be of corrosion resistant steel / MS steel suspended from top. Effect of adjoining structure such as chimney, boilers, cooling towers etc. on magnifying wind loading on the chimney shall be studied in a wind tunnel before the designs are finalized. A provision of 10% increase in the wind load forces (due to dynamic interference effect) as calculated based on relevant codes, shall be considered in the initial designs. However, for final designs, the increase can be as per recommendations of the agency carrying out wind tunnel studies. Wind tunnel studies has to be carried out from SERC, Chennai / IIT, Kanpur A lift will be provided on the inside surface of windshield.

18.3.3 18.3.3.1

Design Criteria Dead Load All permanent loads due to the weight of chimney shell, ladders, flue ducts, staircases, other accessories etc.

18.3.3.2

Imposed Load i) Imposed load on service platform around Chimney shall, shall be taken as 2 500 Kg/m . Design live load during construction / erection shall be considered 2 as 1000 Kg/m . Imposed loads from duct joining the Chimney shall be considered.

ii) 18.3.3.3

Wind Load Basic wind speed = 50 m/s (upto 10m above normal ground level) as per IS:875 (Part-3) : 1987. K1 K2 = = 1.12 (Table 2, Category = 1, Class-B)

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:53

DESEIN

Volume-VI: Civil, Structural & Architectural Works

K3

1.0

The final design will be checked and verified by wind tunnel test by a reputed institute and if needed modification be carried out in the design of shell and foundation at no extra cost. 18.3.3.4 Seismic / Earthquake Load Earthquake forces acting on the Chimney and analysis for the same shall be carried out as per IS: 1893-2005 using the Response Spectrum Method and 5% damping shall be considered for the analysis. The analysis shall be furnished for a combination of five modes. 18.3.3.5 Thermal Effect Due to the effect of temperature gradient, vertical and circumferential stresses are developed. These stresses induced in the concrete shall not exceed values given in IS:4998. Flue gas temperature at inlet / exit 127 C (approx.) The temperature gradient T across the shell thickness will be calculated as per IS: 0 4998 (Part-I) 1975 but subject to a minimum of 30 C. Temperature stresses will be calculated according to the procedures given in ACI-307 and IS: 4998. 18.3.3.6 Load Combination Various load combination for calculation of stresses shall be as under. a) b) c) d) e) f) g) h) Dead load + Wind Load. Dead load + Earthquake effect Dead load + Temperature effect. Dead load + Wind load + Temperature effect. Dead load + Earthquake force + Temperature effect. Circumferential stresses due to temperature effect. Circumferential tensile stresses due to wind inducing ring moment. Circumferential compressive stress due to wind induced ring moment combined with temperature.
0

In Load combinations (a) to (f) above, dead load considered shall be with or without the weight of lining; whichever condition is more critical shall be adopted for design. Across wind loads shall be combined with co-exiting along wind loads. The combined design moment at any section shall be taken as SRSS of the moments due to across wind loads and co-exiting along wind loads. 18.3.3.7 Permissible Stresses for Chimney Shell The Stress in Steel reinforcement and concrete shall not exceed the limits as prescribed in clause 7.0 of IS:4998 (Part-1) 1975 for various combination of loads.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:54

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Except for case of dead load + wind load, the maximum permissible stress in concrete in this case shall not exceed 0.28 Fc. Where Fc Characteristic compressive strength of concrete in Kg/cm 18.3.3.8 Wind Analysis The gust factor will be calculated according to the method given in IS:4998 (Part-I) 1992. Dynamic modulus of Elasticity of concrete as recommended in IS:4998 (Part-1) 1992 will be used for calculating the natural frequencies of the chimney. CD will be taken as 0.8 for the concrete shell in general. It will be increased to 0.96 as per IS:4998 over the portion covered with strakes, if required. Along wind response of chimney shall be calculated both by gust factor method in A5.1 and simplified method in A-4.1 of IS:4998 Part-1, 1992. For design, higher of the along wind loads shall be used. 18.3.3.9 Across Wind The across wind response of the Chimney will be evaluated as per the method given in Section A-4 as well as A-5 of IS : 4998 (Part 1) 1992. CL will be taken as 0.16 and S=02. Higher of the two moments shall be considered for design of the Chimney. 18.3.3.10 Ring Moments Due to Wind The circumferential ring moment due to wind will be calculated in accordance with clause 5.4 of IS:4998 (Part-I) 1992. The wind induced stresses in concrete and steel shall be calculated in accordance with Cl. No. D-2.2.7, D-2.2.8 and D-2.2.9 of IS:4998 (Part-I) 1975. 18.4 Seismic Analysis The Seismic Analysis will be carried out using the Response Spectrum Method according to IS: 1893-2002 taking the first 5 modes of vibration in the account. 18.5 Shell and Foundation The design conditions for the concrete shell shall be as follows: 1) The concrete shall be designed for natural phenomena and loads and loads combinations as specified in spec. Working stress method shall be used for design of shell. The modular ratio shall be calculated as per Annexure B of IS-456 2000. The permissible stress in concrete and reinforcement shall be limited to as specified in the spec. The stress in concrete at the junction of shell and foundation will be limited to 0.28Fc where Fc is the characteristic compressive strength of the weaker concrete between shell and foundation. The thickness of RCC shell shall be provided as required by stress calculations. However, the thickness of the shell has also to be determined on the basis of wind tunnel model studies and any increase, in the thickness of shell or quantities required to be made as per report shall be followed without any extra cost.
2

2)

3)

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:55

DESEIN

Volume-VI: Civil, Structural & Architectural Works

4)

The maximum deflection at the top of the chimney for both static and dynamic cases shall not be more than H/500 where H is the total height of the windshield above top of the pile cap. The dynamic modulus or elasticity of concrete for various concrete grades shall be taken as lower values in the range of values specified in IS:4998 (Part-I) 1992. The static modulus of elasticity of concrete shall be taken as under. 5000 fck for instantaneous loadings. Where fck is the characteristic compressive strength of concrete as per clause 6.2.3 of IS: 456-2000.

5)

6)

7) 8)

Minimum thickness of the shell at top shall not be less than 400mm. Reinforcement in the shell shall be provided as per IS:4998 (Part-I) 1975. However, the maximum spacing or reinforcement shall not be more than 250mm both ways in the shell and 300mm for foundation raft. Minimum 0.12% reinforcement shall be provided on either face and on either side of foundation. While providing vertical reinforcement steel in the shell, the total number of vertical bars shall be continued till such height when alternative bars can be discontinued. However, reduction of bar diameter along the height is permissible. At any section of the shell vertical bars shall be uniformly spaced. Non uniform spacing of vertical bars is not acceptable. One third of the vertical bars can only be lapped at one section.

9)

Openings in the shell shall be provided for ductworks, access doors, ash channel and ventilation system etc. The maximum width of opening shall be 0 limited to an angle of not more than 30 subtended at the centre of the concrete shell. The total plan area of the openings at a particular section shall not be more than 15% of the plan area of concrete shell at that location. The opening size for the purpose of stress calculations shall be taken as 1.1 times the actual width of the opening. The extra reinforcement around opening shall satisfy the requirements given in the following documents and the highest shall be provided. a) IS:4998 (Part-I) b) ACI 307. c) Reinforced concrete chimney and tower by M.G. Pinfold. The value of K1 as given in the book by M.G. Pinfold on page no. 196 shall be taken as 0.11.

10) 11)

Embedments to support the stair case shall be provided in the shell Expansion anchors shall be used to attach conduit, lightning and protection equipments, lighting fixtures and other lightweight appurtenances.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:56

DESEIN

Volume-VI: Civil, Structural & Architectural Works

18.6

Foundation The chimney foundation will be resting on piles. A circular pile cap preferably annular shall be provided. The pile cap (min. M-25) shall be designed as rigid member with uniform thickness and no tapering of thickness shall be allowed. Minimum thickness of raft shall neither be less 0.09 times the diameter of raft or 0.3 times the overhang of the foundation beyond shell whichever is greater. Minimum reinforcement shall not be less than 0.12% in either face and in each direction. Wind and earthquake shall be treated as normal load and no enhancement of stress is permitted on this account in soil, concrete and steel. No tension will be allowed under the raft during earthquake and wind. Working stress method shall be adopted for design of foundation. Foundation will be designed for SRSS of moments of along wind response and across wind response.

18.7

Outer Platforms Nos. of outer platforms to be provided are governed as per the requirements of aviation obstruction lights which are required to be provided at various levels so as to meet the requirements of IS:4998 (latest edition) I.C.A.O regulations and instructions issued by the Director General of Civil Aviation. The minimum clear width of the platforms shall be 1000 mm and a live load of 500 Kg/m shall be considered for their design.
2

Hand railing shall be provided all around external platforms 32 NB G.I. pipes. The spacing of railing posts shall not be more than 2000 mm centre to centre. The height of hand railing shall not be less than 1250 mm. There shall be three handrails at about 450 mm and 850 mm & 1250 mm respectively above platform level. 32 mm dia G.I. drainage spouts shall be provided in platforms for drainage of rainwater. 18.8 18.8.1 Steel Liner (Flue) General Liners shall essentially be constructed from structural steel and shall be of the hung type (i.e. of tension type). The liners shall be provided with externally wrapped thermal insulation. The portion of the liners projecting above the chimney roof shall be constructed of stainless steel. Stainless steel liner shall commence immediately above the flue supporting platform but below the roof supporting platform. The liner shall be of corrosion resistant steel type COR-TEN B of minimum 10 mm thick. Top 10m length or length equal to 2 times flue diameter whichever is larger shall be provided in stainless steel grade AISI 304; finish grade 2B (cold rolled, annealed & pickled and skin passed). The liner shall be primarily suspended from the top, with a small length at the bottom near breach elevation supported from the bottom with a suitable expansion compensator in between. The structural steel transition inlet ducting shall be bottom supported. The transition ducting shall be suitably profiled from a rectangular shape at the chimney inlet to a circular shape up inside the chimney where it shall be connected to the suspended circular steel liners through suitable (non-metallic) fluroelastomeric fabric expansion compensator.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:57

DESEIN

Volume-VI: Civil, Structural & Architectural Works

18.8.2

Design of Steel Liners Steel liners shall, in general, be designed meeting the requirements of the document, Design and construction of steel chimney liners, prepared by Task committee on steel chimney liners, Fossil power committee, Power division published by ASCE-1975. The flue diameter shall be so sized to ensure that the flue gas exit velocity is of the order of 20 to 25 meters/second at the normal continuous operating load. It should be ensured that the flue gas exit velocity at the lowest continuous unit load is high enough (of the order of 15 meters/second) to enable adequate dispersion of the flue gases. For this purpose, 100% turbine MCR condition with design coal firing shall be considered as normal continuous operating condition, and 60% turbine MCR condition with design coal / worst coal firing (whichever yields lesser flue gas quantity) shall be considered as the lowest continuous load condition. The supporting / restraining arrangement of the liners should be such that expansion of the liners longitudinally or circumferentially is not restrained. NOTE: Chimney shall be suitable for specified coal and future installation of FGD. i.e. after installation of FGD no modification shall be done in inner surface of Chimney.

18.9

Design of Transition Ducting The number, size and location of flue opening in the shell shall be as per the requirement of boiler supplier. The Contractor shall make arrangement for the proper support of ducting on the shell and provision of restraint / support arrangement as required. The CONTRACTOR shall be responsible for furnishing, fabricating, shop painting and delivery of ducting which shall run from the chimney liner to the flange of the boiler vendors duct including all necessary auxiliary ducting as well as soot collecting hoppers located outside the chimney shell. Soot hoppers shall be lined with SS grade AISI 304. Suitable flange connection shall be provided at the exit of the hopper to provide SS / CI pipe connection to drain ash / condensed acid mixed water. The duct work profile and the guide vanes shall be so configurated and sized to achieve the desired flue gas flow characteristic and to minimize flue gas pressure losses. The plate thickness of the ducts shall be arrived at from minimum (i.e. codal) requirements, structural considerations and corrosion allowances. The minimum installed thickness of the mild steel ducts shall not be less than 10 mm in any case. Material of construction shall be mild steel conforming to IS:2062. In case COR-TEN steel is used minimum thickness shall be 8 mm. The duct work shall be insulated with 75 mm thick insulation (3 layers of 25 thick sheets) as per requirements of clause 18.11 and protected with aluminium foil of minimum 1mm thickness. Access doors shall be provided for the ducting where required for inspection and cleaning.

18.10

Load Bearing and Side Restraints of Flues Load bearing insulation assembly to have (i) a properly machined mild steel plate with recess at its top for seating PTFE (Poly Tetra Fluoro Ethylene) sheets conforming to BS:5400 (ii) saddle plate (MS) in the middle having stainless steel plate fixed at its bottom surface and lead / elastomeric sheet at top, and (iii) top late formed of two

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:58

DESEIN

Volume-VI: Civil, Structural & Architectural Works

numbers insulation blocks each made of minimum 50 mm thick rigid, non-combustible asbestos fibre reinforced lime-silica board (SINDANYO BLOCKS NATURAL GRADE CS-51) or equivalent bonded to mild steel plates at top and bottom. For side restraints assembly of insulation blocks of SINDANYO Natural Grade CS-51 or equivalent and stainless steel plate shall be used. All stainless steel in these assemblies shall conform to AISI-316L and mild steel to IS:2062. SINDANYO o BLOCKS or equivalent shall be suitable for operation at 320 C and shall primarily satisfy the following physical properties: i) Minimum compressive stress prior to onset of compression yield of not less than 12 N/sq.mm. Minimum shear strength of 30 N/sq.mm when tested in accordance with BS:3497-1979. Thermal conductivity shall not exceed 0.67 W/m Deg.C at a mean o -5 temperature of 200 C and its coeff. of linear expansion not to exceed 1.2x10 per Deg.C. Adhesive used for bonding purposes shall be of material with equivalent high temperature properties as approved Foundation Engineer. It may be of Fortafix Fiborclad Adhesive as manufactured by Fortaxfix Ltd., England or equivalent.

ii)

iii)

iv)

The insulation thickness shall be determined based on the maximum ambient temperature, surface air velocity worked out based on the draught of ventilation air in the annular space between the flue liner and chimney shell, insulation surface emissivity of 0.3 and the insulation cold face maximum temperature not exceeding o 55 C. The draught of air in the annular space shall be the natural draught created by the heating of air by the flue liner and the air being vented out through the openings in the chimney shell. The increase in the annulus air temperature due to the rising heated air shall be taken into account while calculating the insulation thickness. The insulation thickness shall not be less than 100 mm, in any case, and shall be provided in two layers with the second layer of insulation covering the joints of the first layer. The insulation shall be wrapped on the outer most surface with galvanized wire mesh. 18.11 Insulation The flue shall be insulated externally. The insulation shall be semi-rigid, resin bonded type, in the form of slabs and shall conform to IS:8183. Blanket type insulation shall not be used. The density of insulation shall not be less than 64 kg/cum for resin bonded 0 rock wool. Maximum coefficient of thermal conductivity shall be 0.062 Kcal/m/hr/ C at a 0 mean temperature of 150 C. The insulation thickness shall be chosen based on the maximum ambient temperature, surface air velocity worked out based on the draught of ventilation air in the annular space between the flue liner and chimney shell, insulation surface emissivity of 0.3 and 0 the insulation cold face maximum temperature not exceeding 60 C. The draught of air in the annular space shall be the natural draught by the heating of air by the flue liner and the air being vented out through the openings in the chimney shell. The increase in the annular air temperature due to the rising heated air shall be taken into account while calculating the insulation thickness. However, a minimum of 50 mm thick (2 layers of 25 mm) insulation shall be provided on the external face of flue. The insulation shall be tightly secured to the exterior surface of the liner by impaling them on studs welded to the surface at 450mm c/c both horizontally and vertically. The

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:59

DESEIN

Volume-VI: Civil, Structural & Architectural Works

studs shall be galvanized plated and be of a minimum thickness of 10 gauge and 75 mm wide. The studs shall extend a minimum of 25 mm beyond the thickness of insulation. Circular or square metal plate speed washers of standard thickness shall be placed on the extended portion of the studs to hold the impaled insulation material well in place. Further, 20 gauge galvanized wire mesh with a 25 mm hexagonal pattern conforming to IS:3150 shall be wrapped around. Where the wire mesh is jointed, a minimum 150 mm overlap shall be provided. The mesh shall be bound and tied in place with a 16 gauge GI wire at 300 mm centers. Any form of lacing the mesh fibres together will not be permitted. Insulation for the exposed portion of flue at the top shall consist of 6 layers of insulation material each of a minimum thickness of 25 mm and all joints shall be staggered. The material shall have a minimum density of 200 kg/cum. This shall be protected from the elements by means of a stainless steel cladding, flashing and hood of grade 316 L stainless steel. Testing of insulation material to satisfy the specific requirements and properties as outlined in this specification IS: 8183 and in the relevant drawings by the contractor shall be carried out. Insulation materials shall be added to walls where necessary to reduce cooling loads. Also, insulation shall be used for sound absorption on walls which enclose equipment that has been determined as generating excessive noise. This sound insulation shall be provided in interior concrete block, sound block, or insulated metal wall panel liners as appropriate. The liner panels shall be as described above, except they shall include perforations and insulation enclosed in plastic bags. The overall noise Reduction Coefficient shall be 0.80 or better. 18.12 Expansion Compensator The suspended portion of the liner shall be connected to the bottom supported portion of the liner by an expansion joint. The joint shall be able to compensate for the large thermal movements of the steel flue, gas tight, acid resistant, heat resistant and provide an adequate insulating medium to avoid excessive overheating in the access void. The materials used for the fabrication of the expansion joints shall be suitable for the flue gas conditions specified herein, and shall not deteriorate during transit, site handling, storage and installation. The expansion joint shall be manufactured by a specialist for similar type of joints. The BIDDER shall furnish outline proposals for the expansion joint during the bid stage along with the manufacturers qualifications and experience for the EMPLOYERs review. On award of contract, full details of materials to be supplied along with fabrication drawings shall be supplied by the CONTRACTOR for the EMPLOYERS approval. The CONTRACTOR shall procure the units only after obtaining the EMPLOYERS approval. The expansion joints shall be made of flexible fibre. They should be air tight and impermeable and should withstand the maximum serviceable temperatures of the flue gas. The CONTRACTOR shall furnish in complete an installation, dismantling and maintenance user handbook. A draft of the handbook shall be submitted to the EMPLOYER for his approval well before the installation commences. The CONTRACTOR shall also supply spare expansion joints complete with instructions for storage, fitting, instructions, spare accessories, tools for installation, etc., to replace

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:60

DESEIN

Volume-VI: Civil, Structural & Architectural Works

faulty / used expansion joints at a later date. period of not less than 10 years.

The spares should withstand a storage

The fabric for expansion compensator shall comprise several layers of materials given below in order from the gas side: a) Two layers of insulation, each consisting of heavy weight glass cloth impregnated with graphite suspension, having an approximate weight of 1.00 kg/sqm. A continuous filament glass cloth coated both sides with a fluro-elastomer having an approximate weight of 1.5 kg/sq.m. Two layers of PTFE (Poly Tetra Flouro-Ethylene) film of minimum thickness 0.15 mm each. A layer of glass felt of minimum thickness 10 mm and an approximate weight of 1.5 kg/sq.m.

b)

c)

d)

18.13

Liner Test Ports Gas sampling ports fabricated from stainless steel with flanged ends shall be provided for liner at platform levels where indicated including proper insulation, blank plates, nuts, bolts, etc. The location, orientation and level of ports shall be as per Central Pollution Control Board regulations. Bidder shall provide for the purposes of instrumentation other than the sampling ports mentioned above required number of 38 NB conduits including pull wires, junction boxes and pull boxes, all securely tacked / anchored to internal of shell and S 316 L plates below each pipe insert for fixing of measuring instruments.

18.14 18.14.1

Accessories Liner Hood: The liner hood provided at top of flue shall be fabricated from 6mm thick (minimum) stainless steel sheets of grade 316L. The hood shall completely cover the annular area packed with insulation material between the stainless steel flue and cladding. All sections of the hood shall be anchored in places with stainless steel bolts / nuts. Slot holes shall be provided to make allowances for differential expansions / movements.

18.14.2

Internal Platforms Internal platforms shall be provided (minimum 5 numbers excluding roof platform) unless indicated otherwise in Data Sheet-A. The platform shall be supported on a grid work of structural steel beams supported from the wind shield. Topmost grid work shall support RCC roof slab, where as other grid work shall support M.S. gratings as required from functional requirement. Corrosion allowance of 2 mm (minimum) shall be kept in the design of girders. Live load for the design of platform shall be 5 kN/sqm. The members of the beam grid shall be assembled by high precision bolted connections only. The member dimensions shall be made to suit the as built dimension within the wind shield. The beams shall be painted with 2 coats of zinc

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:61

DESEIN

Volume-VI: Civil, Structural & Architectural Works

chromate red oxide primer and 3 coats of synthetic enamel paint of approved brand and shade after surface preparation as per IS: 1477. The support of the beams on the R.C.C. shell shall be so designed that only vertical load is transferred to the wind shield without any temperature effect and local torsional / local bending moment. After fabricating, the members of the individual platforms shall be pre-assembled at ground level land checked for trueness with respect to dimensions and orientation. The gratings shall be fabricated from M.S. flats comprising of 40x5 thick bracing bars spaced at 40 c/c and 25x4 thick space bar. The grating shall be hot dip galvanized. Handrails shall be provided with kick plates 65x8 mm along the platform edges. Openings for the elevator shall also be surrounded by a handrail as above, with a hinged gate section on the elevator door side only. The same arrangements shall be provided at all stair case landing/ladder access points, stopper plates shall be provided to prevent gates from swinging outwards. 32mm galvanized steel pipe posts at not more than 2000mm spacing shall be provided for handrail. Height of hand railing shall not be less than 1250mm. There shall be minimum of three handrails at 450mm, 850mm, & 1250mm above platform level. 18.14.3 Staircase A structural steel staircase shall be provided inside the wind shield, connecting the grade slab to the topmost platform below the roof slab. The staircase shall be supported by a structural steel framework supported from platform to platform independently of the wind shield. Connection of the structural support to the platform beam shall be so chosen as to permit unrestrained deflection of the platform supporting beam. Clear width of the stair treads inside stringers shall be 750 mm. Tread shall be of 25 mm thick M.S. gratings hot dip galvanized with anti-skid nosing. Tread shall be minimum 250 mm wide. Maximum riser shall be 175 mm. Handrail shall be of M.S. pipe type medium of 32 mm NB as per IS:1161 with toe protection of 65x8 mm flats, the complete handrail being hot dip galvanized. 32mm galvanized steel pipes posts at not more than 2000 mm spacing shall be provided for handrail. Height of hand railing shall not be less than 1250 mm. There shall be minimum of three handrails at 450 mm, 850 mm & 1250 mm above platform level. All structural steel work other than stair treads shall be provided with 2 coats of zinc chromate red oxide primer followed by 3 coats of synthetic enamel painting of approved brand and shade. All field connection shall be by bolting only. The arrangement of staircase shall ensure easy accessibility to elevators. Staircase and its connection shall be designed for a live load of 5 kN/sqm. 18.14.4 Ladder Steel cage ladder hot dip galvanized shall be provided from the last platform to the roof slab. Stringers shall be of flat 75x10 with a clear distance of 400 mm in between; rungs shall be of 20 mm diameter mild steel rods spaced at 300 mm centres. Ladder stringers shall be provided with suitable stays connected to the platform supporting framework. The ladder and its connection shall be designed for a load of 175 kg at any location. 18.14.5 Lift Lift shall be provided for the chimney inside the wind shield. The lift shall be of open cage type and suitable for corrosive and dusty atmosphere that generally exists in

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:62

DESEIN

Volume-VI: Civil, Structural & Architectural Works

thermal power stations/industrial complexes. It shall generally confirm to the provisions of IS:1860 and IS:4289 unless otherwise specified. The lift shall have a minimum carrying capacity of 400 kg at a speed of 0.70 metre per second. The lift shall be of rack and pinion driven service type of approved make. All the control devices inside the car shall be housed in a dust free and water proof enclosure. Only copper conductor FRLS insulated armoured cable of suitable size shall be included in CONTRACTORs scope. Landing at all locations of platforms shall be provided unless otherwise specified in Data Sheet-A. Construction of guard cage and supply of other accessories required for satisfactory and safe operation of lift shall be included in CO NTRACTORs scope. CONTRACTOR shall also supply and install safety devices such as automatic stop equipment, over speed governor etc. all complete as per Manufacturers recommendation. All the embedments for the lift structure, approach platforms at landing levels and the lift supporting structure including lift car shall be hot dip galvanized. 18.14.6 18.14.6.1 Doors Clean Outdoors Steel flue shall be provided with clean outdoor having clear dimension of 650 mm x 825 mm at appropriate location with proper access for operating the door. The edges of the doors shall be of hollow steel construction with inner plate of 8 mm and outer plate of 6 mm with suitable infill of stiffeners. The hollow space shall be filled up with insulation of the type used around flues. In addition around the door openings, removable type of insulation similar to the insulation provided around flue shall be provided. The door shall be of hinged type and provided with locking device in addition to Swivel studs with wing nuts on the remaining 3 edges. The door shall be openable both from inside and outside. 18.14.6.2 Removable Cladding / Access Door Opening provided near the base of the wind shield for the purposes of flue can erection shall be closed using a removable type of colour coated galvanized aluminium sheet min. 0.6 mm thick on structural steel framing which also can be dismantled if required. Within the cladding area, an access door of size 2100x1000 mm shall be provided with sill level at 300 mm from paved level. This door shall be similar to hollow steel doors provided in other buildings. The door shall be provided with a minimum two coats of acid and alkali resistant paint conforming to IS:158 type I to give a DFT of 75 microns. The outside surface shall be provided with 2 coats of zinc red oxide primer and two coats of synthetic enamel paint. The door shall be provided with suitable locking arrangement. 18.14.7 Chimney Roof & Roof Drainage The chimney roof shall be of RCC slab suitably supported on MS beams. The roof shall be sloped towards rain water down take catch pits covered with CI gratings. The roof shall be designed to cater for differential movement between the shell and the liners including circumferential expansion and contraction due to temperature

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:63

DESEIN

Volume-VI: Civil, Structural & Architectural Works

variation. 1200 mm high RCC parapet formed by windshield shall be provided at roof level. The roof shall be provided with a hatch for access from the flue support platform. The hatch shall have a single leaf door with a minimum thickness of 6 mm to cover a clear opening of 750 mm x 1000 mm. The hatch shall include the door, metal curb, draft seal, spring latch, hold-open device and all hardware. All joints shall be welded and ground smooth. The curb shall be 300 mm in height with a suitable lip which shall include a continuous neoprene seal strip to make the hatch air-tight when the cover is closed. The hatch shall be operable from both inside and outside and shall be provided with automatic hold open arm, easy one hand release and spring latch. All the items of the door shall be of stainless steel of grade 316 L and then painted with heavy duty acid and heat resistant paint as per requirement of IS:158. The roof slab and the inside surfaces of the wind shield shall be lined with 20 mm thick acid proof tiles conforming to IS: 4457. Bedding mortar (of average thickness 10 mm) shall conform to IS: 4832 Part I and shall be of potassium silicate base. Roof slab structure shall be designed to serve as a lifting platform for supporting the weight of flues during erection. The tiles shall be pointed using a phenolic based resin cement mortar conforming to IS:4832 (Part-2). The bedding mortar and phenolic based resin mortar should be acid-proof, chemical resistant and waterproof. They shall in particular be resistant to sulphuric acid and hydrochloric acid. HDPE rain water pipes shall be provided within the interior of the shell to remove rain water collected on the roof. Rain water inlet into the pipes at roof level shall be provided with CI grating. The rain water down take pipe shall be led to a manhole chamber inside wind shield suitably lined with acid / alkali resistant brick lining. From the manhole the drainage water shall be led out of the chimney wind shield through CI pipe to a manhole chamber outside wind shield and from there to Effluent Treatment Plant. 18.14.8 Acid Drains and Manholes In the event of flue gas condensation within the flues acids may be drained out at the base with the provision of stainless steel pipes connected to the soot hopper outlets in each flue located outside the wind shield. The stainless steel pipes, bends, bolts, fixing sleeves, collecting sumps, etc., shall conform to relevant IS codes or BS:3605, and shall be procured, supplied, fabricated and erected in position by the BIDDER. The sumps shall be of adequate size suitable lined with acid resistant bricks and provided with a RC roof and a heavy duty manhole cover. The effluent shall be led by means of stoneware pipe to the nearest manhole of effluent treatment system. 18.14.9 Louvres Air outlet louvers shall be provided as per the requirement of this specification near the top. The louver fins shall be of Z-shape in cross section and made from anodized aluminium plates of a minimum thickness of 4 mm. The frame work supporting the louver fins shall be made from extruded aluminium sections of

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:64

DESEIN

Volume-VI: Civil, Structural & Architectural Works

minimum thickness 6 mm. The louvers shall be mounted in the form of panels. The fins shall be closely spaced to cut off any driving rain entering the chimney wind shield. All panels must be approved by the EMPLOYER before installation. To outside face of louvers ST mesh on SST mesh frame work shall be provided. 18.14.9 Maintenance Provisions The outer face of the chimney wind shield shall be provided with adequate number of stainless steel insert plates of grade 316 L at the top to enable fixing and supporting painters trolleys and other accessories. The insert plates shall be provided with suitable number of threaded holes and nuts welded at the rear end to enable bolting of the assembly when desired. Similar arrangement shall be made at each platform level but to fix the painting trolley arrangement directly on the platforms for the purpose of painting the internals of the chimney. A lifting beam shall be provided at platform level to cater for lifting of materials during maintenance and painting. The size and capacity of the lifting beams shall be as indicated in relevant drawings. 18.15 Chimney Painting Painting the entire inner surface for full height, all air tight enclosures with white cement paint (not less than four coats) to give a paint DFT not less than 150 micron. The entire outside surface of concrete shell shall be painted with alternate bands of signal red and white colour, out of which top 15 m shall be painted with acid and heat resistant paint and rest of the outside surface shall be painted with synthetic enamel paint conforming to IS:5410 in alternate bands of red and white colour. Surface preparation and paint application should be in accordance with manufacturers recommendation. 18.16 Electrical Requirement For Electrical requirement refer Volume-IV. 18.17 Lightning protection system complete with air terminal rods, circumferential conductor, down conductors are duly earthed or connected to the general grounding system for the plant shall be provided in accordance with the provisions of IS:2309.

19.0

SEA WATER INTAKE SYSTEM Sea water intake system comprises of an offshore intake well and an on-shore pump house. The intake well is at a distance of 600 meter approx. away from shoreline and o o the GPS coordinate is 13 12 2.69 N & 80 19 43.14 E. The construction of all works including preparation of sea bed by providing rock armour and transportation of pre fabricated concrete structure to desire location of dewatering, coffer dam, anchoring of the RCC intake structure in to sea bed by suitable arrangements etc., and all other works necessary, whether described / specified or not deem to be necessary for successful completion of the work in respects.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:65

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Intake structure shall be suitably anchored with sea bed. The material and size, method of anchoring shall be submitted along with the bid. The sea water intake structure will be of installing an intake well and laying two nos. RCC pipe line buried in the sea bed, constructing a De-silting basin in the land portion at a suitable location and allowing the water to flow by gravity from the intake well to fore-bay / De-silting basin. For the design of intake system, wave condition during cyclonic weather needs to be considered. RCC wall is to be designed for total intake flow of 25,000 m /hr with 2 Nos. RCC pipes submerged with a velocity cap. The drawl velocity should not be more than 1.2 m/sec. The flow will be gravity flow. The general arrangement of the system will be in line with study report of National Institute of Oceanography, Dona Paula, Goa. Detail geo-technical study at the location of pump house and intake well is to be carried out by EPC Contractor. On the basis of this study, rock armour foundation will be designed. Cathodic sensor arrangements for avoiding galvanic corrosion shall be provided. Sea water structure shall be protected from corrosion by cathodic protection based on sacrificial anodes shall be provided. The replacement life of the anodes shall be minimum of five years. Electro-chlorination system shall have a provision for dosing the chlorine at the intake point inside the intake well. Chlorination shall be done in the intake well and the chlorinate pipe shall be routed through intake pipe. The intake well shall have velocity cap with adequate entry velocity to avoid entrainment of fishes. The draft above the velocity cap shall be adequate for fishing vessel. Marine buoys shall be provided at the intake location. The concrete structure is to be designed as un-cracked section as per IS:3370, Part-I to IV. A 1:25 scale model of the intake well is to be tested in the wave basin of the Ocean Engineering Centre of IIT-Chennai or National Institute of Oceanography, Goa to measure the wave forces and moments on the intake well and the variation of water levels inside and outside the well. The well model study is to be subjected to the action of both regular waves for two test conditions, intake well inlet closed during installation and intake well inlet open. The experimental results on wave forces and moments are to be compared with the results of the Linear Diffraction Theory. The water level inside the well is to be measured to determine the submergence of suction pipes of pumps and location of the inlet opening of the intake well. The wave crest elevation in front of the well is also to be measured in order to fix the deck level of the well so as to avoid water overspill onto the deck. The EPC contractor shall carry out a detailed soil investigation in the deep sea at intake well location and laying the pipe line in the sea bed in order to obtain sufficient information on the sub-soil condition for the proposed intake well and other structural foundation at his own cost.
3

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:66

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Along the alignment of the intake pipes and discharge pipes there may be some crossings of the power lines, pipe lines, fire hydrant, compound wall, sewer lines and other old structures / buildings etc. and the same may be diverted / re-constructed suitably as per the direction of the engineer at site without affecting the operation of the existing power house. No extra claim shall be made on the above account. All clearances / approvals and the cost there upon required from various agencies like Railway, Maritime Board, Public Works Departments etc. in connection with the execution of the work shall be arranged to be obtained by the contractor at his own cost. Necessary assistance will be provided by the owner. A tentative route map of the proposed cooling water system is marked in a separate drawing showing the existing buildings / structures along the pipe line route is enclosed for reference purpose only. 19.1 19.1.1 SEA WATER PUMP HOUSE There shall be 3 Nos. (2W+1S) 50% duty Sea Water Pumps installed in the sea water pump house to provide makeup water to the proposed power plant. Provision shall be made in the pump house for installation of 5 additional pumps at a future date. Refer composite water scheme enclosed in Vol. VII for tentative flow scheme. However, the water quantities shall be worked out by the contractor and equipment sizing shall be done accordingly. Pump house shall be constructed for future unit also and floor reinforcement shall be provided but floor casting need not be done for the future unit. Pump house shall be constructed for future unit also and floor reinforcement shall be provided but floor casting need not be done for the future unit. Separate common intake sump shall be created before the individual sumps for pumps for present unit and future with isolating gates. This shall facilitate construction of partition walls of sump of future pumps without stopping the plant or draining the intake sump. Bidder shall ensure this in his design to ensure seamless construction of sumps for future pumps at a later date. The common intake sump for future unit shall remain isolated with gate being closed and will be in dry condition. Suitable dowels shall be left for building the partition walls and extending the pump floor at a later date for the future pumps. Entire structure shall be of RCC construction. Chlorination building shall be built adjacent to sea water pump house. The chlorination building shall be RC framed structure with brick cladding and adequate louver provision for ventilation. In chlorination building, all doors shall be of flush welded aluminium construction. All windows shall be aluminium glazed side hung. The forebay shall be located at about 70 m away from the High Tide Line (HTL) and the tentative location of forebay is shown in the enclosed drawings. The Forebay shall be designed to cater for a cooling water quantity of 25000 cubic metre per hour. The depth of the forebay shall be decided based on the submergence requirement of the pumps at the lowest water level in the sump. Proper care should be taken during construction of forebay to avoid contamination of ground water with the saline water. Forebay shall be provided with cage ladder at four corners constructed of galvanized steel. Top of the forebay shall be kept 500mm above grade level and hand rail of galvanized M.S. pipes shall be provided on the entire length on either sides. Water level indicator (float type) shall be provided in the forebay close to the pump sump on either side to observe the depth of water.

19.1.2

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:67

DESEIN

Volume-VI: Civil, Structural & Architectural Works

The Forebay shall be constructed either by open excavation or any other approved technique. The bidder is to indicate the method of construction in their bid. The choice of complete dewatering system such as well point system, Filter point etc. shall be the responsibility of the CONTRACTOR. BIDDER shall submit along with his bid, full details of the method he proposes to adopt for dewatering with necessary sketches and specifications. Necessary dewatering system shall be designed and installed by the CONTRACTOR with prior approval of the ENGINEER. Dewatering shall be maintained for at least seven days after the last pour of concrete, for all concreting work below groundwater table. CONTRACTOR shall also suitably direct/dispose off the groundwater obtained during dewatering to safeguard men, materials, structures. The sequence of construction of various items of work shall be as specifically approved by the Engineer.

Corrosion Protection Measures: Additional corrosion protection measures for steel, and concrete required due to the presence of sea water shall be submitted along with the bid. Dimension of the pump sump shall be decided as per mechanical requirements. Sump shall be provided with stainless steel groove for inserting coarse screen, fine screen and stop logs. The floor shall have openings for lowering and lifting of stop log and screens. Each pump shall have an individual sump with proper isolation including the future pumps. EOT crane of adequate capacity shall be provided for maintenance of the pumps and other auxiliary equipments. All the openings shall be covered with epoxy coated mild steel gratings and covered when the screens are placed in position. Provision for handling of stop logs shall be covered with epoxy coated mild steel gratings. Sufficient paved keep space shall be provided to place stop log when not in use and also for maintenance of screens. SS 316L inserts shall be provided with a drain sump to empty the sump for attending to the maintenance of pump. Side of pump house up to motor floor level on the discharge side shall be of RCC. Maintenance bay of the pump house discharge side shall have RCC grade slab with required finish. Motor floor shall also have similar finish. An annex to sea water pump house shall be provided in RCC framed structure to accommodate switchgear and control room with cable vault below, chlorinator room and toilet block. Side cladding shall be of brickwork. All floors and roofs shall be RCC. Roof shall have proper slope and Elastomeric Membrane treatment shall be provided and rain water down fall pipe shall be provided. Control room shall have false ceiling / false flooring and shall be air-conditioned. Necessary office rooms with adequate space (during detail engineering) shall be provided on the first floor of proposed pump house building annex as approved by Owner. All doors shall be of aluminium. For switchgear room, the main entrance door shall be of adequate size to facilitate movement of panels. All windows shall be aluminium glazed side hung. 20.0 CIRCULATING WATER SYSTEM

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:68

DESEIN

Volume-VI: Civil, Structural & Architectural Works

The circulating water system envisaged for the plant is by using sea water. From sea water intake pump house, sea water will be pumped to CW forebay thru ACW pumps. From CW pump house, water will be drawn by volute casing type CW pumps for condenser cooling. RCC cooling water channel shall be of rectangular in shape and is to be designed as a water retaining structures as per IS:3370 Part-I to Part-IV. Depth of channel and width of channel shall match with the width and depth of the cooling water channel from cooling tower. These branch channels shall join together and form common channel leading to the forebay of the CW pump house. 20.1 CW PUMP HOUSE The pump house structures shall be of RCC frame. Cladding shall be of brick work. Crane girder shall be of steel. Cage ladder shall be provided for access to crane platform. Side of the pump house up to motor floor level on the pump discharge side shall be of RCC. Maintenance bay of the pump house shall have RCC grade slab with granolithic finish and non-metallic floor hardener. Motor floor shall also have similar finish. Pump sump shall be designed as water retaining structure. Each sump shall be provided with stainless steel (SS 316L) groove for inserting coarse screen, fine screen and stop logs. Grooves for stop log shall be provided before and after the screens. Where as number of coarse screen and fine screen shall be the same as the number of pump sumps the number of stop log shall be a minimum of two. The stoplog shall be epoxy painted and coarse/ fine screens shall have stainless steel SS 316L mesh over SS 316L frame. Top of the sump floor shall be kept same as of the top of forebay. This floor shall have openings for lowering the lifting of stop logs and screens. These openings shall be covered with galvanized mild steel gratings when the screens are placed in position. Provision for handling of the screens and stoplogs shall be made. Sufficient paved space shall be provided to keep the stop log when not in use and also for maintenance of screens. Galvanized MS handrails shall be provided on 3 sides of the pump floor (sump roof). Each individual pump sump shall also be provided with a drain sump to empty the sump for attending to maintenance of pump. Since concrete volute pumps are envisaged separate pump floor, motor floor & valve floor shall be built in the pump house with proper access arrangements. Suitable staircase, ladders & cross-over platforms shall be provided. An annex to the CW pump house shall be provided in RCC framed structure to accommodate switchgear and control room with cable vault below, chlorinator room and toilet block. Side cladding shall be of brickwork. All floor and roof shall be of RCC. Roof shall be given proper slope and heavy duty water proofing. Rain water down comers shall be of UPVC pipe of class-3 conforming to IS:4985. Roofs shall be made accessible by MS cage ladder. Provision shall be made for installing three Nos. C.T blow down pumps at CW pump house to drain the C.T blow down water to sea. All doors shall be of flush welded steel construction. For switch gear room, the main entrance door shall be of adequate size to transport the panels. All windows shall be steel glazed side hung. Wall in front of transformer yard shall be designed to satisfy fire rating as per TAC regulations.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:69

DESEIN

Volume-VI: Civil, Structural & Architectural Works

An auxiliary transformer yard may be required in front of the switchgear room. Civil work similar to the transformer yard in front of ESP control room shall be included in the scope of work. Outside the pump house support blocks for butterfly valves and pipes along with proper handling facility shall be provided.

21.0 21.1 21.1.1

NATURAL DRAUGHT COOLING TOWER Intent of Specification and Scope Intent of Specification The Purchaser desired to install one Natural Draught Cooling Tower for the proposed 660 MW unit. This specification covers the requirements of design and construction of natural draught reinforced concrete hyperbolic cooling tower. This section of bidding document deals with the technical specifications for the design and preparation of detailed working drawings and getting them approved by the Purchaser and the civil construction works. The provisions of this technical specification (civil works) are general in nature and cover broad aspects. Technical specification outlines the minimum requirements. However, it would be the absolute responsibility of the bidder to collect, interpret, analyze all necessary information / data for the successful design and construction of the cooling tower. Structural safety and successful operation of the tower shall be the total responsibility of the bidder notwithstanding the approval of the Purchaser.

21.1.2

Scope of Work The scope of this work shall consist of, but not limited to, the design and construction of reinforced concrete double curvature hyperbolic shell, raker columns, ring beams, foundations including piling work (vertical/raker piles), cold water basin with partition walls, hot water ducts, drain sumps, external drain chamber with associated pipe work, cold water channels with stoplog gates and fixed screen upto the terminal points as specified elsewhere, hoists & monorails, primary and secondary hot water distribution troughs, fill support systems including columns & beams, drift eliminators (if required), testing of cold water basin for water tightness, external stairs, ladders, platforms, walkways as specified or required for operation and maintenance, access doors, MS handrails, steel fittings, fixtures, inserts including fabrication, galvanizing and erection of associated steel work and other chemicals on the completed structures etc. all complete as per specifications, drawings and directions of Purchaser. The scope of work under this specification shall include providing engineering design and drawings, all labour, supervision, materials, shuttering and scaffolding, construction equipment including tower cranes, hoists, batching plants etc. tools and plant, supply and transportation of all incidental items not shown or specified but reasonably implied for successful completion of the work. The nature of the work shall generally involve piling, excavation, dewatering, shoring and strutting, backfilling around underground structures and plinth filling, sand filling, disposal of surplus soil outside plant boundary, concreting of grade as specified, formwork including automatic climb form, laser beam instruments, fabrication, galvanizing and erection of steel structures and inserts, finishing anchor bolts, RCC sump/duct, laying and testing

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:70

DESEIN

Volume-VI: Civil, Structural & Architectural Works

of hot water pipe line, water proofing, providing PVC water stops and joint filters, drainage and other ancillary items connected with cooling towers as approved. The surfaces that would include are inner face of hyperbolic shell, raker column faces, inner faces of cold water basin, fill support structures, hot water distribution ducts & channels, cold water channels etc. This list is indicative only. The scope shall also include the preparation and supply of all working drawings required for this work. 21.2 Materials All materials including cement, reinforcement steel & structural steel required under this bid shall be provided by the bidder. No materials shall be issued by the Purchaser. 21.3 Layout and Levels The layout fixing the location and levels of all structures shall be made by the bidder (at his own cost) w.r.t. plants grids and bench marked given by the Purchaser. The Bidder shall give all help in providing the instruments, materials and men to the Purchaser for checking the correctness of the layout and levels. However, the bidder shall be solely responsible for correctness of layout and levels and Purchasers approval in no way shall relieve the bidder of his responsibility towards correctness of layout and levels. 21.4 Approval of Design and Drawings The bidder shall submit detailed analysis & design calculations for the cooling tower structures including design assumptions along with arrangement drawings for the approval of the Purchaser/Consultant. Computer programme used in the analysis need not be submitted. The theoretical background utilized for developing the computer programmes shall be made available to the Purchaser. This will be given by the bidder before approval of designs. One set of analysis & design calculation / drawings duly approved / marked with comments by the Purchaser shall be returned to the bidder. After receipt of approval from the Purchaser the bidder shall submit copies of final detailed construction/fabrication drawings as per Distribution Schedule for the approval of the Purchasers. One set of drawings shall be returned duly approved which will become the basis for taking up construction. The bidder shall also furnish to the Purchaser one good quality permanent negative (film type) of each of the final approved drawings. Additionally, all drawings shall be prepared in AUTOCAD and CDs to be submitted to the Purchaser for record. The approval of the Purchaser shall not relieve the bidder from the responsibility of adequacy of the design and correctness of the drawing. 21.5 General Requirements a. b. Tower structure of NDCT shall be supported on pile foundation as required. The cold water basin shaft, channels/trenches and other lightly loaded structures with load intensities less than 5.0 t/sqm may be supported on open shallow foundation resting in virgin / controlled compacted filled-up soil as specified elsewhere in the specification.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:71

DESEIN

Volume-VI: Civil, Structural & Architectural Works

c.

All foundations shall be designed in accordance with provisions of relevant parts of the latest revisions of Indian Standards.

21.6 21.6.1

General Design Criteria Loading The following loads shall be considered for the design of cooling towers: a) b) c) d) Dead loads Wind loads Earthquake forces Loads due to temperature and shrinkage effects. Temperature effects due to solar radiation shall also be considered. Construction load Foundation settlement etc. Any other load likely to come on cooling tower.

e) f) g) 21.6.2

Dead Load For assessing the self weight of the structure, the specific weight of the concrete shall 3 be taken as 2500 kg/m . All other dead loads shall be assessed in accordance with relevant codal provision. Dead load shall include the self weight of structure, weight of fill material, weight due to algae growth, weight of falling water, weight of hot water pipe, weight of water in hot water channel and distribution system including the self weight of channel and distribution system, weight of drift eliminators etc. Secondary stresses, if any, due to permanent fixtures on the shell shall also be considered.

21.6.3 21.6.3.1

Wind Pressure The wind pressure on the towers shall be assessed on theoretical basis as well as with the help of Model tests in a wind tunnel of turbulent boundary layer. All the theoretical methods outlined hereunder for estimating wind load on cooling tower shell shall be valid only if the towers spaced at clear distance of greater than 0.5 times the base diameter at the finished graded ground level. The theoretical method outlined herein forms the basis only for assessing lowest limit of wind forces and shell structure interaction. For conducting model tests, bidders should survey the whole terrain and make their own assessment of likely critical wind forces & wind structure interaction. General topography of the area is uneven and a hillock is present in the vicinity of the plant area. It would be the responsibility of the bidder is collect necessary meteorological data duly vetted from the recognized govt. agencies/institutions. After collection of necessary meteorological data, most critical wind speed, wind pressure distribution and other necessary parameter shall be determined by the bidder and get the same vetted by the above agency/appropriate agency(s). Then with the help of physical model tests in a wind tunnel, offering appropriate aerodynamic similitude, the bidder

21.6.3.2

21.6.3.3

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:72

DESEIN

Volume-VI: Civil, Structural & Architectural Works

shall obtain the most critical forces, stresses etc. with cooling tower at various levels and locations. Such model test shall also include all adjacent topographical features, buildings, and other structures which are likely to influence the wind load pattern on the tower significantly. The model test shall be carried out in a well reputed institute/testing laboratory after obtaining prior approval from the Purchaser. The testing agency selected by the bidder shall have requisite experience and should have successfully carried out tests in the past for atleast one cooling tower of similar capacity. The model tests shall be duly witnessed and approved by the Purchaser. The model test results shall be made available before final approval of the design. 21.6.3.4 The complete cooling tower shall be designed for all possible wind directional and on the basis of worst load conditions as obtained from Model test and theoretical methods. Under the theoretical method, the circumferential net wind pressure distribution and wind pressure coefficient (p1) for the tower shell (without meridional ribs) shall be obtained from the Criteria for structural design of Reinforced concrete Nature Draft Cooling Towers IS:11504-1985. The above circumferential wind pressure coefficient (p1) shall be increased by multiplying it by 1.43 to account for turbulence in the incident wind and load intensification due to turbulence induced by the adjacent cooling tower or the other structures of significant dimensions. Therefore, the actual design circumferential net wind pressure coefficient (p) shall be computed as p=1.43(p1), where (p1) is the wind pressure coefficient as per IS:11504-1985. This design net pressure coefficient (p) and the distribution along the circumference of tower shall be used at all heights of the tower. The above design net pressure coefficient (p) includes the effect of internal suction. In order to compute the quasi-static design wind pressure at a given height along the circumference of the tower, the net design pressure coefficient (p) shall be multiplied by the wind pressure acting at that height [P(z)]. For details, reference shall be made to Criteria for Wind Resistant Design of Structures and Equipments placed under Project Data and as given below. The wind pressure at a given height [P(z)] shall be computed as per the stipulations of IS:875 (Part 3)-1987. For computing the design wind pressure at a given height the basic wind speed (Vb) shall be taken as Vb=50 m/sec at 10.0 meters height above mean ground level. For computing design wind speed (Vz) at a height z, the risk co-efficient K1=1.12 shall be considered. For coefficient K2, Terrain category 2 and class C as per table 2 of IS:875 (Part -3) 1987 shall be considered. Coefficient K3 shall be determined by taking into account of the presence of hillock nearby the plant site and other features of the station & topography. The wind direction for design purposes shall be the one which world induces worst load conditions. However, coefficient K3 shall be less than one under any circumstances. The wind pressure at a given height shall be computed theoretically in accordance to the IS Codal position given as under: Pz = 0.6 Vz N/mm
2 2

21.6.3.5

The bidder shall also compute the wind pressure (pz) along the wind direction by Gust Factor (GF) or Gust effective factor method (GEF). Method for estimating the wind load on the tower and other elements, shall be based on IS: 875 (Part-3)-1987. While calculating the gust factor, the term b shall be taken as the diameter of the throat in Fig. 10 of IS: 875 (Part-3)-1987. Design of the tower shall satisfy quasi-static method & GEF method.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:73

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Dynamic effects on the tower due to wind action shall also be investigated to ascertain the wind induced oscillation such as ovalling and excitation along and across the wind direction. Bidder shall carry out detailed analysis for the tower and consider the worst combination of static & dynamic effects. In case the bidder proposes to adopt aerodynamic rough surface such as provision of meridional ribs in the cooling tower shell, the pressure coefficients as given in the VGB-BTR KUHLTUMRE GERMAN SPECIFICATIONS (latest) (structural design of cooling towers) shall be permitted. The provisions of BTR may be adopted for choosing the value of circumferential wind pressure coefficient (p1) only. The wind pressure coefficient (p1), as obtained from BTR after accounting for internal suction shall be multiplied by a factor 1.43 to arrive at the net design pressure coefficient (p). The bidder shall furnish authorized English Translation of VGB-BTR KUHLTURME GERMAN SPECIFICATIONS (latest) for the review of the Purchaser. All other stipulations as specified in these specifications shall be met with. Entire analysis and designs adopted shall be fully supported with authenticated literatures/documents along with relevant references where the same has been successfully implemented. 21.6.3.6 Earthquake Forces The seismic analysis shall be carried out in accordance with IS:1893 by modal analysis for the hyperbolic cooling towers or any other method as approved by the Purchaser. The earthquake analysis of the shell and its support columns including the foundations shall be carried out by response spectrum method. For the fill supporting structures (RCC frames) response spectrum method is permitted. The modulus of elasticity for concrete shall be obtained from IS:456-2000 Clause 6.2.3.1 with an Age Factor of 1.0. All the analysis shall be carried out as per the theory of elasticity. Entire analysis and designs adopted shall be fully supported with authenticated literatures/documents along with relevant reference where the same has been successfully implemented. 21.6.3.7 Loads due to temperature effects Stresses due to temperature effects: The cooling tower shell shall be designed for stress due to axi-symmetric temperature o distribution corresponding to external ambient temperature variation from 12 C to o 50 C. However, the detailed analysis of actual thermal gradient by considering temperatures inside the tower and external ambient temperatures shall be carried out furnishing detailed references and justification for the same. The shell shall also be checked for thermal stresses arising due to partial operation of the tower in case the operational philosophy so demands. The analysis for the stresses resulting from non-axisymmetric temperature loading shall be carried out. In such non-symmetric temperature loading, the calculation shall be based upon the operating specification. Besides, the shell shall also be designed for one sided solar o radiation effect. Nevertheless an effective temperature difference of atleast 25 C across the shell thickness constant over the height and follow a sine functions along half the circumference shall be considered.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:74

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Entire analysis and designs adopted shall be fully supported with authenticated literatures / documents along with relevant references where the same has been successfully implemented. 21.6.3.8 Constructional Loadings The method of construction and the type of formwork to be used shall be decided by the bidder in advance and should be enclosed in the bids submitted. Construction loadings that may occur during execution of work shall be considered in the design of the cooling tower structure. Factors causing temporary loading may include the following depending upon the method of construction. a) b) c) d) e) c) d) e) 21.6.3.9 Barrowing of concrete Scaffolding and formwork Loads produced by anchoring devices of climbing scaffolds. Hoist fixings Storage of materials on scaffolding Temporary access Tower crane fixings Works temporarily omitted for access purposes.

Any other load such as foundation settlement. All loads likely to act on cooling tower but not specified herein shall also be considered for the design of cooling tower structures. In case different degrees of subsoil stiffness exist, effect of the same shall be taken into account. In such a case, for computing settlements, load distributing capacity of the shell may be considered. Differential settlement between adjacent sections of foundation shall be considered under most unfavourable load combination.

21.6.3.10

Load Combinations Following minimum load combinations shall be considered for the design of cooling towers structures. a) b) c) a) b) c) DL + WL + SL DL + Se L DL + TL DL + WL + TL + SL DL + SeL + TL + SL 1.0 DL + 1.5 WL

Where DL = Dead Load WL = Wind Load SL = Settlement Load SeL = Seismic Load TL = Thermal Load

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:75

DESEIN

Volume-VI: Civil, Structural & Architectural Works

In addition to above, construction loads shall be duly accounted for. Under TL various types of thermal loads, as described above, shall be considered separately. Besides above load combination, other load combinations as per relevant IS codes shall also be followed: 21.6.3.11 Permissible Stresses For load combination (a) to (e) the stresses in concrete and reinforcement shall be restricted as per limit state method of IS:456 with serviceability criteria of crack width limited to 0.1mm. For the load case (f) the shell of cooling towers shall be designed by limit state method as per IS:456. The stress in the reinforcement steel shall not exceed 87% of the specific characteristic strength of reinforcement steel and the compressive stress in the concrete shall not exceed 45% of the specified 28 days cube strength of the concrete as per IS:456. In the design of the cooling tower shell, column, pile caps, pedestals, ring beams etc. no increase in the strength with the age of the concrete shall be permitted. The age factor equal to 4.0 shall be considered. Permissible stress for steel structures shall be as per IS:800 (latest) based on working stresses. 21.7 21.7.1 Tower Design Consideration General The complete cooling tower, including the shell, columns, ring beam and foundation, shall be structurally analyzed using a proven finite element modeling technique or an approved alternative method including validation of software used for analysis. For elastic analysis, concrete may be assumed to be uncracked, homogenous and isotropic. The design geometric profile, thickness variation and support conditions of shell shall be considered in the structural analysis. Regardless of analysis method adopted, the equilibrium checks of internal forces and external loads shall be performed. Analysis based on a recognized bending theory of the elastic shells shall be adopted for the design of the tower and supporting structures. Geometric imperfections, if exceed the permissible limit, then the analysis of shell shall take into account of such imperfections and resubmitted for Purchasers approval. Boundary conditions shall be realistic and based on actual configuration. The magnitude of the calculated displacements should be within limits of the applied theory. A detailed dynamic analysis shall be carried out for complete tower for seismic forces by response spectrum method. Cooling tower shall also be designed for cross wind oscillations (wind induced vibration) if the fundamental natural frequency of the tower is less than or equal to 1 Hz. Frequency calculation for free vibration analysis shall also be furnished by bidder during detailed engineering. Size and Shape

21.7.2

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:76

DESEIN

Volume-VI: Civil, Structural & Architectural Works

The base diameter, air intake opening height, tower height and throat diameter shall be determined by thermal design consideration by the bidder and submitted to Purchaser for approval. As the range of possible hyperbolic shell shapes is infinite, the same shall generally conform to the following major proportions, which have been extensively adopted in cooling tower constructions. H/D = 1.2 to 1.55

Where H is the total tower height above basin sill level. Hb/H = 0.75 to 0.85

Hb is the vertical distance from the throat to basin sill level and D is the b ase diameter at basin sill level. However, other proven profiles may be permitted subject to approval from the Purchaser. Bidders shall submit along with the offer complete details of the profile, in case the profile is not within the limits stated above, and the names of the sites where such shell profiles have been successfully constructed. Notwithstanding what is stated above, the Purchaser reserves the right to accept / reject the shell profile. 21.7.3 Tower Shell Boundary Conditions A. Shell Analysis and Design The following boundary conditions shall be assumed for the design of cooling tower shell: a) At Upper Edge: The top edge of the shell shall be gradually thickened to form a ring beam to guard against possible instability of the top of the shell due to high velocity wind gusts. Top edge shall be considered as a free edge in the analysis. b) At Lower Edge: The lower edge of the shell shall be thickened to form a lower ring beam. The thickness transition from shell to lower ring beam shall be smooth and shall be considered as an integral part of the shell. The lower boundary of the shell shall be considered as elastically supported by discrete columns. The influence of both support structure flexibility and foundation settlement shall be considered in the analysis and design of cooling tower shell. The shell analysis should include following information at o 10 plan angle and of not more than 0.05 of the shell height. i) Meridional and circumferential direct stress resultants and the tangential shear stress resultants. Meridional and circumferential bending moments. Displacements normal to the shell mid-surface.

ii) iii)

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:77

DESEIN

Volume-VI: Civil, Structural & Architectural Works

B.

Buckling of Tower Shells Critical dynamic pressure (wind pressure) at buckling shall be calculated from BS: 4485 Part-4:1996. The shell buckling shall be checked using the design dynamic wind pressure and other relevant loads acting on the tower. The factor of safety against buckling shall be not less than 5 for the completed tower as well as whilst under construction. Besides above, a buckling analysis with wind forces should be made using the theoretical tower geometry and boundary conditions, including the influence of dead weight, by the method of buckling stress state (BSS) approach in accordance with the provisions of VGB. The buckling safety factor shall be atleast 5.0 for load combinations of dead load + wind load. When imperfections in the shell geometry are larger than specified tolerances, the analysis should be rechecked to account for such imperfections and ensure that the desired buckling capacity remains.

C.

Opening in Shells Opening through the shells should be avoided as far as possible. They should be of smallest required dimensions and shall be shaped such that stress concentration is minimized at the boundary of the opening. Should thickening of the edges be necessary, it shall be smoothly tempered back to the shell thickness. Openings shall be provided with additional edge reinforcement of a minimum cross sectional area at each edge equal to 75% of the reinforcement intercepted by the openings in the direction parallel to the edges. In addition diagonal reinforcement shall be provided at each corner as close as possible. 2 The total cross-sectional area in cm of this reinforcement shall be 0.5d, at each corner where d is the shell thickness in cm. No horizontal thrust due to the inlet piping shall be transmitted to the shell.

D.

Minimum Thickness of Shell The minimum thickness of the shell shall not be less than 200 mm.

E.

Minimum Reinforcement in Shell Spacing and Placement The reinforcement used shall be cold worked steel high strength deformed bars of grade Fe 415 conforming to IS:1786 latest. All reinforcement steel shall be fusion bonded epoxy coated reinforcement. Reinforcement steel higher than Fe415 grade may be used if permitted by the Purchaser. The minimum reinforcement to be provided shall be as follows: Top one third portion of shell: 0.4% of concrete cross sectional area along circumferential direction and 0.35% of concrete cross sectional area along meridional direction.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:78

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Remaining two-third portion: of shell

0.35% of concrete cross sectional are in both meridional and circumferential directions.

Minimum bar diameter shall be 8 mm in transverse direction and 10 mm in meridional direction. Spacing of reinforcing bars should not exceed 200 mm in circumferential direction and 250 mm in meridional direction. The two layers of reinforcing meshes shall be adequately joined by S-hook over the total shell surface. Atleast two S-hooks in each square metre area of shell surface shall be provided. The hooks shall be of minimum 6 mm diameter bars. The concrete cover shall be 50 mm minimum. However, the clear cover shall not be less than 1.5 dia of bars. The relevant provisions of IS: 2210 Criteria for the design of reinforced concrete shell structures and folded plates and IS:2204 Code of Practice for construction of reinforced concrete shell roof shall also be deemed to be applicable. All other design criteria for the cooling tower shell which are not specified above shall be in accordance with BS:4485 Part 4 and BTR. F. Provision of meridional ribs in Cooling Tower Shell. Meridional ribs in the cooling tower shell may be provided subject to the following conditions: a) Minimum thickness of shell excluding ribs shall not be less than 200 mm. b) Co-efficients for pressure distribution around the cooling tower circumference including suction may be taken as per VGB-BTR KUCHLTURMEN SPECIFICATIONS (latest). All other factors including load intensification factors shall be as specified else where in these specifications. c) Shell buckling and strength shall be checked as per clause-b above without considering the effect of ribs. d) All other stipulations as specified in these specification shall be met with. e) Bidder shall furnish an authorized English translation of the VGB-BTR KUHLTURME GERMAN SPECIFICATIONS (Latest). 21.7.4 Raker Columns Inclination of the column shall closely match the meridional slope at the shell so that the load transfer to foundation takes place through predominantly axial force in columns. Raker columns shall be designed for the most critical forces transferred to an individual rake column from superstructure considering various load combination as under cl. 15.7.8. For selecting effective length of the raker columns, following restraints shall be considered:

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:79

DESEIN

Volume-VI: Civil, Structural & Architectural Works

a)

In case columns restrained at both the ends, the effective length shall be 0.8 and 0.6 times the length of the column radially and tangentially respectively. In case columns are restrained at one end only, the effective length of columns shall be 0.9 and 0.7 time the length of columns radially and tangentially respectively. The columns shall be designed based on working stress method except for the forces from DL + 1.5 WL which shall be designed as per limit state of strength method of IS:456.

b)

c)

21.7.5

Crack Width Control Under working stress method the maximum crack width of tower shell, lintels, raker columns, cold water basin and fill support structure shall be controlled upto 0.1 mm on basis of formulas as per IS:456 and relevant British codes. Fill support structures and Drift Eliminators shall be designed as per the load combination specified under Cl. 15.7.8. Appropriate Live Loads and imposed loads shall also be considered in addition. The design shall confirm to limit state method as per IS:456 and 15.8.5 except noted otherwise.

21.7.6

Pre-stressed Concrete Members Design construction and workmanship of pre-stressed concrete, members shall be in accordance with IS:1343 (Latest revision). Steel wire for pre-stressing shall conform to IS:1785 (Part 1) (latest edition) or IS:6003 (latest edition). Crack width control shall be limited to 0.1 mm. Particular attention shall be paid to achieve an effective bond of the wires in pretensioned concrete units. For this purpose, indented wire shall be used. Wires shall be corrosion resistant (marine grade) or should have coating system fit for seawater duty condition. Concrete and grouts used shall be sulphate resistant.

21.7.7

Liquid Retaining Structures a) The cold water basin including sludge pits, cold water channels, shall be designed as per IS: 3370, Part-I to Part-IV. The structures shall be designed for the following conditions: i. ii. Water filled inside upto maximum level and no earth outside. Earth pressure with surcharge load of 2.5 t/m , as applicable, and with/without ground water table at final graded ground level outside and no water inside.
2

b)

The basin and associated structures shall be checked against uplift for basin empty condition. Stability shall be checked during construction stage as well as maintenance stage. The factor of safety shall be as per IS: 3370. Loads during construction, erection and maintenance stage shall also be considered. Temperature fluctuations from operation shall be obtained from the design data. Hot water temperature inside and cold air temperature outside shall be considered.

c)

d)

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:80

DESEIN

Volume-VI: Civil, Structural & Architectural Works

e)

Basin floor slab shall be designed to rest on piles or raft/mat foundation including fill-pack support structures. The stiffness of the subsoil shall be taken into account. The founding level of the raft/mat shall be either on virgin ground level or shall be placed at higher level only after scooping out filled up soil upto virgin ground and then filling back with well compacted sand (80% of relative density) upto the founding level of the raft/mat. The bidder shall ascertain the safe bearing capacity of the stratum at the founding level and may adopt the same subject to Purchasers approval. Minimum thickness of basin slab shall be 300 mm with minimum reinforcement 0.35% of gross sectional area in both the directions. Reinforcement shall be placed in two layers, top and bottom surface.

f)

The effect of provision of flap valves/pressure release valves shall not be considered in the design of CW basin. In the space underneath the basin floor slab a layer of atleast 100 mm thick PCC of mix 1:3:6 shall be provided. g) All reinforcements used shall be fusion bonded epoxy coated as per IS: 13620.

21.7.8

Water Distribution System The structural design of the water distribution system shall consider the worst combination of following loads: i) ii) Self weight, other imposed loads and live load. Hydraulic pressures during normal operations including pressure surges.

iii) Hydraulic pressure due to mal-operation of the tower or supply pumps. The water distribution system shall be provided with adequate pressure surge relief facilities to prevent pressure loading in excess of values used in the design. If such facilities are not provided, a further increase in loading shall be considered in the design. For the structural design the pressure level to be considered shall not be less than 1.5 times the design pressure. The design of water distribution system and its supports shall be capable of accommodating all thermal stresses and movements due to changes in inlet water temperature and ambient temperature. The possibility of vibrations being imposed on the distribution system shall be investigated in the design. Seismic loading on the water distribution system shall also be taken into account. The design shall be carried out based on uncracked section as per IS: 3370 under normal operating conditions. Strength check for worst loading including malfunctioning shall be carried out with stress limitations as per IS: 3370. The construction shall be completely water tight without the use of fillets, sealing compounds etc. The method of construction shall be such so as to avoid excessive rise in temperature of concrete due to release of heat of hydration. 21.7.9 Platforms, Walkways, Stairways, Staircases, Internal Grillage etc.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:81

DESEIN

Volume-VI: Civil, Structural & Architectural Works

They shall be designed as per working stress method IS:456-1978 and IS:800 (Latest). The crack width in all RCC structures shall be limited to 0.1 mm. A minimum live load of 400 kq/sqm shall be considered for the design of all platforms, walkways, staircases etc. in addition to their own weight. 21.7.10 Steel Structures These structures shall be designed, fabricated and erected as per IS:800 (latest revision) and other relevant Indian Standard codes for structural steel work. All steel structures shall be coated with anti-corrosive system. 21.7.10.1 Stoplogs Stoplogs and screen shall be designed for worst combination of operating and maintenance condition. All steel components shall be coated with anti-corrosive paint system. However, all side guides of stoplogs shall be of stainless steel of Grade AISI 316L. 21.7.11 Foundations The design of the tower foundation structures shall be based on IS:456 as per working stress method for worst load combination as per clause 21.7.8. In case of load combination DL + 1.5 WL, the limit state method as per IS: 456 shall be adopted. Foundation shall be checked for safety against overturning, sliding and uplift. While checking stability of the structures, neglect favourably acting loads from water fill, soil cover beyond the edge of the foundation. High ground water level upto final graded ground level shall be considered to take into account buoyancy effect. The foundation shall be of minimum M-25 grade concrete resting over 100 mm thick PCC 1:3:6 layer. Clear cover of concrete shall not be less than 50 mm. Pile foundation if adopted shall be designed in accordance with IS: 2911(Part-I / SecI, II and III). Generally net tension should be avoided in the foundations/piles for the shell support foundation unless specifically permitted by the Purchaser. While accounting for over burden of the soil for checking the foundation against uplift, dead weight of the soil directly above the pile cap or ring raft, as the case may be, shall only be considered, neglecting the weight of soil in the cone of up-lift above the foundation. The foundation structures will be subjected to following loading and extreme load combination case shall be considered for design. 1. Most critical forces transferred from superstructure for the various load combinations. Uplift forces Loading due to foundation settlement Concentrated local loading from column nodes

2. 3. 4.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:82

DESEIN

Volume-VI: Civil, Structural & Architectural Works

5.

Thermally induced local loading where supply culverts pass through the foundation structures without structural isolation. Surcharge of 2.5 tonnes/sqm.

6.

CW basin surcharge load shall also be considered in addition to the other relevant loads for the design. 21.7.12 Pack Support Structures The self weight of the pack support structures shall be based on the weight of the packing including weight of standing, running and dripping water in accordance with manufacturers data. Live load of 250 kg/sq.m on the walkways and platforms shall be considered. Hand 2 railings shall be designed for horizontal load of 60 kg/m . Wind deflector walls and any other structural elements shall be designed for an horizontal wind load of 80 kq/sqm or as per manufacturers recommendations, whichever is higher. Thermal loading shall be as per manufacturers recommendations. Earth quake loading shall be considered based on criteria given for cooling tower. Response spectrum analysis shall be considered. Design of RCC members shall be based on IS:456:2000 with limiting crack width of 0.1 mm. The cold water basin slab/raft shall form the common foundation for the pack support structures. The foundation shall be designed for the most critical forces transferred from CW basin & fill supporting structures including loads introduced by constructional equipments and crane deployed for fill supporting structure or shell erection. 21.8 21.8.1 Requirements for Concrete and Reinforcement Structural concrete shall be of design mix complying with the relevant provisions of IS codes or any International Code of Practice as approved by the Purchaser. Durability of the concrete shall conform to very severe exposure category as per IS:456 except noted specifically otherwise. Minimum cement content of all RCC structures shall be 420 kg/cum. All reinforcements used in RCC structure shall be fusion bonded epoxy coated as per IS: 13620. Grade of reinforcement will be Fe 415/500. Column reinforcing bars shall be carefully anchored in the shell and foundation. The anchoring length shall not be less than 80 time the diameter of the bars. All foundations structures shall be provided on all sides with a minimum reinforcement of 0.12% of gross cross-sectional area distributed over top and bottom faces. 21.8.2 The minimum grade of concrete of structural components of cooling towers shall be as follows in accordance with IS:456. a) Precast pre-stressed elements : M-35 grade

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:83

DESEIN

Volume-VI: Civil, Structural & Architectural Works

b) All other RCC concrete

M-30 grade M-25 grade : : 1:3:6 mix M-25 grade

c) PCC encasement concrete except piles : d) Mud mat PCC e) Piles (with OPC/PPC/PFC) f) 21.8.3 Tower foundation (with OPC/PPC/PFC) :

M-25 grade

Coarse and fine aggregates shall be specially selected to ensure that they are not susceptible to alkali/chloride attach or prone to disintegration at high temperatures. In particular limestone aggregates shall never be used. The maximum size of coarse th shall not be larger than 1/8 narrowest dimension between reinforcement bars not more than 20 mm. Washing and screening of coarse and fine aggregates to remove fines, dirt or other deleterious materials shall be carried out by approved means if desired by the Engineer-in-charge. The water cement ratio by weight shall be 0.45 maximum including free moisture in the aggregates, and slump should be suitably decided to provide good quality concrete work.

21.9 21.9.1

Admixtures Admixtures may be permitted to be used in accordance with relevant IS codes to modify the rate of hardening or setting, to improve workability or as an aid to control concrete quality. The Purchaser reserves the right to direct the contractor to conduct laboratory tests or use test data, or other satisfactory reference before granting approval. The cost of all tests conducted shall be borne by the contractor. The admixture shall be used in strict accordance with the manufacturers directions and/or as directed by the Purchaser. No extra payment will be made to the contractor on account of using admixtures. Bipolar concrete penetrating corrosion inhibiting admixtures (CPCIA) meeting ASTM G 109 standards shall be used as per detailed specification given in 8.1 (Corrosion Protection) in all concrete prepared and used at the plant construction site. The dosage shall be as per the specification.

21.9.2

Particular attention must be given to concrete placement because of the thin wall section and the presence of reinforcing steel. Consolidation of concrete shall be by vibration. Removal of air and water at the form surface shall be by vibration and rodding. Particular attention shall be paid to accurately shape the corners at all openings. Point of discharge of the concrete in to the forms be 1500 mm above the concrete surface. Concrete shall be deposited in approximately level layers not greater than 400 mm deep unless permitted otherwise. Concrete in the cooling tower shell in each lift shall be so laid that the no. of vertical or inclined construction joints are minimized to the extent possible. Horizontal construction joints shall be maintained at uniform spacing throughout the height of the cooling tower as per the directions of the Purchaser.

21.9.3

21.9.3.1

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:84

DESEIN

Volume-VI: Civil, Structural & Architectural Works

21.9.3.2

Special attention shall be paid to proper curing of vertical faces of the cooling tower shell so that these do not remain dry. All thin walled structural members shall be protected by means of curing agents. It is recommended to use a curing agent for the cooling tower shell providing additional protection like a single transparent cooling with a material based on vinyl mixed polymer. Inside face of the shell should be protected by a second pigmented coating of the name base material. Any other method of curing, if permitted by the Purchaser may be used. Sampling and testing of concrete shall be carried out as stated in Technical Specification elsewhere and as per relevant Indian Standard Codes. However, following minimum tests shall be carried out, irrespective of whatever stated otherwise: Test of compressive strength Columns 1 cube per column Shell - 2 cubes per climbing section

21.9.3.3

21.10

Cover to Reinforcement Unless indicated otherwise on the clear concrete cover for reinforcement shall be as per IS Codes.

21.10.1

The correct cover shall be maintained by cement mortar cubes or other approved means, reinforcement for footing/pile caps, grade beam, and slabs on subgrade shall be supported on precast concrete cover block as approved by Engineer-in-charge. The use of pebbles or stones as cover blocks shall not be permitted. The 28 days crushing strength of cement mortar cubes/precast concrete cover blocks shall be atleast equal to the specified strength of concrete in which the cubes / blocks are embedded. The minimum clear distance between reinforcing bars shall be in accordance with IS: 456 (latest edition) or as specified elsewhere in this specification. All lapping of reinforcement bars in the cooling tower shell shall be by lapping as per relevant coal provisions. Prior approval of the Purchaser shall be taken for deciding the method of lapping the reinforcement bars in the shell.

21.10.2

21.10.3

Tolerances for the cooling tower construction shall be in accordance with the following: i) Shell wall centerline in horizontal plane measured radially at mid point on a 3m wide chord is + 15 mm. Shell wall centerline in meridional plane measured over a height of 1m is + 10 mm. Shell thickness is + 10 mm or -5mm. Horizontal radius of shell at any section other than shell base is + 50 mm. Horizontal radius at shell base is + 40 mm.

ii)

iii) iv) v)

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:85

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Checking of shell geometry Check for absolute positions may be carried out from ground stations arranged at not more than 10 degree plan angle apart. Readings of horizontal radius shall be taken at every 6m height or weekly during construction period whichever is more frequent. If the permissible dimensional tolerance are exceeded the Purchaser will instruct the contractor, in writing, to stop construction of the shell. The Contractor shall then examine the situation and submit a report to the Purchaser who may require the contractor to demonstrate by calculations that the structural integrity of the shell will not be impaired as a result of the imperfections. The calculations shall be submitted to the Purchaser, for approval, before construction will be permitted to proceed. If in the opinion of the Purchaser the calculations show that the integrity of the shell could be threatened, the Contractor will be required to submit to the Purchaser detailed arrangement and supporting calculations to set right the shell geometry for approval, before construction will be permitted to proceed. The cost of carrying out the calculation, any remedial work required and idle time or any delays to the construction programme as a result of dimensional tolerances being exceeded will be borne by the contractor. Adjustment to the tower shell line on the basis of the survey results shall be made gradually, limiting the maximum change of direction from the existing vertical shell profile to be not more than an angular change of 10 mm measured over 1m of height. Any such adjustment shall be made with full knowledge and consent of the Purchaser. The contractor shall carry out an as-built-survey of each lift of the shell. The results of these checks will be recorded on a suitably developed drawing of the shell from which it will be possible to locate the survey check point. A copy of these results will be presented to the Purchaser prior to commencing the next shell pour. The contractors shell construction procedures shall include for providing the Purchaser with the facilities and a reasonable time period as may be required to carry out an independent check of the completed works. Suitable communication system such as telephone, wireless equipments, etc. shall be provided by the contractor so that the communications are possible at different elevations of the tower from the ground during construction. All piling work shall be carried out by specialist subcontractor approved by the Purchaser. Initial pile load test shall be carried out for atleast 3 sets of piles for direct compression and lateral load. Since the effective action of the piles will depend on the adopted method of construction, the contractor shall guarantee that the piles, as constructed by the subcontractor, shall effectively transmit the maximum loads which can be imposed on the foundation soil and corresponding maximum deflections. 21.10.4 21.10.4.1 General Requirements I) In case the basin slab is divided, the same shall be divided into two equal parts by a partition wall designed to withstand full hydrostatic pressure, with one side empty. The basin construction joints shall be made watertight by injection of chemical grout through nipples. The basin construction shall be tested for water tightness, in accordance with IS:3370 (Part I) (Latest edition).

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:86

DESEIN

Volume-VI: Civil, Structural & Architectural Works

The cost of the test and any rectification and re-test if required is deemed to be included in the contractors quoted price. Any cost of filling and emptying of the basin and to rectify defects shall also be borne by the contractor. ii) PVC ribbed water stops with central bulb shall be used where expansion joints are envisaged. The minimum thickness of PVC ribbed water stops with central bulb will be 10 mm and minimum width 230 mm. For all underground structures such as basement, sump etc. and water retaining structures special care shall be taken to water proof them. Approved integral water proofing compound shall be added to concrete mix to ensure water tightness. 150 / 225 mm wide PVC water stop shall be provided to all construction joints as required. Water retaining structures shall be Hydro Tested as per IS: 3370 for leakage and in case leakage is noticed pressure grounting or any other approved procedure shall be adopted to rectify it. Sumps with pumping arrangements shall be provided at suitable location in underground structures to collect and pump out any incidental water collection to nearest storm water drainage outlet. iii) The basin floor of each compartment shall be provided with a slope of not less than 1 in 120 towards sump for dewatering. From sump, the water will be drained by C.I. drain pipe, embedded below the basin floor, into a drain chamber outside the tower basin or as per the arrangements described elsewhere in the tender document. Suitable sluice gates (rising spindle type) conforming to IS:3042 or sluice valves shall be provided in the drain chamber or any other arrangement specified elsewhere in the tender document. Suitable sluice gates (rising spindle type) conforming to IS:3042 or sluice valves shall be provided in the drain chamber or any other arrangement specified elsewhere in the tender document. Suitable operating platform with access ladders for operating the gates or valves and pipes, if specified, shall be provided in the drain box. A 250 mm high sill shall separate the pond floor from the tower outlet. Uniform surface on the top of basin floor shall be provided. In case undulated surface is observed, a top of layer of minimum 25 mm thick 1.3 mix mortar to be provided to achieve uniform surface.

iv) v)

21.10.4.2

The stoplogs shall be structural steel with anti-corrosive coating specified elsewhere. Number of stoplogs and fixed screen shall be two (2) per tower. Proper rubber seal shall be provided so as to avoid any leakage of water. The rubber seal provided for the stoplogs be tested in accordance with the relevant Indian Standard Code. Stoplogs shall be checked for water tightness and smooth operation in dry and wet conditions. Suitable facilities, as approved by the Purchaser, shall be provided for handling of stoplogs. A screed or concrete layer not less than 100 mm thick and of grade not weaker than 1:3:6 mix conforming to IS:456-2000 shall be provided below the cold water basin and other liquid retaining structures. Lean concrete below other foundations and underground structures, unless noted otherwise shall be 1:3:6 nominal mix (with aggregate of nominal size 40 mm maximum) and shall be atleast 75 mm thick.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:87

DESEIN

Volume-VI: Civil, Structural & Architectural Works

21.10.5

All exposed surfaces of concrete including surface of cooling tower shell shall be given two or more coat of waterproof cement paint of approved make and colour. Unless noted otherwise all concrete surface which are in contact with the earth shall be applied with anticorrosive coat system. Water proofing and plasticizer admixtures conforming to relevant IS codes may be added as per manufacturers instruction to the concrete subject to approval of the Purchaser. i) The tower shall be provided with two numbers external RC staircase, leading to a heavy duty door giving access to the distribution system. Staircase shall be minimum 1000 mm wide (clear), with landings of minimum width of 1000 mm at not more than 2500 mm height intervals unless approved otherwise. The steps shall have a rise of about 125 mm and tread of about 250 mm. Anti-skid nosing at each step shall be provided. Minimum size of all doors shall be 2100 mm high (clear) and 1200 mm wide (clear). The door shall be of steel with anti-corrosive coating of polyurethane as specified elsewhere. However, FRP material or equivalent may also be used subject to approval of the Purchaser. The door shall be air tight when closed. The hand railing on both sides of the staircase shall be galvanized with three rails of 32 mm NB pipes conforming to medium class as per IS:1239, and posts conforming to medium class as per IS:1239 of 32 mm dia galvanized pipes spaced not more than 1.5m centers. The top hand rail shall be at 1000 mm above the steps. Complete hand rails shall be applied with anti-corrosive coating system as specified elsewhere. All galvanization work shall have 610 gm/sqm of deposit.

21.10.6

ii)

iii)

iv) 21.10.7

Approved walkways and platforms shall be provided inside the tower at distribution pipe level. These walkways and platforms shall provide safe and clear access to all sprayers and all distribution pipes. A reinforced concrete platform of 1500 mm clear width shall be provided around the tower valves. Other walkways shall be atleast 600 mm wide with 50 mm (minimum) safety kerbs along each edge. Access ways shall be clear of all obstructions such as distribution pipe support beams, drift eliminator support beams etc. The walkways shall be provided with transverse slots or other opening which will permit the free passage of air and water. Hot double dip galvanized MS handrails as described above shall be provided on all sides where there is a risk of falling through the fill.

21.10.8

Reinforced concrete platforms 1.2m clear width all around the tower circumference shall be provided on the tower for fixing of aviation warning light at levels specified elsewhere. Two (2) diametrically opposite galvanized MS caged ladders, 600 mm wide, made out of 6 mm, x 10 mm flats for full height of the tower shall be provided. The ladder shall have 20 mm dia rungs at 300 mm centers, with stays at every 2250 mm, connected to the concrete shell and galvanized MS caging consisting of 50 mm x 70 mm vertical cage flats on the exterior surface of each cooling tower upto throat. Above throat level, these ladders shall be continued along the inside surface of the tower upto the top of the tower. A PCC landing of minimum size 1mx1m with galvanized handrails and galvanized steel door at the throat for interchange to be

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:88

DESEIN

Volume-VI: Civil, Structural & Architectural Works

provided. In addition to the top platform, intermediate landings of 1.0m x 1.0m with handrails be provided at every 8 to 10 m height of the MS ladders throughout. Some of these landing levels shall be suitably adjusted to give access to aviation warning beacons for maintenance. Handrails as described above shall be provided on all platforms. The ladder leading to the top platform shall have approach from ground via the RCC staircase. In order to provide approach for maintenance of shell (inside & outside forces), all platforms shall have 20 mm wide radial openings shall be provided in the platform floor at locations approved by Purchaser. Adequate numbers of 75 mm internal diameter puddle flanged C.I. pipes shall be embedded in this platform for passing ropes during maintenance of tower shell. 21.10.9 Steel gratings, where required, shall be fabricated out of steel flats with minimum thickness of 6 mm thickness of fabricated grating shall be 32 mm with flats so arranged as to have a maximum opening or 25 mm or less. Treads for staircases, where needed, shall be of similar grating construction but provided with toe flats of 6 mm thick, and non-skid nosing in an approved manner extending upto 100 mm above the walkway surface. All steel gratings shall be galvanised and applied with anticorrosive coating specified elsewhere. The mild steel parts of structures used in cooling towers shall be hot double dip galvanized unless it is coated with a separate anti-corrosive coating system. The minimum coating shall be 610 gm/sqm and shall comply with relevant IS codes. Galvanizing shall be checked and tested in accordance with IS:2629. The galvanized shall be followed by the application of an etching primer and anti-corrosive Hi-build epoxy coating system of DFT 260 microns. All welding shall be done before galvanizing. Any site joints required to be carried out after galvanizing shall be either flanged or screwed joints. Nails, nuts, bolts and all components coming in direct contact with water shall be of stainless steel of AISI 304 or equivalent. The furnished ground level shall be paved for 2.0m width all round the outer edge of the cold water basin. The paving shall consist of 150 thick RCC slab of M-25 grade. The minimum reinforcement shall be 10 mm dia spaced 150 mm center to center both ways top and bottom. The RCC slab shall be overlaid 75 mm thick 1:3:6 PCC mat and 300 mm well compacted sand layer. Performance Guarantees Guarantees The bidder shall guarantee that the cooling towers offered shall meet the ratings and performance requirement stipulated in this specification. The Bidder shall also furnish a declaration in the manner prescribed and included in the BPS for certain guaranteed parameters which shall attract levy of liquidated damages for shortfall in performance. 21.12 21.12.1 Criteria for Wind Resistant Design of Structures and Equipment All structures and equipment of the power plant, including plant auxiliary structures and equipment, shall be designed for wind forces in accordance with the Indian Standard, IS:875 (Part-3)-1987, Code of practice for design loads (other than earthquake) for buildings and structures; and as specified in this documents. Design Requirements

21.10.10

21.10.11

21.11 21.11.1

21.12.2

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:89

DESEIN

Volume-VI: Civil, Structural & Architectural Works

21.12.2.1

Design parameters: The various design parameters for the project site, as defined in IS:875 (Part-3), shall be as follows: a) The basic wind speed Vz at Ten meters above the mean Ground level Category of terrain The risk coefficient : 50.0 metres/second

b) c) 21.12.2.2

: :

Category-2, Class-B 1.12

Along wind forces: Along wind forces shall generally be computed by the peak wind (i.e. 3 second gust) speed method as defined in the standard. Along wind forces on slender and wind sensitive structures and structural elements shall also be computed, for dynamic effects, using the Gust factor or Gust Effectiveness Factor Method as defined in the standard. The structures shall be designed for the higher of the forces obtained from Gust Factor Method and the peak wind speed method.

21.12.2.3

Across Wind Forces and other Wind effects: Investigations shall also be made to ascertain the behaviour of slender and wind sensitive structures to the cross wind effects. Susceptibility of structures to vortex shedding, galloping, flutter, ovalling etc. should be examined and dealt with accordingly following the recommendations of IS:875 (Part 3) and other relevant Indian standards. Specially, stacks, which are susceptible to cross wind excitation shall be checked for such excitation and, if found so, shall be designed for cross wind forces or provided with remedial measures (such as strakes) to reduce/ mitigate the cross wind effects, depending upon the requirement of the design.

21.12.2.4

General Analysis for dynamic effects of wind must be undertaken for any structure which has a height of minimum lateral dimension ratio greater than 5 and/or if the fundamental frequency of the structure is less than 1 Hz. For all the methods described above, for wind loading analysis, it should be estimated if size and relative position of other structures are likely to enhance the wind loading on the structure under consideration. Enhancement factor, if necessary, shall suitably be estimated and applied to the wind loading to account for the interference effects.

21.13

Criteria for Earthquake Resistant Design of Structures and Equipment All power plant structures and equipment, including plant auxiliary structures and equipment shall be designed for seismic forces adopting the site specific seismic information provided in this document and using the other provisions in accordance

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:90

DESEIN

Volume-VI: Civil, Structural & Architectural Works with the Indian standard, IS:1893-1984, Criteria for Earthquake Resistant Design of Structures. For the purposes of information only, however, the project site lies in seismic Zone-III as defined in IS: 1893.

21.13.1

Design Requirements Damping in Structures The damping factor (as a percentage of critical damping) to be adopted shall not be more than as indicated below for: a) b) Steel structures Concrete structures and brick Structures in cement mortar : : 2% 5%

21.13.2

Response Spectrum Method of Analysis Since most structures in a power plant are irregular in shape and have irregular distribution of mass and stiffness, it is necessary to analyse them using the response spectrum method. Atleast the first five modes, in each principle direction of vibration, shall be used for the analysis.

21.13.3

Design/Detailing for Ductility The site specific design acceleration spectra and the spectra of IS:1893 are reduced spectra and have an in-built allowance for ductility. Therefore, structures shall be properly engineered and detailed to achieve sufficient ductility. In this context adherence to IS:13920, IS:4326, IS:800, SP(6) etc. is necessary. If in a particular structure, the ductility is expected to be low or is considered inappropriate, the acceleration values shall be suitably enhanced.

22.0

COAL HANDLING SYSTEM 1. External coal handling system from NCTPS to ETPS: External coal handling system will consist of modification in existing conveyor gallery / JNT, new conveyor galleries, trestles, junction towers, crusher house, dust suppression & extraction system, MCC / Electrical building at NCTPS premises and also the pipe conveyor system from NCTPS to ETPS. In new crusher house of 2x100% capacity per stream has to be erected in the NCTPS yard where the coal would be crushed and the crushed coal will be transported to ETPS yard through pipe conveyor of capacity 2x1000 TPH. The pipe conveyor will cross the National Thermal Energy Power Corporation coal conveyor, Highways Bridge, Chennai-Howrah railway line and the embankment of the Buckingham canal / Ennore creek before entering to ETPS, covering a distance of about 6 km. The pipe conveyors will be supported on cross-over, trestles, piers etc. At the crossing of Highway Bridge the cross-over should maintain 7.0m clear height from the top of road and at the railway crossing the cross over should maintain 10.0m clear height from the top of rail.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:91

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Considering the declaration of Buckingham Canal as National Inland Waterway and Formation of terminal etc., at the crossing of Buckingham canal / Ennore creek the span of the supporting cross-over and height of the pipe conveyors shall be decided with reference to the Water Resource Department, PWD guideline. (Annexure Vol VII) Necessary statutory clearances / approval from Railways / Highway Authority / PWD shall be obtained by Contractor at his own cost. Once the piping conveyor system is commissioned, the rail transportation of coal to ETPS will be stopped and the EPC contractor will remove all the railway lines within the project boundary. Total length of Rail Track to be dismantled approximately 13.50kms. 2. In-plant coal handling system necessary for the proposed plant: In-plant coal handling will consist of junction towers, tunnels, pent house, conveyor galleries, trestles, MCC room, stacker reclaimer foundation, coal stack pile, stack yard drainage, water sprinkler system, dust extraction system etc. 22.1 Over Ground Transfer Points Over ground TPs shall have RCC foundations and pedestals at (+) 500 mm above ground level. The superstructure for TPs shall be of steel framed structures with adequate bracing arrangement. The ground floor and all intermediate floors shall be of RCC and will be finished with IPS and metallic hardener having proper slopes for drainage. The roofs shall be of flat RCC slab with water proof treatment and drainage slope. The cladding shall be of pre-coated colour steel sheet. Plinth protection and storm water drain shall be provided around the structure suitably. Roof and all intermediate floors will be of reinforced concrete minimum 150mm thick of concrete M25 grade. All grade floors will be 150mm thick of M-20 grade concrete with nominal reinforcement of 8 Tor @ 250 c/c top and bottom both ways over PCC, soling over sand cushion of required suitable thickness. However the codal regulations shall also be completed with. Continuous handrails shall be provided for the staircase with 32 mm NB GI pipe hand rails. TPs shall be provided with independent steel staircase with steps of MS grating from ground of highest operating floor level. The clear width of the stair shall be minimum 1.0m. The tread shall be atleast 250 mm and riser shall be uniform throughout the height and shall not exceed 190 mm. However the codal regulations shall also be completed with. Continuous handrails shall be provided for the staircase. Drive units shall be directly supported on floor beams from suitable structural steel stools and not on concrete floors. All transfer houses shall be provided with adequate no. of windows and doors. The window area shall not be less than 10 percent of total wall area. Maintenance platform inside / outside of transfer house may have chequered plate floors with horizontal floor bracing. Transfer points / crusher house with metal sheeting as cladding shall have 1.0m high 230 mm brick enclosure from finished ground floor around the building. Brick wall shall be inside face of sheeting with a lapping of 150mm. Adequate floor washing arrangements shall be made of all TPS. Provision of floor dust collection and removal by chute shall be made.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:92

DESEIN

Volume-VI: Civil, Structural & Architectural Works

22.2 22.2.1

Crusher House and Crusher Foundation The crusher house will be braced structural steel structure with one brick thick (230 mm). Floor and roofs shall be RCC M25 flat slab supported on steel beams. Roof will be provided with roof water proofing treatment in line with architectural requirements mentioned elsewhere in the specification. Adequate steel doors and windows shall be provided for natural lighting and ventilation as mentioned for TPs. The crusher house shall have an independent staircase for general use like other TPs. In addition, it shall have a separate open staircase for fire escape suitably located to comply with fire fighting norms. An open elevator up to the top floor shall also be provided at suitable location at periphery of the building. The crusher shall be supported on RCC M30 deck slab of designed thickness mounted on vibration isolation system of GERB comprising springs and viscous dampers, which in turn supported on steel girders. The framework of girders shall be an integral part of the building, which houses the machine. There shall be isolation gap between building floor slab and crusher deck slab. Suitable provision for maintenance platforms for springs and damper shall be provided.

22.2.2

Crusher Foundation Detailed dynamic analysis shall be done for the top deck together with springs and dampers and the natural frequencies and amplitudes of vibration shall be determined. A mathematical model of the top deck shall be formulated with three dimensional beam / plate finite elements for the purpose of analysis with the spring idealized with vertical and horizontal stiffnesses. The mass of the machine together with that of the top deck shall be considered for the analysis. Natural frequencies up to at least 10% above the operating speed shall be determined and three frequencies shall be checked against the design criteria. Forced response dynamic analysis shall be carried out of for the operating condition unbalance forces using a sinusoldal forcing function. Unbalance forces as given by this specification shall be used for his purpose.

22.2.3

Isolation Efficiency The vibration isolation system shall be designed for about 90% isolation efficiency.

22.2.4

De-coupling A ratio of the least 10 (ten) shall be ensured between the stiffness of the supporting structure and the stiffness of the spring system in the vertical direction of achieve decoupling between the two (the stiffness of the spring system being lower). This ensures that dynamic analysis of the supporting structure need not be carried out.

22.2.5

Frequency Criteria The frequency criterion has already been laid down implicitly foundation isolation efficiency criteria and de-coupling required. The bending mode frequency of the top deck shall be atleast 20% above the operating speed.

22.2.6

Unbalance Forces

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:93

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Unbalance forces arising out of all the following cases shall be considered for checking the design and amplitudes. Balance quality grade Q40 as per VDI 2060-1966. One hammer broken condition. The missing hammer shall be assumed to be closest to the crusher non-drive end of the crusher. Three hammers broken condition. All the three hammers broken shall be assumed to be from the same suspension bar and located at the non-drive end of the crusher. 22.2.7 Amplitude Criteria The calculated amplitudes (mean to peak values) shall not exceed following limits under the specified conditions: a) Operating speed of 750 RPM.

150 microns for an unbalance force arising out of balance quality grade Q40 as per VDI 2060-1966. 300 microns in case of a one hammer broken condition. Amplitudes need not be checked for a three hammer broken condition. Operating speed of 450 RPM. 200 microns for an imbalance force arising out of balance quality grade Q-40 as per VDI2060-1966. 300 microns in case of a one hammer broken condition. Amplitudes need not be checked for three hammer broken condition. Operating speed of 450 RPM. 200 microns for an imbalance force arising out of balance quality grade Q-40 as per VDI 2060 1966. 400 microns in case of a one hammers broken condition. Amplitude need not be checked for a three hammer broken condition. For intermediate operating speed between 450 to 750 RPM, the amplitude limits can be linearly interpolated. The amplitude limits mentioned above are in both vertical and horizontal directions. The amplitude shall be calculated at critical points on the top surface of the RCC deck. The amplitudes shall be checked for the most unfavourable superposition of modes in any direction. However, phase difference between the maximum amplitude occurring in different directions due to the rotating vector may be considered while superimposing the modes. 22.2.8 Transient Resonance

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:94

DESEIN

Volume-VI: Civil, Structural & Architectural Works

22.2.9

Transient resonance, which may occur during the start-up or coasting down condition of the crusher, shall be checked and the amplitudes in such a condition should not exceed one and half times those at operating speed for each design condition. Strength Criteria The following criteria shall apply for the design of top deck: Dead loads, live loads, seismic loads and dynamic loads shall be considered for the design. The most unfavourable combination shall considered for design. Seismic loads shall be assumed to act together with dynamic loads for a one millimeter eccentricity in the rotor. However, seismic loads and dynamic loads arising out of hammer breakage need not be considered together. Fatigue shall be considered while designing for dynamic forces. A fatigue factor of 2.0 shall be used on all dynamic forces to arrive at the equivalent static force for the purpose of design. Working stress method shall be used for the design of RCC deck. In survival condition, 10% overstressing may be permitted. The RCC top deck shall be atleast of M30 grade of concrete as per IS:456-2000. Fatigue need not be considered for the three hammer broken condition. For calculating unbalance forces, the heaviest hammer (plain or toothed) shall not exceed the value specified by the manufacturer. Loss of contact of foundations at founding level shall not be allowed for any combination of loads.

22.3

Coal Handling Control / Electrical Building The control room for the coal handling plant shall be RCC framed structure with brick masonry walls or steel framed structures with brick masonry walls and RCC roof designed to be completely dust proof. Large glazed windows shall be provided for a complete view of the coal handling plant from the control room. Provision for fire escape stair shall be provided in accordance with TAC requirement. The building shall be provided with toilet. Air conditioning to be provided for the operators / working area suitably.

22.4

Foundations of Stacker-cum-Reclaimer Foundations for Stacker - Reclaimer shall be designed as a continuous wall or RCC framed structures (in longitudinal and transverse direction). Lateral tie beams shall be provided between two rail supporting elements shall be provided at a regular interval of min. 3.0m center. The foundation shall be designed for the most critical combination of loads as prescribed by the manufacture. The foundation shall also be designed for deflection and settlement as required by the manufacturer.

22.5

Over ground Galleries & Trestles On grade and over ground galleries shall be enclosed type for adequate weather protection. The walkways for on-grade galleries shall be raised and they shall be made of concrete with skid proof finish or with metal bar grating. Overhead conveyor galleries shall be structural steel consisting of two girders braced at top and bottom and

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:95

DESEIN

Volume-VI: Civil, Structural & Architectural Works

supported on trestles. Walkway portion of over ground conveyor galleries shall be of chequered plate with antiskid bar or expanded metal grating. The maximum span of standard gallery shall be 30m. The galleries for double stream conveyors shall have one central walkway and two side walkways and single stream conveyors shall have two side walkways. Hand railings shall be provided as required. At crossing points of roads, buildings and railway lines and other important locations seal plate shall be provided. The over ground conveyor galleries shall be designed for adequate ventilation and natural lighting. Conveyor gallery having slopes grater than 10 degree, stepped walkways of tread 250 mm of chequered plates with nosing and toe guard shall be provided all along the conveyor. Suitable floor washing arrangement shall be made in the conveyor gallery with down comers. In between transfer house / buildings four legged trestles shall be place at a maximum interval of 90m. The arrangement shall be such as to ensure that force in the longitudinal direction of conveyor gallery of length not more than 90m will be transferred to four legged trestle. Two legged trestles at regular interval may be placed between four legged trestles. The end supports resting on the four legged trestles can have either ends hinged or one hinged and the other on slide type. Slide type support shall be with PTFE bearing to allow both rotation and movement. End of conveyor gallery which will be supported over transfer points, shall be so detailed that only vertical reaction is transferred from gallery and no horizontal force in longitudinal direction is transferred from gallery to transfer points and vice-versa. All RC trestle pedestals should be raised to (+)1.0m above FGL. Trestles shall be of structural steel braced adequately and provided at suitable locations. Location of trestles shall be decided carefully so that there is no interference with underground and over ground structures, tunnels, trenches, drains etc. The minimum clearance over road crossing should be 7.0 metres. 22.6 Coal stock yard Entire area shall be excavated to average 250mm depth and given slope of 1 in 100 in suitable directions as approved. Entire excavated area shall be watered and rammed and compacted with 10 tonne roller. 100mm thick river sand cushion layer shall be placed over compacted subgrade and consolidated by flooding 150mm thick boulder soling shall be laid over sand cushion, joints filled with river sand. Over boulder soling, 75mm thick lean concrete (1:4:8) shall be spread. Final layer shall be minimum 150mm thick RCC slab of grade M20 having double layer reinforcement. Slope is to be maintained through all layers. The coal stack area shall be graded with suitable slope for draining the surface by longitudinal drains shall be of RCC trenches with graded gravel packets at about 1.5m intervals on the sides to trap coal dust. Weepholes shall be provided in the trench walls at the locations of filter pockets for collecting surface water in the longitudinal drains for discharging into the main surface drain to be provided by the Contractor by the side of the road. Retaining wall 1m depth to be provided around the crushed coal pile to prevent coal spillage into the drain. Necessary control joints in the grade slab shall be considered to avoid temperature and shrinkage cracks in the slab. The design of coal stack area should take care of loads arising due to dozer movement and shall be designed to sustains coal water pressure.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:96

DESEIN

Volume-VI: Civil, Structural & Architectural Works

22.7

Drainage of CHP Area Suitable drainage arrangement shall be provided for underground structures if any with sump pumps. Coal stockyards and surrounding areas also shall have suitable surface drainage facilities.

22.8

Road / Rail Crossings: Hume pipes of appropriate size of class NP2 shall be provided under the roads and rail tracks for pipe and cable crossings at the required locations.

22.9

Loadings For different loads on structures, latest IS:875 shall be followed. All structures shall be designed for dead load, live equipment load (including impact / vibration), erection load etc. in addition, seismic load (as per IS:1893) or wind load (as per IS:875) shall also be considered. The following minimum live loads shall be adopted for design of buildings / structures. a) Flat Roof : Accessible roof 200 Kg/m 2 2 (150kg/m for L.L. & 50 Kg/m for dust load) Non-accessible roof125 Kg/m (75 2 2 Kg/m for L.L. & 50 Kg/m for dust load). A per IS:875 for live load plus 25 Kg/m for dust load to be Considered on plan area. 500 Kg/m
2 2 2 2

b)

Inclined roof (including roof for Conveyor Galleries) All building floors & stairs Toilet rooms Walkways Galleries of Conveyor

c) d) e)

: : :

200 KG/m

300 Kg/m (including Coal dust load) or a concentrated load of 300 Kg. at centre whichever is critical. 1000 Kg/m
2

f) g) h)

M.C.C. Floor Equipment Load Tunnels under roads, culverts per & its allied Structures including hume pipes. Underground basement tunnel trenches etc. Tunnel

: : :

As applicable Class A or class 70R as higher or load due to bulldozers.

i)

A surcharge pressure of 2T/m .

j)

The loading shall be highest of the following:

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:97

DESEIN

Volume-VI: Civil, Structural & Architectural Works

i)

Two bulldozers (maximum capacity indigenously available) operating side by side without any coal heap over reclaim tunnel & surroundings and uncrushed coal storage area. Two bulldozers operating side by side over a coal heap of 4.0m.

ii)

k)

Rail loads

As per I.R.S. including latest amendments All structures under influence of Railway load shall be designed as per provisions of Indian railway code of practices and the contractor shall get the designs and drawings of structures approved by railway authorities also.

l)

Other loads

As per IS:875 or as decided by the Purchaser For design purpose the values for Seismic Zone III as per IS:1893 shall be considered. Importance factors for all buildings shall be considered as 1.75. In addition, provision contained in IS:4326 & 13920 shall also be considered.
As per IS:875. Basic wind speed = 50 m/s.

m)

Seismic Loads

n) o)

Wind Load

Minimum thickness of walls / raft for all underground structures will be as follows: i) ii) iii) iv) Walls of depth from 0 5 M Walls of depth from 5 10 M Walls of depth from 10 15M Base slab of u/g basement and roof of tunnel : : : : 300 mm 500 mm 700 mm 500 mm

p)

A minimum safety factor of 1.2 against uplift of due to underground water shall be ensured during execution and after execution, considering dead weight of the structure to be 0.9 times only, ground water table at adjoining formation level and soil wedge angle of not more than 15 degress. Also FOS against uplift to be taken as 1.0, considering the dead weight of structure and soil resting on side projections, if any in the vertical plane. Inclined wedge action of soil shall not be considered in this case. For Underground structures, earth pressure to be considered for design shall be due to earth pressure at rest (K0) condition only. Earth pressure due to surcharge intensity of Railway Loads (where applicable) or Uniformly Distributed Load (UDL) of intensity 2T/sqm whichever is critical, shall be considered in the design.

q)

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:98

DESEIN

Volume-VI: Civil, Structural & Architectural Works

r)

For design of coal hoppers, bulk density and angle of repose for coal shall be considered as 1.2 MT/cum and 31 deg. respectively. For deep underground structures, minimum clear cover for reinforcement shall be 50 mm unless otherwise stated.

s)

23.0 23.1

ASH HANDLING SYSTEM CIVIL, STRUCTURAL AND ARCHITECTURAL WORKS Ash handling system shall comprise of bottom ash and fly ash handling systems, ash slurry pump house, ash water pump house, ash pipe supports including culverts, bridges etc. upto the specified terminal points. Works shall include bottom ash hopper supports, dry extractor / cooler supports & foundation, pre-crusher / primary crusher supports, vibrating feeder supports & foundation, conveyor trestle supports & foundation, bottom ash silo, bottom ash pipe supports, bottom ash extraction equipment supports, ash slurry pipe supports from ash slurry pump house, surge tank, dry fly ash & bottom ash pipe supports, supporting structure for buffer hopper, buffer hoppers, fly ash silos, development of silo area (including paving, fencing, access roads, office block and watchman cabin), pump and equipment foundations, compressor house, MCC room, RCC thrust blocks, 80 tonne electronic weigh bridge and other buildings, supporting structure facilities required to complete the system upto terminal points. Structural arrangement, pile foundation system, if required, cladding interior and exterior finishes, area paving etc., shall be as per total plant building design and finish schedule furnished elsewhere in the specification. Pipelines shall be supported on steel structures supported on RCC pedestals and pile foundations, if required. The top level of the pipe pedestals shall be 300mm above the formation level. Pipes shall be suitable anchored with RCC pedestals to resist lateral and vertical movements. For crossing of the pipe lines and maintenance road with nallahs, canals etc. and / or for road / rail crossings, pipes shall be laid through RCC box culverts / bridges. Road leading to silos shall have minimum width of 7.5m with both sides berms 1m and drains. Existing ash dyke and bund shall not be disturbed. The compressors and their associated equipments shall be housed in RCC building along with requisite MCC room. Crane / monorail of adequate capacity shall also be provided in all pump / compressor house. Spot levels along the ASP line Road Bridge Road Bund : : : : (+) 9.00 & (+) 8.75 M (+) 12.05 M (+) 8.75 M (+) 11.00 M

23.2 23.3

Specification for Civil, Structural and Architectural Works will be referred. Following facilities shall be provided near the remote silo as per Vol. III of specification.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:99

DESEIN

Volume-VI: Civil, Structural & Architectural Works

i) ii) ii) iv) v) vi) vii)

Ash slurry sump with pump house. Ash water sump house with pump house. Recovery Water Pump House. MCC Room / Control room. Pipe Rack / trenches etc. in the plant area. RCC paving in Silo area Office block of minimum 50 sqm and Watchman cabin of minimum 5 sqm area shall be provided.

viii) 24.0

Dry ash storage silo area shall have compound wall all around with gate.

SWITCHYARD STRUCTURES & CONTROL BUILDING Extent of GIS switchyard and number of towers and gantries and the size of switchyard control room will be as per the layout of the switchyard which has been outlined in Vol. IV of the specification. Switchyard control building will be of concrete frame structure having brick wall cladding. A crane of suitable capacity will be housed in switchyard building. The building shall be complete with toilets, drains, plumbing, sanitary drainage and treatment piping, space conditioning for a non-air-conditioned area, building lighting, station combinations and fire protection etc. An adequately sized dedicated air conditioning plant shall be provided for the control room. Epoxy coated flooring shall be provided in battery room of switchyard control building.

25.0 25.1

PLANT WATER PRE-TREATMENT AND DM PLANT SYSTEM Raw water pre-treatment for CW and DM plant will generally consist of the following facilities / buildings. However, the bidder may add / delete / club facilities as per approved system: Electro-chlorination buildings Aerator Stilling chamber and inlet channels and measuring flumes Clarifiers Chemical house Sludge pit (reject sump) Clarified water reservoir and pump house RO Stage I Permeate Tank & Pumphouse RO Stage II Permeate tank & Pumphouse

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:100

DESEIN

Volume-VI: Civil, Structural & Architectural Works

The stilling chamber and aerator shall be of RCC structure. The chambers and water channels shall be watertight structures. The high rate solid contact clarifier shall be of RCC construction. The watertight circular RCC structures shall have continuous platform with handrail along periphery at the top. At least 3 nos. ladder shall be provided at the outside and vertical rungs shall be provided inside for maintenance. The sludge sump (reject sump) shall be an underground RCC pit, part of the pit shall be cover with RCC slab for supporting the vertical sludge pumps. The sludge pumps shall be housed in a pump house with RCC roof supported on RCC columns and beams. There will be hoist and monorail of required capacity for handling of pumps. Capacity of reject sump is indicated in Vol. III & Composite Water Scheme. Clarified water reservoir shall be of water tight RCC construction having two compartments covered with RCC roof. It will be aboveground. Vent pipes shall be provided at roof. Clarified water reservoir including RCC roof shall be designed as uncracked structure as per IS:3370. The clarified water pump house structure shall be of RCC framed construction with RCC flat roof. Side cladding shall be of brick masonry. Monorail or gantry shall be provided for handling pumps. The building shall be complete with doors, windows and rolling shutter. Floor and other finishes shall comply with architectural specification. Capacity of the clarified water reservoir is indicated in Vol. III & Composite Water Scheme. RO Stage I Permeate Tank shall be of water tight RCC construction having two compartments covered with RCC roof. It will be aboveground. Vent pipes shall be provided at roof. Ro Stage I permeate tank including RCC roof shall be designed as uncracked structure as per IS:3370. The RO Stage I Permeate Pumphouse structure shall be of RCC framed construction with RCC flat roof. Side cladding shall be of brick masonry. Monorail or gantry shall be provided for handling pumps in line with Volume III. The building shall be complete with doors, windows and rolling shutter. Floor and other finishes shall comply with architectural specification. Capacity of the RO Stage I Permeate Tank is indicated in Vol. III & Composite Water Scheme. Pretreatment chemical house shall be a two storied concrete RCC framed building. Clear height of 5.5m (minimum) shall be provided in each floor. The building shall be complete with brick work, plastering, doors, windows, rolling shutters, flooring, plaster, painting, roofing etc. and all other items necessary for satisfactory performance of the building. The building shall have toilets and the scope shall include supply and fixing W.C.s urinals, showers and all plumbing sanitary and other work required for satisfactory completion of the above building. The tanks and parts of floor slabs shall be lined with acid / alkali proof tile lining. Monorails of adequate capacities shall be provided as per functional requirements. The building shall be provided with adequate toilet facilities. Near the chemical house there will be a single storeyed RCC framed building housing the electro-chlorination plant. Hoists with monorail shall be provided for normal plant operation and for handling of equipment during erection / maintenance. The building shall be complete with brick work, plastering, doors, windows, rolling shutters, flooring and painting, roofing etc. and all other items necessary for safety and satisfactory performance of the building. Brick masonry wall with suitable windows and doors will be provided in accordance with architectural specification. The RO / DM plant building will be RCC framed building having brickwork cladding on all four sides. Ground floor shall house MCC and control room. Control Room which shall have false ceiling and shall be air-conditioned. Central chemical laboratory and

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:101

DESEIN

Volume-VI: Civil, Structural & Architectural Works

office rooms etc. shall be at first floor level, which will also have false ceiling and air condition provision. Equipment foundations & trenches in ground floor slab shall be of reinforced cement concrete. Ground floor shall have ironite flooring except at locations, which may come in contact with acid/ alkali where acid / alkali resistant tile lining with epoxy mortar shall be provided. Effluent drain trenches shall also have acid proof lining at inside surfaces of drain as well as soffit of pre-cast removable covers. The building shall be provided with adequate toilet facilities.

. Neutralizing pit shall be of watertight RCC construction. Internal surfaces shall be lined with acid / alkali proof lining with matching epoxy mortar. Acid / alkali storage tanks shall be resting on RCC saddles on elevated RCC platform. The platform shall be supported on RCC beams, columns with RCC foundations. The saddles along with platforms shall be lined with acid/alkali proof tiles. Acid / alkali storage and handling area shall also be lined with acid / alkali resistant tiles. The DM storage tanks shall rest on thoroughly compacted fill of gravel, coarse sand or other stable material topped with minimum 75 mm thick compacted crushed stone, screenings, fine gravel, clean sand or similar material mixed in hot asphalt (8 to 10 percent by volume) and rolled or compacted. This filling shall be confined within a RCC ring wall with foundation. The tank shall have complete bearing with the foundation fill. All backfilling within tank foundation shall be done by compacted sand. Degasser shall be supported on RCC framed structure. Minimum 2.5m wide RCC pavements shall be provided around each outdoor equipment. 26.0 FIRE WATER PUMP HOUSE AND TANK FOUNDATIONS Fire Water sump shall be water tight RCC construction having two compartments with covered RCC roof. It will be over ground. Vent pipes shall be provided at the roof. RO Stage-I permeate sump including RCC roof shall be designed as uncracked structure as per IS: 3370. The Fire Water permeate pump house shall be single storeyed flat roofed RCC / steel framed building with brick / colour coated metal sheeting as side cladding. Monorail & gantry shall be provided for handling pumps. The building shall be complete with doors, windows and rolling shutter. Capacity shall be as per Vol. III and Composite Water Scheme The fire water sump capacity shall be as per Vol. III of specification. 27.0 27.1 INFRASTRUCTURE FACILITIES Plant Roads and Drains for Buildings / Facilities Access within the plant site shall be provided by a system of roadways. Roads shall be three types: Type I, Type II and Type III. All the roads inside the plant area shall be with reinforced cement concrete of minimum 25 cm thick. Type I roads shall consist of 7.5 metres wide RCC paved carriageway with 2.5m wide hard shoulders. The main plant access road and a portion of the main plant complex circumferential road shall be Type I.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:102

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Type II roads shall consist of one 4.0 metre wide RCC paved carriageway with 1.5m wide hard shoulders with drains on either side. A turning area at blind ends shall be provided. Plant areas where infrequent access is needed shall be served by Type II roads. Examples of Type II roads are the lay-down area roads. Type III roads shall be 3.0m wide with 1.0m wide hard shoulders on either side. Type III roads shall be provided along the plant boundary for access for security and maintenance. Road at entrance shall be widened with proper Bell Mouth. Road leading to main gate to the power house of double road with suitable berm with a minimum thickness of 25 cm and width of 7.5m each as per MOST specification / relevant IRC codes. All roads shall be surfaced with gravel during the construction period. Occasional applications of a dust palliative material shall be used to minimize the dust problem during the dry seasons. All Type I roads shall have a minimum turning radius of 10 meters and for Type II and Type III roads shall have a minimum turning radius of 7 meter. Boulders shall be provided along side all type roadways near equipment which requires protection. Spare duct banks shall be provided under all type roads spaced at 100 meter intervals. Signs shall be provided for vehicle management and shall meet the Indian standards. All signs shall be dual worded in both English and the local Indian language. Finished top (crest) of roads shall be 250 mm above the surrounding grade level. Geometric design of road shall be in accordance with IRC:73. The ruling gradient for roads longitudinal shall not exceed 1 in 20. Main roads shall be designed for movement of heaviest equipment of the plant. California Bearing Ratio (CBR) method shall be followed for the design of roads as per IS:2720 (Part XVI). CBR test shall be carried out in remoulded soil samples under soak condition. The shoulder shall be laid with slope of 1 in 30. All the culverts shall be designed for IRC Class AA loading and shall be checked for class A loading. The equipment moving load shall also be properly considered. All building shall be approached by access road, which shall either be single or double lane road depending upon the functional requirement. Access roads shall also be provided to areas such as transformer areas, steam generator area and other equipment area shown in the plot plan, where access is necessary for inspection, operation and maintenance. Concrete paving of grade M-20 with suitable underbed shall be provided in the entire area of backside of turbine generator building for full length up to 2m beyond chimney. Sufficient pavement areas adjacent to administrative building, canteen building, service building, fire station and first aid centre shall be provided for parking facilities.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:103

DESEIN

Volume-VI: Civil, Structural & Architectural Works

The inside of fuel oil dyke area shall be provided concrete paving. The transformer area shall be provided with minimum 100 mm thick crushed aggregate topping with top layer of soil treated with anti weed chemicals. No underground service piping except for drainage and sewage system shall run directly below the road (including up to 1.0m from edge of road) along its longitudinal direction. Surface drainage of roads shall be provided by giving proper longitudinal slopes and cross falls. The roads and pavements shall be considered as per relevant IRC Codes and MOST standards. Drainage on both sides along approach road to ash pond with necessary culverts, crossings shall also be within the scope of this tender. The drainage system shall be designed for precipitation intensity of 80 mm per hour (maximum hourly intensity of rainfall). The run-off coefficient of 0.9 and 0.6 shall be considered for paved area and other area respectively. Surface drains will normally have a slope of 1 in 1000 along longitudinal direction and RCC pipes to have such slopes such as to have effective discharge. RCC structures will be provided at drops / falls to prevent scouring. Minimum self-cleansing velocity should be adopted as 0.7m/sec but the velocity of flow shall not be more than 2.4 m/sec for concrete drain. RCC storm water drainage system for the entire plant area shall be provided for draining the entire water including re- routing the existing storm water drain with out affecting the generation of the existing plant shall also be within the scope of this tender 27.2 27.2.1 Fencing and Security Boundary Wall and Gate a. The boundary wall / peripheral industrial compound wall of RR masonry approximately 6 km length with minimum height of 4.5m and the bottom 1.5m thickness is of 60 cm and 45 cm of middle 1.50m and 38 cm thk of top 1.50m height with anti climbing device of 600 mm high MS angle Y-frame fixed to each pillar and provided with spiral spun barbed wire. Gate latches shall be arranged for padlocking with the padlock accessible from both sides of the gate. Padlocks shall be provided and the key shall be in accordance with the Purchasers requirements. Cantilever type motorized sliding gate shall be furnished at the main plant entrance. The gate shall be operable by push button at both the guard house and the security office in the Administration / Plant Service area, and by card reader or key switches. The main entrance gate to be double leaf gate fully covered with sheet.

b.

c.

d.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:104

DESEIN

Volume-VI: Civil, Structural & Architectural Works

e.

Separate wicket gate on either sides of the main gate with a width of 1200mm. The road near the main entrance to be widened additionally by 7.5 m on either sides of the road for parking of vehicles for security check. Suitable median arrangements to be made. Security cabin to be provided on either sides of the road near the main gate. Elevated platform either in steel structure / Brick work or RCC to carry out checking on Lorries/Tippers by security personnel while the vehicles getting in or going out from the premises.

f.

g. h. i.

27.2.2

Fencing around Transformer Yard a. Minimum 3m height fencing above toe wall shall be provided around transformer yard and other areas where fencing is necessary due to statutory requirements. Fencing shall comprise 3.0m height PVC coated galvanized chain link fencing of minimum 8 gauge including PVC coating of mesh size 75 mm and galvanized concertina. Galvanized barbed of a height of 0.6m shall be provided above the chain link fence The diameter of steel wire for chain link fencing excluding PVC coating shall not be less than 12 gauges. MS entry gate shall be provided for all fenced areas. Top of toe wall shall be min. 200 mm above formation level.

b.

c.

d.

27.2.3

Plinth Protection All buildings shall be provided with 1000 mm wide and 100 mm thick plain cement concrete paving alround the outside. Plinth protection shall be laid over prepared subgrade and base formed with broken brickbats or rubble laid to a thickness of 150 mm.

27.3

Waste Water Treatment and Drainage System Waste water treatment plant will receive plant drain water except RO plant reject and CT blow down. The treated water and the solid waste will be used within the plant. Guard pond will hold the RO Stage-I reject, clarifier sludge treated water from oil water separator and this will be pumped to the sea. For this return water to the sea o temperature shall not exceed 5 C over the inlet temperature of cold water. The cooling tower blow down shall be pumped to sea with the help of blow down pumps installed in the CW pump house. All necessary civil / structural works for waste water treatment plant shall be under scope of contractor. The major source of plant drain water are Boiler blow down, coal mill area drainage, PH and boiler area oil effluent drain, F.O. pump house oil drainage, boiler and ESP area floor washing drains, water pre-treatment plant

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:105

DESEIN

Volume-VI: Civil, Structural & Architectural Works

effluent, fly ash silo area effluent, transformer yard waste water etc. Design and construction of channels / settling pits / sumps / pipe lines / separators shall be done by the Bidder. The description of some of the major structures / components covered under the waste water system package is given below: Coal pile area run-off will be led to settling pond. Earthen settling pond with two (2) compartments will be provided. Top of earthen dyke shall be 500 mm above surrounding finished grade level to restrict ingress of storm water from adjacent areas. Capacity of pond shall be determined on the basis of inlet drain invert. The side slopes and bottom will be protected with PCC blocks of minimum 75 mm thickness with suitable under-bed having interstices filled with cement-sand mortar. At the downstream of pond RCC overflow weir and sump shall be provided. Design and detailing of pond shall be as per good engineering practice so as to satisfy functional requirement as specified in the specification. Necessary sluice gates with hoisting arrangement shall be provided in inlet drain carrying coal pile area run-off so that one settling pond can be operative while the other one under excavation. The Power House and boiler area service water waste shall be collected in a RCC underground oily waste re-tension pit. Necessary pumps and supporting floor / maintenance area shall be provided. This effluent will finally be treated in TPI (tilted plate interceptor). Foundation fro TPI shall be designed as per IS:456. RO Stage-II reject shall be led to fire water sump and green belt development. In case the fire sump is full then arrangement shall also be made to lead this to the guard pond. Oil storage and handling area run-off will be collected to a conventional baffled oil water separator. This oil water separator will be an underground RCC structure having RCC baffle wall and overflow sump for collecting water at outlet end. An oil collection pit shall be provided on sidewall of oil water separator. This structure shall be designed as un-cracked section as per IS:3370. The structure shall project at least 300 mm above finished grade level. Handrail shall also be provided around the pit. The overflow sump shall be covered at top over which pumps will be installed. RCC sump for collecting boiler blow down and ESP area floor washing is included in scope of bidder. Civil work for outlet of this effluent shall also be under scope of this package. Guard Pond (effluent monitoring pond and equalization basin) sized for holding waste water from RO Stage-I reject, clarifier sludge, treated water from oil water separator and boiler blow down as per capacity indicated in Vol. III & Composite Water Scheme. The guard pond (earthen) shall have adequate capacity as per design requirement with 750 mm free board. Top of earthen dyke shall be 500 mm above finished grade level. The pond shall be of such construction as to prevent pollution of ground water by seepage of any wastewater having side slopes and bottom lined with minimum 250 micron LDPE for minimizing seepage loss. Over the LDPE lining, PCC blocks of minimum 75 mm thickness having interstices filled with cement-sand mortar shall be provided. Filter media shall be suitably designed and provided below liner. 27.4 Sanitary Sewerage System Sanitary Sewerage System shall be carried out as specified in VOL III (Mechanical Spec.). The treated water to be provided with necessary pumps and distribution lines for reutilization for Horticulture / Green belt development.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:106

DESEIN

Volume-VI: Civil, Structural & Architectural Works

The sewerage system of foul water from toilet shall include layout and laying of sewers up to a sewage treatment plant together with all fittings and fixture and inclusive of ancillary works such as connections, installation of man-hole and inspection chambers. The construction of a sewage treatment plant of adequate capacity including settling tank, lifting stations, pump house and all other necessary provisions shall be made for treating the sewage water by using the latest CAACO technology developed by M/s. Central Leather Research Institute, Taramani, Chennai. The domestic effluent from the plant shall be collected and treated in proper STP to meet the prescribed BIS standard before being discharged or reutilized for green belt development. 27.4.1 Sanitary Sewer Drains a) Sanitary sewers shall be designed for a minimum self cleansing velocity of 0.75 m/sec. and the maximum velocity shall not exceed 2.5m/sec. Very hot (over 60 C) water shall be first cooled down to less than 60 C in collecting basin by mixing with cold water before connecting to storm drainage system. The maximum temperature, quality, quantity and location of drain water of individual equipment shall be tabulated and furnished to the Owners representative. All underground piping below concrete slab shall be cast iron of minimum 100mm dia and for outdoors it shall be reinforced concrete pipe of minimum 200mm diameter. In buried piping system manholes shall be placed at every change in direction and at every SOM (max.) interval in straight run. Suitable clean outs shall be provided for buried piping under floor slab. Following minimum drainage slope shall be provided: 28.0 28.1 Pipes of diameter less than 200mm : 1 (vertical) : 100 (horizontal) Pipes of diameter 200mm & more: 1 (vertical): 200 (horizontal).
0 0

b)

c)

d)

e)

SERVICE BUILDING The service building shall be a reinforced concrete framed building. The building shall generally not exceed four storeys (G+4) and shall be directly connected to the main plant building at operating floor. The floor area shall not be less than 1000 sqm for each floor. The building shall generally be air conditioned with false ceiling. Elevators as indicated in Vol III shall be provided. For elevators, necessary civil works to be executed including foundation, roofing etc. based on Mechanical Specification. A grid of concrete beams and columns shall support the reinforced concrete roof (minimum 3% slope) and the floor slabs. The walls shall be of masonry construction, plastered internally and rendered externally. The service building shall have the following provisions: a. Seating accommodation for senior O&M executive along with supporting staff including furnitures of latest style. For the accommodation of all Executives

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:107

DESEIN

Volume-VI: Civil, Structural & Architectural Works

permanent brick wall not to be provided, instead wooden partition wall of cubicle type is to be provided. b. c. d. Safety and Welfare Cell, First aid room Reception, drawing hall, library, print rooms and records room/ archives. Conference hall with all amenities like latest style furnitures, loud speaker systems, LCD display equipments, service room etc. Mini conference hall with furnitures near UCB. Relay testing lab, electrical lab, C&I repair lab and transmitter lab. Pantry Toilets Ladies & Gents in each floor as per specification. Telephone Exchange of 500 lines Electrical and LAN points at each seat in the cubicle, cabins & conference rooms with wiring and fittings.

e. f. g. i. j. k.

28.2

Fuel Oil Handling System Separate FOPH building shall be constructed. The structure shall accommodate the necessary requirements. The building shall be of RCC framed structure with brick cladding.

28.3

Air Washer Room & Compressor House This shall be a single/double storied steel framed building adjoining to the Turbo generator bay. Roof shall be of RCC supported on colour coated trough shaped permanent decking supported on steel beams. Side cladding shall be by brick supported on concrete encased steel beams. Internal wall surfaces shall receive cement mortar plastering mixed with water proofing compound. Water tank and RCC supporting structures for louvers, filter and foundation for equipment such as fans and pumps are also included in the scope. Proper drainage of the floor has to be provided for. Doors shall be of flush welded steel and they shall be made airtight. Rolling shutter of adequate size should be provided for taking the equipment inside and truck with compressor. The roof framing shall support an underslung crane of adequate capacity. Compressor foundation shall be isolated from the grade slab. Air receiver and Air drier can be supported from RCC grade slab. All trenches shall be sloped towards drain sumps. Trenches shall be provided with chequered plate cover. Steel glazed windows shall be provided for ventilation and natural lighting. A minimum of 2 flush type steel door shall be provided for movement of personnel. Dimension of the building shall be decided by the CONTRACTOR to suit the dimension of the equipment he is supplying duly taking into account maintenance requirements.

28.4

Diesel Generator House This shall be a single storied RCC framed structure with electric hoist. The dimension of the building shall be decided by the CONTRACTOR to suit equipment supplied. D.G set foundation shall be isolated from the floor.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:108

DESEIN

Volume-VI: Civil, Structural & Architectural Works

All trenches shall be of RCC and shall be designed as water retaining structure. There shall be no entry of cables / pipes to these trenches below grade level from outside. All these trenches shall be covered with chequered plate over steel framing. Adequate number of sumps shall be provided to drain these trenches. 28.5 Pipe racks and cable racks All cable and pipe routing in out lying area shall be clubbed and shall run over ground on structural steel pipe / cable racks at a height not less than 4500 mm clear above grade level. Where the pipes cross roads / railway clear headroom shall be 7500 mm. The racks can be multi-tiered. Cable shall normally be laid above the pipes. Pipe racks/cable racks shall be of structural steel frame and longitudinally braced and shall be designed for worst combination of loadings. Expansion provision shall be provided wherever there is a change in direction or where length of the rack exceeds 100 metres. Pipe racks for all connections from the existing station, existing pipe racks is to be used with necessary modification (or) new rack is to be erected Necessary access ladders and platforms to be provided for maintenance. Where so required chequered plate platforms shall be provided for maintenance purpose 28.6 Workshop and Stores It shall be of RCC structure with RCC roof. Cranes/ monorails shall be provided as per requirements. It shall accommodate the machinery and facilities listed in the Mechanical section of the document. In addition the workshop and store shall provide for office space for superintendent and his supervisory staff, locker room and change room for workers, toilet etc. Entry and exit of trucks shall be through adequately sized rolling shutters. In addition, a minimum of 2 single-leaf, steel flush doors shall be provided for entry of the staff. Adequate steel windows shall be provided for ventilation and lighting. Offices inside shall be of glazed wooden partition above 900 mm high single-brick wall. Total height of partition including brickwork shall be 2400 mm. 28.7 Parking Sheds Parking sheds shall be provided at service building, security complex, at CW pump house area etc., at all locations for operating staff. The parking sheds shall be of RCC. The bidder has to furnish the three dimensional architectural plans along with the colour codes for the above buildings for approval of the Purchaser for adopting one among the alternatives proposed. 28.8 Allowable Settlement The total permissible settlement and differential settlement of the foundations will be governed by IS:1904, IS:13063 and from functional requirements whichever is more stringent. Maximum allowable total settlement should be restricted to 25 mm for foundations of all plant structures like cooling towers, CW pump house, DM plant, crusher house, TPS.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:109

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Maximum allowable total settlement should be restricted to 40 mm for all other foundations. All foundations shall be so designed that the settlements are within permissible limits as per relevant Indian Standard or from consideration of safe equipment / machine operation whichever is critical. In case of open foundations without piles, if contractor opts for ground improvement methods like sand drains / stone columns etc. to reduce settlement and increase the rate of settlement, detail methodology of such installation supported by calculation based on relevant field data shall be furnished for approval of Owner / Consultants before execution. In the event, the contractor adopts any patented method of ground improvement or retain any specialized agency for such purpose, the same can be done subject to prior approval of owner. The differential settlement to be considered between Bunker and TP Bunker to be finalized at Detailed Engineering stage.

29.0 29.1

GENERAL REQUIREMENTS Minimum thickness of structural elements: The following minimum thickness shall be followed: Flat roof slab Suspended floor / slab / walkways / canopy slabs etc. Ground floor slab (non-suspended) Water retaining slabs / walls : : 125 mm 150 mm

: :

150 mm 200 mm

Cable / pipe trenches / underground pits / Launder walls and base slab All footings (including raft foundations) Parapets Sunshades at edge Pre-cast louvers / fins Pre-cast trench cover slabs / floor slabs / louvers Paving Basement walls and base slab Silo / bin walls Underground reservoir: Below ground Above ground

125 mm

: : : : : : : :

200 mm 125 mm 75 mm 50 mm 75 mm 150 mm 200 mm 150 mm

: :

200 mm 150 mm

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:110

DESEIN

Volume-VI: Civil, Structural & Architectural Works

4.2 from fire resistance point of view minimum thickness of reinforced concrete members shall be as per fig. 1 or table 16a of IS:456. 29.2 Minimum height for pedestals / encasement of steel columns Pedestals to steel columns for building structures In case the top of pedestal is kept at a lower level so that the column base plate together with gussets and stiffeners remain below finished floor level (FFL) the column bases as well as the column sections shall be encased in concrete above FFL as per following: a. b. Open area Covered area : : 300 mm above paved level 300 mm above FFL

Stair and ladder pedestal shall be kept 200 mm above the finished floor level. 29.3 Pedestals to steel columns for equipment structure: a. b. c. Equipment in open area Equipment in covered area Structures and equipment supplied by vendor : : : As required (300 mm min.) As required (150 mm min.) As per vendors data subject to minimum as specified above.

Dense and durable concrete with controlled water cement ratio preferably 0.45 shall be used for all underground concrete structures such as foundations, basements, pump houses, water retaining structures, cable and pipe trenches etc. for achieving water tightness and durability. All foundation, embedments, inserts, block-outs etc. required for equipment shall be provided by the Bidder. Fly ash bricks shall be used for masonry work. Bidder shall ascertain himself at site 2 regarding the availability of fly ash bricks of minimum 75kg/cm compressive strength before submitting his offer. Aluminium nosing shall be provided for edge protection in RCC stairs. Wherever possible around floor openings an RCC kerb of 100 mm wide 150 mm high shall be provided. All concrete edges, where breakage of concrete corners expected shall be provided with angles of minimum size L 50x50x6 with lugs for edge protection e.g. alround the cut-outs I openings in floor slab, edges of drains supporting grating covers, edges of. RCC cable I pipe trenches supporting covers, edges of manholes supporting covers and supporting edges of precast covers etc. All cables & pipes in outlying area shall run above ground over steel trestles or other supporting structures for easy inspection & maintenance except in transformer yard area and some other localized area where the same can run in RCC trenches. However, for facilities for which buried pipe & cables are permitted by Purchaser, the same can be provided. In case of trestles, minimum 7.0 m head clearance shall be provided for road crossings. In other areas, the clear height shall be 3.0m minimum.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:111

DESEIN

Volume-VI: Civil, Structural & Architectural Works

All cable and pipe trenches shall be of RCC of minimum M25 grade. Trenches located outside buildings shall project at least 200mm above the finished formation level so that no storm water shall enter into trench. The bottom of the trench shall be sloped suitably for draining out the collected water into sump pit. The pre-cast covers shall be of minimum M25 grade and shall not weigh more than 65kg. Lifting hooks shall be provided in the pre-cast covers. Pre-cast covers shall have edge protection angles at top and bottom on all the four sides along with lugs. All construction drawing furnished by Bidder shall consist of total quantity of concrete (grade-wise), reinforcement steel (diameter wise) and structural steel (Section wise). All roofs shall be provided with access through a staircase. Minimum 1.0m wide access path on roofs shall be provided with tiles. All roofs shall be provided with water proofing treatment. The plinth of powerhouse and its surrounding area is to be kept 23.25m. Top of main approach road and internal road are to be kept at 23.50M level. Duct banks consisting of PVC / GI conduits for cables shall be sealed using approved fire retardant sealing compound. All water retaining structures designed as un-cracked section shall also be tested for water tightness at full water level in accordance with IS:3370 (Part I) and IS:6494. 29.5 The number of construction joints in the columns of steam turbine foundation shall be restricted. Construction joints at the following three locations shall be provided: a) b) c) At the meeting points of the columns and the raft. At the points of contra-flexure in the columns. At the meeting points of the column and the top deck.

Additional reinforcement and shear keys shall be provided at the construction joints. The base raft for steam turbine and GT foundation and table top for steam turbine shall be cast in single pour. Mild steel bars required for earthing / grounding mat shall also be supplied and installed. All cable vaults shall be located above ground level i.e. cable vaults shall not be provided as basements in the buildings. Connection work at terminal points is included in the scope of the Bidder. All transformer / shunt reactor foundations shall be designed as per relevant IS Codes. This will include collection of oil, drainage of oil along with rainwater collected in such foundation. 29.6 The Bidder shall carry out the topographical survey of the area within leveling boundary to establish existing ground levels before commencing the detailed design and site leveling activities. All levels shall be established with reference to the

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:112

DESEIN

Volume-VI: Civil, Structural & Architectural Works

permanent bench mark existing near the plant site. Base on field observations the bidder shall prepare detailed survey maps showing topographical details and contour levels and submit the same to Purchaser for approval. Ground floor slab of the building and RCC paving shall be of minimum 150mm thick of M-20 grade laid over minimum 75mm thick PCC and 230mm soling (minimum) course unless specifically mentioned otherwise. The reinforcement shall consist of minimum 8mm diameter bars at 200 mm c/c of grade Fe 415 at top and bottom in both directions. For all buildings, suitable arrangement for draining out water collected from equipment blow downs, leakages, floor washings, fire fighting etc. shall be provided for each floor. 30.0 INTERIOR DESIGN A comprehensive interior design scheme shall be conceived with the intention of projecting a definite theme and aesthetic appearance to inside working environment. It shall take into account the multidisciplinary engineering activities involving power plant technology, and architectural and civil engineering for a smooth control hierarchy and man machine inter face. All the design aspects such as flooring, false ceiling, furniture, colour scheme, equipment design and layout, illumination, fire fighting, acoustics and ergonomics requirements shall be detailed out so as to present an overall unified aesthetic spatial appearance. The areas to be undertaken for this interior design process shall be control room complex including common control room, computer room, conference rooms and office areas in the main plant building and the following aspects shall be reviewed and evaluated for design. Furniture to be supplied by Bidder for the control room complex shall be as specified under C&I specification. a) Layout, keeping in view the main-machine interface and suitable ergonomic practices. Integration of civil engineering with architecture and interior design. Illumination levels, noise levels, electromagnetic interference levels, taking into account the equipment and furniture. Comfort and safety requirements such as air conditioning, fire fighting, fire escapes etc. Microprocessors based control system to control the functional requirements.

b) c)

d)

e)

The above design philosophy put into practice shall be detailed out through presentation drawings, perspective views, scale models, detail drawing etc. 30.1 Finishing Schedule The minimum quality of finishes used for various building areas are furnished in Table-1 in this section. The Bidder is at liberty to use superior finishes provided all specific requirements for the finish specified herein below are satisfied. 31.0 Master Key System An appropriate serviceable and functional master key system for the whole plant shall be installed. The elaboration of the system itself shall be made in close co-ordination with

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:113

DESEIN

Volume-VI: Civil, Structural & Architectural Works the Purchaser / Consultant and only after obtaining the Purchasers / Consultants approval in writing shall the order of production be placed. The following requirements shall be met: The general master key shall operate all locks The main key shall open all locks of one building The single key shall open the lock of a single room.

Necessary attention shall be paid to later extensions of the master key system, which shall be suitable for the entire plant including all final stages. The profile cylinders shall be sea water resistant and shall suit all plant requirements. The material of the cylinders shall be of massive brass, nickel-plated with six security pawl studs. The keys shall be made of material approved by the Purchaser / Consultant and shall have an engraved indication of the applicable key system and the building or door number. Keys shall be supplied in the following numbers: General Master Key Main keys Single keys 32.0 32.01.00 LAND SCAPING General This specification covers broadly the requirements for Landscaping within the Plant Area. Landscaping shall be carried out after all the underground utilities and drainage systems are in place. The entire work of Landscaping shall be carried out to the satisfaction of the Engineer and in a manner to have a beautiful appearance after completion of the work. The Landscaping plan should be prepared by the Contractor with the help of an expert Horticulturist with due considerations for Fauna & Flora grown in the adjacent area and which can sustain in the saline climate. The area to be landscaped shall be clearly demarcated at site and got approved by the Engineer and the work shall be divided into following sub-items. 32.01.01 Preparing Lawn For this purpose, within the area where lawn is to be grown, about 0.3 metres of earth shall be removed. This shall be replaced by fresh garden soil and manure in 2: I proportions spread evenly. Fresh garden soil & manure shall be mixed thoroughly, well watered and left overnight. The next morning, the variety of lawn, as per approved plan and as directed by the Engineer, shall be planted. This grass shall be maintained till well established by watering, weeding, clipping, rolling etc. 10 10 3 nos nos. per each building nos. per each door

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:114

DESEIN

Volume-VI: Civil, Structural & Architectural Works

32.01.02

PREPARING CLIPPED HEDGES Hedges made of Casuarinas or other shrubs as directed by the Engineer shall form borders between footpath and the Lawns. The shrubs shall be planted at spacing not more than 25 cms.

32.01.03

PLANTING SHRUBS Shrubs with coloured leaves like Crotons, Acalyphia, Oleander and Bougainvillea, Hibiscus etc. which are perennial shall be planted in clusters or over a large area at locations and in the manner as per approved layout. These shrubs shall be planted at spacing of not more than 25 cms.

32.02.00

INSTALLATION OF WATERING SYSTEM Shall prepare and submit watering System for the Plants. Drip Irrigation and Spray System consisting of complete PVC pipe with all necessary bends, Tees, Elbows etc., valves, stop cocks, Spray nozzles, sufficient lengths of Flexible PVC pipes to reach all area of Landscaping shall be included in the watering system. Only after approval of the Engineer, the Contractor shall commence the work.

33.0

Roof Drainage System a) Roof drainage system shall be provided for quick and efficient draining of rainwater from roof to avoid seepage and damage to roof. The runoff gradient for the roof shall not be less than 1 in 100. Roof drainange system shall consist of roof drain heads, rain water down comers and fixtures. System shall be designed to handle design rainfall for the specific site and shall be in accordance to stipulations of IS: 1742 and IS: 2527. Rain water down comers shall be of HDPE Pipe.

b) 34.0

SUMPS: In case of underground structures, sumps with pumping arrangement shall be provided at suitable location to collect and pump out any incidental water collection to nearest storm water drain.

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:115

DESEIN

Volume-VI: Civil, Structural & Architectural Works

TABLE 1 FINISHING SCHEDULE

STG Building Ground Floor: Unloading bay Acrylic washable distemper Granolithic with non-metallic hardner Granolithic Acrylic distemper -Water proof cement based paint Water proof cement based paint Water proof cement based paint Water proof cement based paint

Ground floor general area

Acrylic washable distemper

Acrylic distemper

--

Toilet

Dadoing for 2100 mm high + Acrylic distemper Acrylic washable distemper

Heavy duty ceramic tiles

Acrylic Distemper

--

Mezzanine Floor

Granolithic flooring

Acrylic Distemper

--

Operating floor: 1. Operating Area, laydown area 2. General circulation and movement areas 3. Heater area Acrylic washer distemper Glazed vitrified ceramic tiles Acrylic Distemper -Water proof cement based paint Water proof cement based paint

Acrylic washable distemper

Glazed vitrified ceramic tiles

Acrylic Distemper

--

Acrylic washable distemper

Heavy duty cement concrete tiles --

Acrylic Distemper

--

Water proof cement based paint --

Roof

--

--

Elastomeric water proofing treatment --

Lockers room

Acrylic washable distemper

20 mm thk Thandur blue st stone (1 quality) 20 mm thk Thandur blue st stone (1 quality) Glazed vitrified ceramic tiles

Acrylic Distemper

--

Pantry

Dadoing for 2100 mm high + Acrylic distemper Acrylic washable distemper

Acrylic Distemper

--

--

SWAS room

Acrylic Distemper

--

--

Clarified

Water

Acrylic washable

Granolithic floor

Acrylic Distemper

Heavy duty

Water proof

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:116

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Building / Area Pump House

Wall (Internal) distemper

Floor with non metallic floor hardener Granolithic floor with non metallic floor hardener Granolithic floor with non metallic floor hardener Granolithic floor with non metallic floor hardener Acid / Alkali resistant tiles

Ceiling

Roof Treatment water proofing as per IS:1346

Wall (External) cement based paint Water proof cement based paint Water proof cement based paint Water proof cement based paint Water proof cement based paint Water proof cement based paint Water proof cement based paint

Cooling Water Pump House

Acrylic washable distemper

Acrylic Distemper

Heavy duty water proofing as per IS:1346 Heavy duty water proofing as per IS:1346 Heavy duty water proofing as per IS:1346 Heavy duty water proofing as per IS:1346 Heavy duty water proofing as per IS:1346 Heavy duty water proofing as per IS:1346

Raw Water Pump House

Acrylic washable distemper

Acrylic Distemper

Bunker Building

Acrylic washable distemper

Acrylic Distemper

Chlorination Building

Chlorinated rubber based paint Acrylic washable distemper

Acrylic Distemper

Coal Handling Switchgear Room

Granolithic floor with non metallic floor hardener Granolithic

Acrylic Distemper

DM Plant

Chlorinated rubber based paint

Chlorinated rubber based paint

Control & Switchgear Building Central Room Control Acrylic emulsion paint Glazed vitrified ceramic tiles Acrylic Distemper Elastomeric water proofing treatment -Water proof cement based paint Water proof cement based paint

Conference room, senior executive room

Acrylic emulsion paint

Glazed vitrified ceramic tiles

Acrylic Distemper

Switchgear room

Acrylic washable distemper

Granolithic with non-metallic floor hardner Acid / alkali resistant tiles

Acrylic Distemper

--

Water proof cement based paint Water proof cement based paint

Battery Room

Acid & alkali tile dadoing for 2100 mm high + Chlorinated rubber based paint Acrylic emulsion paint

Chlorinated rubber based paint

--

Office, Common areas & corridor

Heavy duty ceramic tiles

Acrylic Distemper

--

Water proof cement based paint Water proof cement based

Cable Room

Acrylic distemper

Granolithic with non-metallic floor

Acrylic Distemper

--

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:117

DESEIN

Volume-VI: Civil, Structural & Architectural Works

Building / Area

Wall (Internal)

Floor hardener

Ceiling

Roof Treatment

Wall (External) paint

Toilet

Dadoing for 2100 mm high + Acrylic distemper Acrylic emulsion paint

Heavy duty ceramic tiles

Acrylic Distemper

--

Water proof cement based paint Water proof cement based paint Water proof cement based paint --

Electronic cubicle room & Computer room Laboratory room

Heavy duty ceramic tiles

Acrylic Distemper

--

Acrylic washable distemper

Heavy duty ceramic tiles

Acrylic Distemper

--

Records Room

Acrylic washable distemper

20 mm thk Thandur blue st stone (1 quality) 20 mm thick polished granite stone only for lobbies. Vitrified tiles provided for other areas

Acrylic Distemper

--

Service building, Administrative building and lobbies

Acrylic emulsion paint

Acrylic Distemper

Roof of service building shall be provided with Elastomeric water proofing treatment

Granular finish (Vineratex)

1x 660 MW Supercritical Ennore Thermal Power Station Expansion Project Spec. No. SE/C/ P & E/ EE/ M/No.03/2012-13
Vol. VI:118