Vol II Tech Spec Sct1367

TENDER SPECIFICATION
BHEL PSSR SCT 1367
Fabrication & Erection of Structural steel in GTG Hall,

STG Hall, Pipe Rack, Compressor House, Raw Water
Pump House, Fuel Oil Pump Shed, De-aerator Structure
and other Misc. Structures
at
PHASE III REFINERY PROJECT FOR MRPL-CPP,

MANGALORE, KARNATAKA
VOLUME - II
TECHNICAL SPECIFICATION
BOOK NO …..
BHARAT HEAVY ELECTRICALS LIMITED

(A GOVERNMENT OF INDIA UNDERTAKING)
POWER SECTOR – SOUTHERN REGION
690, ANNA SALAI, NANDANAM, CHENNAI – 600 035
PROJECT INFORMATION
1.0 OWNER : MANGMANGLORE REFINERY AND PETROCHEMICALS LIMITED
2.0 PROJECT TITLE:
MRPL PHASE III REFINERY PROJECT
3.0 INTRODUCTION
Mangalore refinery and petrochemicals limited (MRPL), is setting up a

new refinery facilities as part of the MRPL Phase III Refinery Project. To
cater to the steam and power requirement a new power plant is planned.
Engineers India Limited (EIL) has been retained by MRPL to provide
services to project management consultancy (PMC).
4.0 Key Features of Project Site
4.1 Project site : Mangalore, Karnataka.
4.2 Nearest town : Mangalore

4.3 Nearest Railway Station : Surathkal
4.4 Nearest Sea Port : New Mangalore port.
4.5 Nearest Airport : Mangalore (BAJPE)
4.6 Site Temperature : t min = 16.0 0C
t nor = 32.0 0C
t max = 38.00C
4.7 Relative Humidity : 75 @ tnor
4.8 Rainfall data(Annual) : 3467mm Avg
4.9 Rainy season : June to September
4.10 Wind velocity : 20-68 Kmph (Max. 28 days/years)
4.11 Wind direction : Morning East to West,
Evening North west to South East.
4.12 Elevation above mean sea : Min – 5.5m

level
Average – 8m
Max – 8 – 78m
4.13 Barometric pressure : 1007mbar
4.14 Source of Fresh water : River Netravadi
4.15 Seismic zone : As per 1893- Latest
SCOPE OF WORK/ SUPPLY SECTION: C-1.3
GENERAL CIVIL
6782-380-16-47-SP-01-B
CAPTIVE POWER PLANT
PHASE-III REFINERY PROJECT, MRPL Page 1 of 14
C-1 SCOPE OF WORK/ SUPPLY
C-1.3 GENERAL CIVIL
CAPTIVE POWER PLANT
PROJECT : PHASE-III REFINERY PROJECT
OWNER : MANGALORE REFINERY AND PETROCHEMICALS LTD
PMC : ENGINEERS INDIA LTD.
JOB NO. : 6782
MRPL COMMENTS INCORPORATED & ISSUED FOR

B 08.05.07 RAJEEV RKS NK
BIDS
A 01.02.07 ISSUED FOR BIDS RKS UCJ UCJ
Rev. Prepared Checked Approved
Date Purpose
No by by by
Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

GENERAL CIVIL
6782-380-16-47-SP-01-B
CAPTIVE POWER PLANT
CONTENTS
1.0 SCOPE OF WORK....................................................................................................... 3
2.0 DETAILED SCOPE OF WORK.................................................................................... 5
2.1 SITE GRADING AND STORM WATER DRAINS .........................................................5
2.2 ACID/ ALKALI PROOF LINING/ CHEMICAL RESISTANT FLOORING .......................5
2.3 DRINKING WATER SYSTEM.......................................................................................6
2.4 SANITARY AND PLUMBING SYSTEM ........................................................................6
2.5 SAFETY SHOWER & EYE WASH................................................................................6
2.6 FIRE PROTECTION SYSTEM......................................................................................6
2.7 FIRE PROOFING..........................................................................................................8
2.8 MAIN ROADS, APPROACH ROADS, STORM WATER DRAINS & CULVERTS ........8
2.9 CABLE CROSSING ......................................................................................................8
2.10 RCC TRENCHES..........................................................................................................8
2.11 OWS/ CRWS SYSTEM.................................................................................................8
2.12 HARD STAND...............................................................................................................9
2.13 STORAGE TANK AREAS.............................................................................................9
2.14 COOLING TOWER AND COOLING WATER TREATMENT FACILITIES ....................9
3.0 DRAWINGS/ DOCUMENTS REQUIRED FROM CONTRACTOR .............................. 9
3.1 WITH OFFER................................................................................................................9
3.2 AFTER AWARD OF THE CONTRACT.........................................................................9
4.0 APPROVALS ............................................................................................................... 9
5.0 SCOPE OF SUPPLY.................................................................................................... 9
5.1 OWNER’S SCOPE OF SUPPLY ..................................................................................9
5.2 CONTRACTOR’S SCOPE OF SUPPLY.......................................................................9

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6782-380-16-47-SP-01-B
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1.0 SCOPE OF WORK

The scope of work of this package tender involves design, detail engineering, preparation of
drawings, obtaining approval from PMC/ Owner, construction, fabrication, erection,
installation, tie-up with main system, testing, painting, commissioning, trial runs, supply of all
materials, items, equipment, transportation, labour, consumables, tools and tackles etc.
required for completion of job as per specifications, standards, codes, data sheets, drawings
& good engineering/ national/ international standards/ practice accepted by client and
direction of Engineer-in-charge in all respect of all the General Civil works including taking
approval from Statutory Bodies (like PESO, TAC or equivalent agency, DGCA etc.) /Local
Bodies and preparation of drawings/documents for approval from Statutory Bodies/Local
Bodies for the Captive Power Plant (CPP) and its associated facilities, sub station, control
room, DG shed, STG building, tank farm area, Cooling Tower, Cooling water sump, Cooling
water pumps, Cooling water supply & return piping and cooling water treatment facilities etc
to cater to the complex facilities at Phase-III Refinery Project, MRPL, Mangalore.
The scope of work mainly involves as described below, but not limited to the following.
- Design, engineering, construction, testing and commissioning of RCC Induced draft
counter flow cooling tower with PVC fill, Cooling Tower sump & pump, cooling Water
Treatment facilities including side stream filters, antiscalant, biological control & other
dosing systems as required.
- Cooling Water Supply (CWS) and Cooling Water Return (CWR) system.
- In Power Plant area only Operating & maintenance area shall be provided with RCC
pavement.
In the cooling tower area upto 5m all around including below basin shall be provided with
RCC pavement. Cooling water pump station shall be provided with RCC pavement.
- Internal roads, approach roads etc.
- Stone Masonry Dyke walls for Tank farm
OWS / CRWS with triple valve pit, drainage inside dyke, sand traps and connecting up to
main refinery system.
- Distribution network of Drinking water system shall be provided for control room, sub
station building, Safety shower & eye wash or any other places required in the power
plant block from tapping point connected with the main drinking water network as per
scope enclosed with this bid package.
Any boosting pump required to enhance the drinking water pressure is in EPC
contractor’s scope.
Individual buildings shall be provided with HDPE water storage tank on roof of he
building as per IS:12701.
- Sanitary and plumbing system for the control room and sub station building in the power
plant block up to main sanitary network as per scope drawing enclosed with this bid
package.
- Safety shower and eye wash at caustic & chemical handling areas.
- Design, engineering, construction, testing of fire protection system for entire power plant
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including sub station, control room, tank farm area, STG etc. within scope limit including
taking tapping from isolation valve as per scope drawing including hydrants/ monitors
required to provide proper coverage as per OISD/ TAC norms.
Automatic High Velocity Spray system shall be provided on transformers
Medium velocity spray system shall be provided on cable galleries / cellars with smoke
detectors and control shall be manual, local through push button and remote from control
room
CO2 flooding system shall be provided for STG enclosures.
First aid fire fighting equipments shall be provided.
All hydrocarbon storage tanks shall be provided semi fixed foam system and fixed water
spray system as per OISD.
- Storm water drains within scope limit & connecting the same up to existing drains&
storm water culverts below the approach road for crossing of storm water drains .
- Electrical cables Road Crossing (ERC) / Instrumentation cables Road Crossing (IRC)
providing Poly Vinyl Chloride (PVC) pipes below approach roads.
- RCC trenches for electrical and instrumentation cables in paved area.
- Oily Waste sewers (OWS) system.
- Contaminated Rain Water System (CRWS) system
- All construction approaches, culverts, fencing as required.
- Oil catcher, if required
- Acid/ Alkali resistant lining in and around acid/ caustic and chemical storage and
handling areas.
- Hard stand required for erection of heavy equipments
- Preparation of basic/ detailed engineering drawings for construction, and getting approval
of the same from EIL/ Owner
- Any temporary work/ activities required to complete the work
- Any change in specifications/ design must be got approved from Owner/ EIL
- Earth work for filling in Micro grading & disposal of surplus and unserviceable material
anywhere outside the complex boundary limit.
- Approval from statutory and local authorities
- The plot for construction area/ fabrication yard/ field office/ construction stores has to
be developed by the EPC contractor of its own and the Client shall only identify the
space on as is where is basis. All the infrastructure facilities which includes
approaches, drainage system, pavements etc. shall be developed & provided by the
contractor of its own

GENERAL CIVIL
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2.0 DETAILED SCOPE OF WORK
2.1 SITE GRADING AND STORM WATER DRAINS
a. SITE GRADING
Graded site shall be handed over to the contractor. However, micro-grading shall be done by
the LSTK contractor up to required levels. Grading shall be done as per specifications/
standards. Filling/ Cutting required to bring the site up to the finished levels is in the scope of
Contractor. Extra earth required to make up to paved levels shall be arranged by the
contractor at his own cost from the approved borrow areas. Borrow areas shall be arranged
by bidder anywhere outside the refinery complex limit for all leads and lifts. Unserviceable
material / debris shall be disposed off anywhere outside the refinery complex. The disposal
areas for unserviceable material / debris shall be arranged by Contractor including obtaining
necessary permission and approvals, royalties, etc.
b. STORM WATER DRAINS
Storm water drains on either side of roads shall be provided for collection of surface drainage
within scope limit. Pipe culvert / Box culverts shall be provided on the drain crossing of the
roads. and hook up with main drainage system.
Additional culverts shall also be provided across the newly constructed roads for approaches
within scope limit on the already existing and new storm water drains. All culverts shall be
designed to suit crane movement.
Pre cast covers on the drains shall be provided for approaching fire hydrants, monitors,
footpaths etc.
Any modifications required at the hook up connection between the CPP drains & Main road
side drains shall also be the scope of the contractor.
c. RCC PAVING
Design and construction of RCC pavement within battery limit for Power Plant, Cooling Tower
and Cooling Water Treatment Plant area shall be as per standards and specification.
Thickness shown in the standards enclosed with tender are minimum. However, contractor to
provide RCC pavement as per actual loading condition.
In Power Plant area only Operating & maintenance area shall be provided with RCC
pavement.
In the cooling tower area upto 5m all around including below basin shall be provided with
RCC pavement. Cooling water pump station shall be provided with RCC pavement.
RCC pavement shall be provided for Pump House/ Pump Station and below piping manifold
areas.
2.2 ACID/ ALKALI PROOF LINING/ CHEMICAL RESISTANT FLOORING
Contractor shall provide Acid/Alkali proof floor lining within and around the Caustic
treatment/Handling/ Wash areas/ other chemical handling areas over RCC pavement and
on associated equipment foundation and kerb wall on both the sides. The entire area shall be
curbed by RCC kerb wall.
The tile lining/ epoxy coating shall be strictly as per contract specifications and
manufacturer standard and hazardous material shall have prior approval from owner/ EIL.
Normally 25 mm thick tile shall be used except for traffic area where 65 mm thick brick shall
be used.

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2.3 DRINKING WATER SYSTEM

Contractor shall lay the drinking water lines underground directly buried or above ground with
suitable insulation. A minimum dia 2" (exact size of pipes to be ascertained by contractor),
drinking water header to safety shower & eye wash units, drinking water post in power plant
unit and drinking water & sanitary system in sub station & control room building, DG shed
building shall be provided. The same shall be hooked upto main drinking water header along
with isolation valve in valve pit as per scope drawing.
2.4 SANITARY AND PLUMBING SYSTEM
All plumbing and sanitary works within buildings and disposal of sanitary waste upto hook up
points as per scope drawing is in contractor’s scope of work. All the sanitary fixtures and
fittings shall be as per Architectural drawings/ specifications and relevant Indian/ International
Standards.
2.5 SAFETY SHOWER & EYE WASH
Contractor shall provide combined safety shower (SS) and eyewash (EW) units. as per
attached specifications at various places within scope limit where either caustic or other
chemicals are handled or toxic chemicals may be present. Safety Shower & Eye wash units
shall meet the requirements of IS: 10592. No. of SS & EW to be provided for units shall be as
per process hazard/safety requirements. Water shall be fed from drinking water line. If
drinking water lines are laid Above Ground (A/G), it should be insulated in such a way that
temperature of water should not exceed 20°C.
2.6 FIRE PROTECTION SYSTEM
Contractor shall provide fire protection system inside the entire power plant and hook up with
main refinery system considering the following and as per codes, specifications and
standard. Fire protection system shall be provided as per OISD requirement and
requirements of TAC/ NFPA for entire power plant including sub station, control room, tank
farm area, DG shed taking tapping from isolation valve as per scope drawing including
hydrants/ monitors required on fire water network to provide proper coverage. including
cutting and repair of roads. If any modifications are required to be done in the fire water
network within the scope limit, the same shall have to be done by the contractor. The
complete area within contractor’s scope shall be protected to satisfy the requirements of
OISD/TAC and NFPA-850. The following fire protection systems are envisaged:
- Fire water header with hydrants & monitors around the power plant / Tankage area
within scope limit.
- Landing valves and hose reels
- Hose reel protection around unit
- Fire protection for tankages : Semi fixed foam and manual water spray system
- Hose cabinets with hoses and accessories
- Water spray system on process equipments/ pumps as per OISD requirement and as
identified by process licensor
- Medium velocity water spray system for cable cellars of sub station shall be provided as
per TAC/ NFPA with smoke detectors. The control shall be manual, local and remote
from control room.
- Automatic fixed high velocity water spray system (emulsifier) for oil filled transformers
having capacity 2000 litres as per TAC / OISD.
- Providing semi-fixed foam system and manual medium velocity water spray system on
hydrocarbon storage tanks as per OISD.
- Contractor shall provide electronically operated, fully automatic CO2 flooding system for
Gas Turbine enclosures with alarms & trip interlocks.
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- First Aid Fire protection (Portable Fire extinguishers) as per TAC / OISD / NFPA.
- Any other specific protection as identified during detailed engineering.
- TAC and any other agency’s approval
2.6.1 Hydrants and monitors shall be provided by EPC contractor on road sides on the fire water
headers. However for full coverage of the power plant unit, internal double headed hydrants
& monitors shall be provided by contractor
Landing valves (double headed) shall be provided on each staircase landing of technological
structures supporting elevated equipments etc. Tapping for the riser shall be taken from
header located within the scope limit with an isolation valve.
Hose reels shall be provided along with every landing valve and an additional hose reels
within and around CPP Plant as per OISD requirement. Hose reels shall be hooked up to fire
water header within the scope limit with an isolation valve. Hose reel shall be provided as per
specifications/ standards enclosed.
Hose cabinets along with hoses and accessories shall be provided at every alternate hydrant
location/ every landing valve location.
2.6.2 Contractor shall provide manually operated fixed water spray system on :-
- Water spray system for hazardous locations and equipment in process unit areas as
per OISD –116 requirements.
- In case it is required to provide boosting arrangement, the same shall be provided by
EPCC contractor.
2.6.3 Portable fire extinguishers as per TAC/ OISD/NFPA.
2.6.4 Contractor shall provide electronically operated, fully automatic CO2 flooding system for Gas
Turbine enclosures with alarms & trip interlocks. Fire detection, alarm and auto actuation
shall also be in Contractor’s scope of work.
2.6.5 The firewater header and branch lines shall be laid above ground on independent sleepers
for offsites and utilities areas. For road crossings and crane / vehicle movement area the
same shall be laid underground. Encasing shall be provided as applicable. All firewater
headers around units shall be kept underground with suitable corrosion protection. Above
ground fire water piping shall be painted with fire red paint conforming to shade no. 536 of
IS:5. Painting shall be as per specs. enclosed else where in the contract document.
2.6.6 The entire fire protection system shall be got approved from TAC accredited agency. All the
comments, modifications etc. suggested by TAC accredited agency shall have to be
incorporated by the contractor without any extra cost to the owner. OISD requirements shall
be satisfied in addition to the requirements mentioned in the above scope of work.
2.6.7 All the equipments connected with fire water system shall either be TAC approved and BIS
marked or from companies which carry ISO certification or FM/UL listed.
2.6.8 The contractor shall meet the requirements of TAC/OISD/NFPA/ recommendations, over and
above the requirements which are mentioned above.
2.6.9 The system shall be designed for maximum insurance rebate.
2.6.10 RADIOGRAPHY
At least 10% of all welded joints shall be radiographically tested and shall be found in order
as per TAC requirements. At least 50% of welded joints selected for radiography shall be
field joints.
2.6.11 A minimum clear cover of 1.0 M shall be provided in open areas for buried fire water lines
and 1.5 m under roads if applicable.
2.6.12 First Aid Fire Fighting Equipments as per TAC/ OISD/NFPA

GENERAL CIVIL
6782-380-16-47-SP-01-B
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2.7 FIRE PROOFING

As per OISD specification and as defined in structural section in the tender.
2.8 MAIN ROADS, APPROACH ROADS, STORM WATER DRAINS & CULVERTS
All approach roads for sub station & control room, DG shed and other areas within scope
limit, footpaths (as applicable) for maintenance and operational requirement of plant shall be
provided by EPC contractor as per equipment layout and as per detailed engineering
requirement. Any additional approach roads around CPP, sub station, tank farm and other
areas to facilitate crane movement or any other vehicle movement during construction shall
be in contractor’s scope of work. Crossings for all services shall be in the scope of contractor.
Additional WBM layer and premix carpeting of damaged road during construction shall be in
the scope of EPC contractor.
All roads around each facility shall be made good while handing over after completion of
construction activity. Any culverts, pipe way bridges, cable crossings, electric road crossings,
road crossings for OWS/ CRWS system, cooling water lines, fire water lines, drinking water
lines, etc. coming below the main roads and approach roads shall be in EPC Contractor’s
scope of work and shall be designed for crane loads.
Any strengthening/ widening of existing main roads for crane movement for erection shall be
in the scope of the contractor.
2.9 CABLE CROSSING
For all electrical/ instrument cables crossing the main/approach roads, suitable road
crossings either by PVC pipes encased in concrete or RCC ducts/ culverts shall be provided
as per Electrical/ Instrumentation requirements. Crossings shall be designed to withstand the
load of crane movement envisaged for erection / maintenance.
2.10 RCC TRENCHES
a) Cable trenches
RCC Electrical/ Inst. cable trenches with pre-cast RCC covers shall be provided as per
structural standards and electrical/ instrumentation requirements. Trenches and covers in
crane movement area shall be designed to withstand the load of crane movement envisaged
for erection / maintenance. Cable trenches within scope limit shall be filled with sand before
placing of pre-cast cover.
2.11 OWS/ CRWS SYSTEM
Oily Waste sewer (OWS) from all process equipments shall be discharged in to OWS
funnels & conveyed through underground gravity sewers and hooked up with main Refinery
OWS header. Catch basins, Manholes, funnel points, vent pipes, flame arrestors, steel
gratings, clean outs shall be provided as per attached specifications. Floor wash/ rainwater
from continuously oil contaminated (COC) areas shall also be discharged to existing OWS
header.
Contaminated rain water/ floor wash/ fire water shall be collected through catch basins
located in the contaminated areas of the new facilities in the power plant unit and shall be
conveyed through under ground gravity sewer and hooked up with main refinery CRWS
header. Catch basins, funnel points, vent pipes, flame arrestors, steel gratings, clean outs
shall be provided as per attached specifications.
Contractor is required to design and develop/ provide the CRWS/ OWS collection system
and get the same approved from Owner/ representative of Owner.
U/G carbon steel piping for OWS/CRWS shall be provided with corrosion protection as per
specification attached with the tender.
RCC Manholes / Catch basins shall be designed as liquid retaining structure.

GENERAL CIVIL
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2.12 HARD STAND

Based on soil data, the hard stand required for erection of heavy equipments to be designed
and provided as per equipment erection philosophy/type of cranes to be used inside and
outside the battery limit of units. Dismantling of hard stand if required, as per directions of
Engineer-in-Charge / representative of Owner, disposal of unserviceable material outside the
complex boundary limit as per direction of engineer – in Charge.
2.13 STORAGE TANK AREAS
Complete fire protection along with PESO approval and approval from TAC accredited
agency for storage tanks is in contractor’s scope of work. RCC ring beam foundations shall
be provided for all tanks of dia upto 10M. For dia > 10M sand pad foundation with
bituminous anti corrosive layer shall be provided. However, structural input should be
referred for foundation details of tank dia upto 10M. Geo-tech recommendation shall be
taken care while designing the tank pad foundation.
Stone masonry dyke wall shall be provided as per PESO requirements. Tanks shall be
located as per statutory regulations of OISD and PESO etc.
Oily Waste sewer (OWS) from all tankages shall be discharged in to OWS funnels &
conveyed through underground gravity sewers and hooked up with main Refinery OWS
header. Catch basins, manholes, funnel points, vent pipes, flame arrestors, steel gratings,
clean outs shall be provided as per attached specifications.
Contaminated rain water/ floor wash/ fire water shall be collected in the contaminated areas
of the tank dyke and shall be sent to CRWS header/storm water drain through oil catcher &
through a double valve pit. Skimmed oil shall be sent to OWS manhole and water shall be
sent to storm water drain. Catch basins, funnel points, vent pipes, flame arrestors, steel
gratings, clean outs shall be provided as per attached specifications.
2.14 COOLING TOWER AND COOLING WATER TREATMENT FACILITIES
The scope of work shall cover design, detailed engineering, procurement, supply of all
materials, equipments, installation, construction, fabrication, erection, manufacture, receipt,
storage, conservation and preservation of all materials at site, handling at site, assembly,
painting, testing, commissioning and guaranteeing of cooling water system, post
commission services and fulfilment of performance guarantee of the RCC Induced draft
counter flow cooling tower with PVC fill, Cooling Tower sump & pump, cooling Water
Treatment facilities including side stream filters, antiscalant, biological control & other dosing
systems as per requirement, as per specifications, Design basis, standards, data sheets &
P&IDs enclosed including all electrical, instrumentation and other works as per scope
defined in various sections of tender and as detailed below
2.14.1 Nos. of cells and capacity of cooling tower and cooling water pumps shall be
decided by bidder as per the requirement and as mentioned elsewhere in the
bid document.
2.14.2 The main components for the above Cooling tower shall be as below but not
limited to same
- Cooling tower, basin, cold water channel
- Cooling water sump
- Cooling water pumps
- Cooling water treatment plant consisting of side stream filters, antiscalant,

biological control & other dosing systems as per requirement
- CWTP building

GENERAL CIVIL
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- Cooling Water Pump house, pump foundations, flooring, pumps & pump
house piping
- Allied instrumentation/ electrical and other civil works.
- Cooling water supply & return piping
- RCC pavement upto 5m all around cooling tower area including below basin
Cooling water pump station shall be provided with RCC pavement.
- Other Civil works such as approach road, ERC /IRC, pipe culvert for
approach road
2.14.3 COOLING TOWER
The scope of work shall cover :-
i) Design, detail engineering, supply of all materials, erection, construction of
mechanical induced draft, counter flow RCC cooling tower with PVC fill
ii) The cooling tower cells shall be so designed so that each of them can be repaired,
maintained and cleaned while the other cells are in service. The cooling tower fan
shall be made of FRP. Oil skimming arrangement in the channel at entry for sump
shall be provided to remove floating oil to OWS. HC and H2S detectors shall be
provided at the cooling tower top.
iii) The basin shall be provided with an overflow arrangement from each cell which shall
be suitably connected to the nearest storm water drain. The basin shall be provided
with sludge removal arrangement from each cell which shall be suitably connected to
the nearest storm water drain.
iv) A chain pulley block of suitable capacity with all necessary lifting arrangement shall
be provided for maintenance work on cooling tower fan, gearbox and motor as per
specifications.
v) The cold water from the basin shall be conveyed through a sluice gate to the sump
through cold water channel covered with pre-cast RCC slabs. The sluice gate shall be
provided at a level such that maximum flow occurs through the gate at normal water
level.
vi) Return hot water from various units etc. shall be combined into a common line and
further taken into the cooling tower as per vendor's design requirements for each cell.
Corrosion probe and corrosion coupon shall be provided by the vendor in the return
header near the cooling tower. Vendor shall also check minimum pressure
requirement in return header and fan deck height with return header pressure
available at cooling tower grade and finalise Cooling Tower height accordingly &
design the hot water riser
vii) Painting of above ground piping, structural steel etc. shall be done as per job
specifications for field painting enclosed with bid.
viii) Area below cooling tower basin, cold water channel and upto 2.0m all around the
cooling tower basins and cold channel shall be provided with RCC Pavement Type-III.
ix) Providing approaches for cooling tower, cooling water treatment plant building, pump
house and any other approaches if required.
x) Providing treating effluent makeup system with control valve and ACF
xi) Any other work required for the completion of the job in all respects.

GENERAL CIVIL
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2.14.4 COOLING WATER SUMP AND PUMP HOUSE

i) Design, detail engineering, construction of RCC sump to receive water from the cold
water channel of the cooling tower and Cooling water pump house The top slab of
each sump shall be provided with two number of 0.6m x 0.6m manholes with RCC
covers for maintenance of each sump. Each manhole shall be provided with a ladder
for access inside the sump up to bottom level.
ii) Suction pipe nozzles for all pumps shall be provided in sump. Puddle flanges shall be
provided in sump and basin wall for pump suction pipes, sludge outlet pipes, overflow
pipes and level transmitter nozzles .
iii) Additional manhole of 0.5m x 0.5m with removable RCC covers shall be provided on
the top of each slab of sump just above each suction line of the cooling water pumps
for inspection. These manholes shall be provided with access ladders.
iv) Level instruments shall be mounted on the sump as per Standard Specifications,
Standards. Monkey ladder shall be provided for access to sump top Sufficient number
of vents of CS pipe with insect screen shall be provided on the top slab of each sump.
v) Level transmitters shall be located on the top of each sump.
vi) The sump shall be provided with scour valve / drain valve at the bottom and overflow
shall be suitably connected with the nearest storm water drain through CS pipe. The
overflow pipe in cold water basin shall be minimum 2 nos. of 300 mm diameter.
vii) The Cooling Water Pump House building shall be with RCC columns, structural steel
truss and side sheeting arrangement. Necessary insert plates and steel and steel
platforms as walkways shall be provided on the inside faces of the columns as per
detailed engineering by the contractor.
viii) Supply and erection of HOT crane in pump house of suitable capacity.
ix) Supply, erection of corrosion coupon and corrosion probe.
x) Any other work required as per scope drawing and P&ID and required for the
completion of the job in all respects.
2.14.5 PIPING WORKS
i) Supply and erection of cooling water supply, return piping, cooling water make-up and
other piping with in the battery limits of cooling tower. All piping, valves, fittings,
gasket, nut and bolts etc. shall be provided by the contractor as per the requirements
of process P&ID and piping material specifications.
ii) Supply and erection of suction piping for all the pumps inside sump up.
iii) All above ground cooling water piping, cooling water make up, basin drain piping,
OWS piping etc.
iv) All under ground CS piping shall be provided with corrosion protection as per
specifications attached with bid.
v) All potable water piping for the safety and eyewash shower shall be as per piping
specifications J2A.
vi) Painting of pipelines, structural steel, etc. as per job specification for shop and field
painting specification including supply of all paints required and colouring as per
colour codes.
vii) All other works not exclusively mentioned in the tender document, but are necessary
to complete the system in all respects with respect to process requirements, P&ID,
and data sheet etc. shall form a part of total scope of work.

GENERAL CIVIL
6782-380-16-47-SP-01-B
CAPTIVE POWER PLANT
2.14.6 COOLING WATER TREATMENT AND DOSING SYSTEM

i) The bidder scope of work covers supply, design, detail engineering of all the work
connected with cooling water treatment and dosing consisting of side stream filters,
antiscalant, biological control & other dosing systems as per requirements, safety
shower & eye wash, all interconnecting piping works & piping from treatment plant up
to dosing points, all instrumentation, electrical works, civil & structural works for the
building required for housing this facilities works.
ii) Design and construction of Cooling Water Treatment Plant building in RCC and brick
construction as per the schematic layout drawing including RCC/Steel columns, pump
foundations, equipment foundations, RCC flooring/ paving, plinth protection, brick
walls, necessary building works like doors, windows, plastering, white washing etc. as
per Architectural scope and lay out and any incidental work, etc. complete. The entire
specifications for cooling water treatment plant building shall be as per architectural
specifications and drawing.
The scope of work shall also include following

• Plumbing & building drainage
• Supplying & fixing plumbing fixtures in toilet blocks.
• Supplying & laying of drinking water piping with gate/ globe valve
located in valve chamber & hook up with plant drinking water supply
line.
• Construction of floor trap, gully trap, inspection chamber etc. including
laying of soil & waste pipes to IS:3486 jointing with lead etc.
• Joining the sanitary line from buildings to plant sanitary sewer (SS)
system, construction of RCC manholes, laying of RCC (P1 class to
IS:458) pipes etc. complete.
iii) The cooling water treatment plant area shall be RCC paved type-II.
iv) Painting of steel structures, equipments piping etc. shall be as per attached
specifications
v) Supply, fabrication and erection of supporting structural elements for piping such as
shoes, clips, clamps, cradles, anchors, guides etc.
vi) Providing of RCC sleepers/overhead pipe supports, guides etc. for above ground
piping
vii) Testing and trial run for the performance of each dosing system including supply of
chemicals for trial run is included in the scope of work.
viii) Precast concrete interlocking block footpaths shall be provided between CWTP &
dosing point in cooling water channel
ix) Design, engineering, supply, installation, testing and commissioning of entire
electrical system including lighting for Cooling Water Treatment plant as per electrical
scope of work, specifications, etc. complete.
x) All other works not exclusively mentioned in the tender document, but are necessary
to complete the system in all respects with respect to process requirements, P&ID,
scope drawings & data sheets etc. shall form a part of total scope of work.
2.14.7 ELECTRICAL, CIVIL AND STRUCTURAL WORKS
i) Complete electrical, civil & structural works for Cooling Tower, CWTP and Pump
house shall be carried out as per detailed specifications of the tender enclosed
elsewhere. Platforms & ladders shall be provided for safety and ease of maintenance,
operation of the plant as per requirements of the owner/EIL at no extra cost.
GENERAL CIVIL
6782-380-16-47-SP-01-B
CAPTIVE POWER PLANT
ii) Supply, fabrication and erection of supporting structural elements for piping such as
shoes, clips, clamps, cradles, anchors, guides etc, construction of RCC sleepers for
running above ground piping, civil construction of cable trenches including supply and
installation of metal inserts for running power/ lighting and control cables shall be in
the scope of this tender.
2.14.8 COMMISSIONING OF THE SYSTEM
i) Commissioning of the entire system within scope of work including all equipments,
etc. flushing out all piping etc. complete, including testing and trial runs at no extra
cost to owner shall be provided by the contractor.
ii) On completion of the work, the contractor shall remove and dispose off, all
unserviceable material, debris etc.
iii) Owner or his authorised representative will have the right to inspect at any stage of
manufacture and construction, all materials, components and workmanship and
testing of materials. The contractor shall provide all facilities of inspection and
testing without any extra cost to the owner.
iv) It shall be clearly understood that the contractor shall be responsible to complete
and commission the entire work in all respects including the work not specifically
mentioned in the scope of work or specifications or in drawings, but are necessary
to achieve completion.
2.14.9 PERFORMANCE GUARANTEE & TESTS
i) The cooling tower shall be tested and guaranteed to meet the performance
requirement when tested in accordance with the procedure set forth in the latest
revisions of the test code ATC-105 of CTI.
ii) If the performance test shows a deficiency, the contractor shall rectify the defects
without any additional cost to the owner
2.14.10 TWO YEARS RECOMMENDED SPARES.
i) The contractor shall submit the list of spares required for trouble free operation of
Cooling Tower for a period of two years along with their prices with the offer.
ii) All other works as mentioned package specification shall deemed to be in the
scope of this tender.
iii) Any other works not listed above but required to complete the work in all respects
unless specifically mentioned otherwise.
2.14.11 TECHNICAL EVALUATION CRITERIA FOR COOLING TOWER
COUNTER FLOW TOWERS

The offer of counter flow tower will be evaluated by Fulkerson's method using
Fulkerson's demand curve and fill characteristic curves applicable to the case.
The inlet air velocity shall be 1.5m/sec to 4m/sec. No tolerances are acceptable.
A partition cell shall be provided from the basin bottom to the top of basin and from
bottom of fill to fan deck levels. Designer/ vendor shall decide whether to provide wall
from basin top to the bottom of fill. End walls of cooling tower shall be kept closed.
Bidder shall submit calculations preferably in the enclosed Tower sizing format.

GENERAL CIVIL
6782-380-16-47-SP-01-B
CAPTIVE POWER PLANT
3.0 DRAWINGS/ DOCUMENTS REQUIRED FROM CONTRACTOR
3.1 WITH OFFER

The list of drawings/documents as required to be submitted along with offer is
enclosed in the tender document.
3.2 AFTER AWARD OF THE CONTRACT

The list of drawings/documents as required to be reviewed by representative of
Owner/ Owner is enclosed in the tender document.
4.0 APPROVALS
Approval of the facilities within contract scope limit from PESO, TAC/ TAC accredited
professionals & DGCA shall be obtained by the EPC package contractor.
EPC Contractor to comply with the requirement of these authorities irrespective if it is
mentioned or not in the bid package & shall form part of contractor’s scope of work including
preparation of required drawings/ documents. Contractor shall comply with the requirement of
local bodies including preparation of required drawings/ documents.
5.0 SCOPE OF SUPPLY
5.1 OWNER’S SCOPE OF SUPPLY

Nil
5.2 CONTRACTOR’S SCOPE OF SUPPLY
- All items consumables/non consumables required to complete the job.

- All tools tackles, plant machinery etc to complete the job.

1 SCOPE OF WORK/ SUPPLY SECTION: C-1.4
STRUCTURAL & ARCHITECTURE 6782-380-16-48-SP-01Rev.B
CAPTIVE POWER PLANT
C-1 SCOPE OF WORK/ SUPPLY
C-1.4 STRUCTURAL & ARCHITECTURAL
CAPTIVE POWER PLANT
OWNER : MANGALORE REFINERY AND PETROCHEMICALS

LTD
JOB NO. : 6782
REVISED AS / OWNER’S COMMENT & REISSUED FOR S.

B 13.06.2007 SM MBL
BID MAJUMDAR
A 03.01.2007 ISSUED FOR BID PACKAGE GANESH VGOEL MBL
Rev. Prepared Approved
Date Purpose Checked by
No by by

CAPTIVE POWER PLANT
PART – A : STRUCTURAL
PART – B : ARCHITECTURAL

CAPTIVE POWER PLANT
CONTENTS
SUB SECTION DESCRIPTION
1.0 SCOPE OF WORK
2.0 SCOPE OF SUPPLY
3.0 LIST OF ATTACHMENTS

CAPTIVE POWER PLANT
1.0 SCOPE OF WORK
The scope of Civil-Structural works under this contract shall include complete
design, detailing, supply and construction of all relevant civil and structural
works for COGENERATION COMBINED CYCLE POWER PLANT and
Cooling Towers for CPP for MRPL Phase III Refinery Project at Mangalore
as per specifications enclosed with the bid document.
Major civil-structural works involved shall include but not be limited to the
following:
Design and construction/installation of all foundations (including installation,

testing etc. of piles) and superstructure for:
i. Foundations for Gas Turbine Generators (GTG) along with Heat

Recovery Steam Generator (HRSG), Steam Turbine Generators
(STGs), Utility Boilers and other auxiliaries equipments (static and
dynamic), Bypass Stacks for GTGs and Main Stacks for HRSGs &
Utility Boilers etc.
ii. Steel Chimney for Heat Recovery Steam Generator (HRSG) & GTG
and RCC chimney for Utility Boilers, Control Room, Substation
building with switch gear/cable cellar, structural shed for GTG & STG
with EOT crane, DG room, Boiler operator room, MCC room etc,
Pump foundations, Pipe Rack, Cable Rack, UG Cable Trenches,
Platform & Pipe supports/sleepers, Transformer foundations, Cable
supports etc. all complete.
iii. All foundations and structures in BFP & Deareator Area.
iv. Soil treatment for foundations, wherever required.
v. Water proofing and damp proofing wherever specified/directed by

Engineer-in-charge.
vi. Protective lining/coatings wherever required as per the specifications

enclosed elsewhere.
vii. Painting of structural steel members.
viii. Preparation of fabrication drawings for all structural steel works and
bar bending schedules for all RCC works.
ix. Anti-termite treatment for buildings.
x. Obtaining statutory approval from local authorities such as Inspector of

Factories and any other concerned authorities before starting the
works at site.

CAPTIVE POWER PLANT
xi. Monorails or overhead cranes of required capacity for

operation/maintenance of equipment/pumps in technological
structures, compressors houses, under pipe racks, etc.
xii. All other civil structural works forming part of scope of works of
General Civil, Architectural, Mechanical and Electrical disciplines and
as laid out elsewhere in this bid package.
xiii. Any other civil and structural works required/directed by Engineer-in-

charge for the satisfactory and successful completion of the project.
xiv. Fire proofing of steel structure members wherever required as per

OSID-STD-164 norms. Specification No. 6-68-033 shall be used.
2.0 SCOPE OF SUPPLY
All materials (consumables/non-consumables) required to complete the civil &

structural works including Tools & Tackles shall be supplied by the Contractor.
LIST OF SPECIFICATIONS:
Serial Document Rev. NO OF

Title
No no NO SHEETS
Standard Specification for Fire Proofing of Steel

1 6-68-0033 5 12
Structures
Standard Specification for RCC & Steel
2 6-68-0053 1 27
Chimneys for Turnkey Package
LIST OF STANDARDS:
Serial Standard Rev. No of

Title
No No. No. Sheets
1 7-67-0008 Pedestal for stair/ladder 4 1
2 7-68-0061 Handrail fixing to RCC structure 4 1
3 7-68-0202 Typical grating support 4 1
4 7-68-0203 Typical chequered plate supports 4 1
5 7-68-0417 M.S. Anchor Bolt Assembly 4 7
6. 7-68-0501 Handrails 5 10

CAPTIVE POWER PLANT
7 7-68-0506 Steel stairs 4 6
8 7-68-0507 Details of steel ladder 5 3
9 7-68-0509 Steel ladder joint details 4 4
10 7-68-0561 Standard grating detail type - I to type – III 3 6
3.1 JOB SPECIFICATIONS (Doc. No.6782-380-16-48- JS-01, Rev-A)
3.2 GEOTECHNICAL DATA (TO BE SUBMITTED LATER)
3.3 SITE SPECIFIC SPECTRA FOR MANGALORE (DOC. NO. 6782-9-2554-DB-

01 Rev-0)
3.4 PAINTING SPECIFICATIONS (6782-0642-PT-H06 Rev-1, Not enclosed)

CAPTIVE POWER PLANT
PART – B : ARCHITECTURE
CONTENTS
1.1 DETAILED SCOPE OF WORK

1.2 SCOPE OF SUPPLY
1.3 DELIVERABLES BY THE CONTRACTOR
1.5 ARCHITECTURAL DESIGN BASIS
1.6 SPECIFIC ARCHITECTURAL REQUIREMENTS

CAPTIVE POWER PLANT
1.1 Detailed Scope of Work
1.1.1 General
Contractor shall develop the FEED to Approved For Construction (AFC) status,
taking due account of the detailed requirements of the drawings, design basis,
specifications and standards for architectural works for the scope of work covered
under this Contract. CONTRACTOR shall not proceed with construction till those
documents which are specifically listed at “Review” category are reviewed by
OWNER /PMC.
The scope of architectural works under this contract shall include design, detailed
engineering, procurement, supply and construction of all relevant works as per
specifications enclosed with the bid document. The scope of work as defined herein
shall be read in Conjunction with Job Specifications for Architectural works and
Architectural Standards.
Scope of work by the Contractor shall consist of Architectural design & detail
engineering including preparation of Architectural drawings, construction including
construction supervision & supply of all materials, labour, tools & tackles etc.,
obtaining approvals from Statutory Authorities, supply of deliverables like drawings,
documents, preparation of As-built drawings etc and co-ordination with EIL & the
Owner etc. all complete for the following buildings:
1) Sub Station & Control Room Building
This bldg. shall be a RCC framed structure and shall comprise of Console
Room, Rack Room, UPS Room, Battery Room, Cellar, MCC Room, A/C
Plant Room, Operator Room, Storage Rooms as/ requirement, Toilet & D/w
area etc.
2) G.T & STG Shed.
Steel structure, Precoated galvanised steel sheet roofing and side

cladding . Dropout bay shall be provided on one end of the Turbine Hall. Bay
shall be sized so as to allow the entire turbine / generator to be removed
from there.
3) Analyser Room, DG Room Boiler Operator Room
The building shall be RCC frame structure with brick masonry wall, RCC
roof.
4) Pump House
Steel structure, Precoated galvanised steel sheet roofing and side cladding.
The buildings as mentioned above can be designed seperately or as a combined

building based on the building layouts as indicated on the approved plot plan during
the detail engineering stage. Owner decision in this regard shall be treated as final
and binding. In addition to above, the following rooms shall be provided in the Power
Plant Buildings :
1. Air conditioned Offices for Station managers and Production superintendents

(four nos.) located near Control Room and adjacent to the Turbine Hall.
CAPTIVE POWER PLANT
2. Operator Change Room, Locker Room and toilet in the Turbine floor.
3. Air-conditioned Maintenance Offices (Three nos. room large enough to

accommodate required maintenance staff).
4. Water Chemistry laboratory with all required facilities.
5. Separate Maintenance Room, Change Rooms and Tool Rooms at

substation, turbine Floors and at Ground floor of the building.
6. Separate Office for Shift Engineer, Documentation Room and Instrument

Maintenance Room adjacent to the Control Room.
7. Documentation and Record Room.
8. Conference Hall (one no.) and Meeting rooms at each floor.
9. Four nos. Field Cabins (at UB,GT-HRSG./STG-BOP, FO Area, Cooling

Tower) .
10. Toilets at Turbine area and at each building floor.
Contractor shall submit a schematic architectural layout of the buildings as

envisaged during the offer stage. All the activity area/ rooms with clear dimensions
shall be indicated in the schematic layout for Owner/ PMC review at offer stage.
1.1.2 Detail Engineering
Detail Engineering shall be based on "Architectural design basis" and approved

preliminary drawings. The Contractor shall prepare construction drawings and
submit the same to Owner/PMC for review/approval. The requirement of
deliverables by the Contractor for detail engineering is indicated elsewhere.
1.1.3 Construction
The Contractor in strict conformity with Owner/PMC reviewed/approved construction

drawings, using materials as per Specifications, Standards & List of Approved
Manufacturers as attached in the Tender Documents shall carry out construction
including construction supervision. Construction shall include supply of all materials,
labours, plants, tools & tackles by the Contractor unless specifically mentioned
elsewhere in the Tender Document.
1.1.4 Statutory Approvals
The Contractor shall obtain all necessary approvals from statutory authorities such
as Factory Inspector, Tariff Advisory Committee (TAC), Local Municipal or
Development Authorities for the design and construction. The Contractor shall also
prepare all drawings, documents as required for obtaining such approvals. Any
changes/ modifications etc. in design/construction required for obtaining such
approvals shall also be done by the Contractor without any time & cost implication to
the Owner or PMC.
1.2 Scope of Supply

CAPTIVE POWER PLANT
1.2.1 Owner’s Scope of Supply
NIL
1.2.2 Contractor’s Scope of Supply
All architectural materials (consumables/ non-consumables) required for satisfactory

completion of the job shall be supplied by the contractor.
1.3 Deliverables by the Contractor
1.3.1 Drawings / Documents Required after Award of contract
The Contractor shall submit a detailed schedule of submission of deliverables as

indicated herewith for review by Owner/PMC as per agreed schedule. Such a
schedule shall be made in line with the overall time schedule indicated elsewhere in
the Tender Documents. Submission of all deliverables shall be as per the said
schedule as reviewed by Owner/PMC.
All deliverables shall be prepared using Computer software and shall be complete in
all respects including correct titles indicating Owner, Consultant, Contractor, Project
name, PMC Job No., Dates, Issues, Revisions and signatures of Performer,
Checker & Approver of the Contractor.
Incomplete, unsigned & unchecked Documents/ Drawings shall not be accepted and
shall be returned.
All revisions shall be clearly pointed out clouded for easy identification/ review.
All deliverables shall be submitted in requisite number of prints as per methodology

mentioned elsewhere in the Tender Documents.
Deliverables by the Contractor shall be as listed herewith.
1. Drawing/Document Schedule
The schedule shall include all Drawings/ Documents with Title, Number,
Dates of issues (scheduled & actual) & present review status etc. The
schedule shall be updated and submitted at regular intervals as mentioned
elsewhere.
2. Drawings
A. Preliminary Architectural Drawings of the buildings in accordance

with bid indicating Plans, Sections & Elevations & Architectural
treatment. Such preliminary dwgs shall be prepared after finalisation
of sizes & layout of the required spaces/ areas/ rooms and review of
the same by the originating department of PMC.
B. Construction drawings of all the Buildings shall be prepared

incorporating comments etc. on the preliminary Dwgs.
Construction Drawings shall contain the followings.
1. Plan of all levels, Terrace Plan, Key Plan.

CAPTIVE POWER PLANT
2. Sections as required for complete understanding of the Design &

Construction.
3. Elevations of all sides.
4. Door/Window details.
5. False ceiling details & layouts.
6. Schedule of Architectural Finishes.
7. Architectural details as required.
8. Any other Dwg as required for complete understanding of the
Design & Construction.
Drawings shall be prepared using AutoCAD software of latest (at the time of
floating the Tender) version.
Drawings shall be prepared in 1:100 or 1:50 scale. For Construction details,

Door Window Details the scale shall be 1:20 to 25. For key plans larger but
legible scale may be used.
The Contractor shall prepare & submit specifications of materials etc., which
are not covered or attached in the Tender Documents for review by
Owner/PMC.
4. Documents/ Drawings for Statutory Approval
The Contractor shall prepare & submit Documents/Drawings for Statutory

Approval in accordance with the statutory requirement for
Information/Record of Owner/PMC.
5. As Built Drawings
The Contractor shall prepare & submit As-built drawings both in requisite no.
of hard prints as well as in form of computer files for Information/Record of
Owner/PMC.
6. List of Sub- vendors/ authorised applicators for specialised items
The Contractor shall submit list of all Sub- vendors/ authorised applicators to be
engaged for execution of various specialised items (like Aluminium Doors and
Windows, Waterproofing and Underdeck Insulation, False ceiling, False Flooring
etc.) for approval.
1.3.2 Review of the Contractor's Drawings/Documents
Drawings/ Documents submitted by the Contractor shall be reviewed by

Owner/PMC within agreed upon time schedule.
It shall be Owner/ PMC's right to review any/ all or none of the Drawings/
Documents submitted by the Contractor.
Review by Owner/ PMC shall not relieve the Contractor of his responsibility for
correct Design, Engineering and Construction. The sole responsibility of the
correctness of Design, Engineering & Construction shall lie with the Contractor
irrespective of the fact that the Drawings/Documents submitted are reviewed or not
reviewed by Owner/PMC. The Contractor shall correct all faulty design &
construction detected at any stage of work without any cost & time implication to
PMC or the Owner.

CAPTIVE POWER PLANT
Following Parameters of Design & Drawings shall not be reviewed.
A. Adequacy of provisions (in terms of spaces, services & utilities) and space/
area/ Room sizes for Plant Buildings or Plant Areas in other Buildings. The
Contractor shall ensure correctness of such provisions vis-à-vis Owner/ PMC
reviewed/ approved G.A. drawings & submit Architectural dwgs only after
approval/ review of such provisions by concerned deptt. of PMC.
B. Correctness of Drawings in terms of dimensions, matching of Plan, Elevation,

Section, etc. These parameters may be reviewed at random only.
C. Location, Co-ordinates, Orientation & Road/Ground/Pavement levels. The

Contractor shall ensure correctness of these vis-à-vis EIL reviewed/approved
G.A. drawings.
1.4 List of Attachments
1.4.1 Drawings
NIL
1.4.2 Standard Specifications
Sl. Specification No. of

Rev. Title
no. no. sheets
01 7-49-1101 08 1 Vendor List for Architectural Products.
1.4.3 Standards
Title
No. of Revisi
Sl. Standard No.
Sheets on
No.
01 7-75-0002 Details of skirting (with bk. Work) 01 2
02 7-75-0003 Details of skirting (with RCC col.) 01 2
03 7-75-0004 Details of dado 01 2
04 7-75-0011 Wooden flush door with steel frame 01 2
05 7-75-0014 Aluminium glazing details 01 2
06 7-75-0015 Glazed aluminium window 01 2
07 7-75-0027 Steel windows (General Spec.) 01 1
08 7-75-0028 Steel windows (use of sections) 01 2
09 7-75-0029 Steel windows (section details) 01 2
01
10 7-75-0031 Steel windows (with louvers) 2
11 7-75-0032 Steel windows (fittings & fixtures) 01 2

Aluminium panel false ceiling (84C
12 7-75-0042 01 3
system)
13 7-75-0047 False flooring details (channel type) 01 2
14 7-75-0060 Orissa pan w.c. fixing detail 01 2

CAPTIVE POWER PLANT
Title
No. of Revisi
Sl. Standard No.
Sheets on
No.
15 7-75-0062 European type w.c. fixing detail 01 2
16 7-75-0063 Urinal fixing detail 01 2
17 7-75-0064 Wash basin fixing detail 01 2
18 7-75-0068 Roof drainage & water proofing 03 2
19 7-75-0070 Pressed steel door (single shutter) 01 2
20 7-75-0071 Pressed steel door (double shutter) 01 2
1.4.4 Job Specifications
Sl. No. of
Specification no. Rev. Title
no. sheets
Job Specifications-
01 6782-380-16-48-JS-01 73 A
Structural & Architectural
1.5 Architectural Design Basis
Architectural design of the buildings shall be in conformity with the following:
1.5.1 Codes and Standards
A. National building Code of India

B. Local Municipal or other authority’s bye-laws
C. Relevant state Govt. Factory Acts
D. TAC (Tariff Advisory Committee) regulations
E. Any other rules/regulations/recommendations as applications
1.5.2 Space Requirement :
Space requirement shall be based on one or combination of the following depending

upon the specific situation
a. Occupancy
b. Equipment layout and clearances
c. Maintenance and safety requirements
d. Storage requirement
The height of the buildings shall be provided as per the statutory requirements and
equipments and crane/ monorail requirement.
1.5.3 Safety Requirements
Safety from fire and like emergencies shall be taken into account in building design.
Every building meant for human occupancy shall be provided with sufficient no. of
exits (as per TAC requirements) to permit safe escape of occupants in case of
emergency.

CAPTIVE POWER PLANT
Following references shall be adhered to in this regard :

A. National Building Code of India
B. State Factory Act
C. Tariff Advisory Committee
1.5.4 Day Lighting And Ventilation
Established level of illumination shall be maintained for all parts of the building by
means of windows, ventilators, skylights etc. For this IS:3646 Part I & II and IS:2440
shall be adhered to. For the purpose of illumination day lighting shall be
supplemented by artificial illumination.
Established level of ventilation in items of air changes per hour shall be maintained
for all spaces. IS:3103 and IS:3362 shall be adhered to for this purpose. Natural
ventilation shall be supplemented by mechanical/electrical means.
1.5.5 Aesthetics
Architectural design and treatment of the buildings/sheds shall ensure proper

aesthetics by adopting general principles of Architecture. An overall architectural
control shall be maintained with the rest of the buildings of the project, outside the
Contractor’s scope.
1.5.6 Building Elements
a) Plinth Protection
All the buildings & sheds shall be provided with minimum 1000 mm wide
plinth protection around the building/shed plinth at top of Finished Grade
Level. The rain water down pipes shall discharge rain water on this
pavement.
b) Steps/Ramps
Steps/ramps shall be provided for access to the Buildings/sheds for

Pedestrian/Vehicular, equipment entry. Minimum 1000 mm wide platform
shall be provided in between Entrance door and steps/ramps. Following
dimensions of the steps/ramps shall be adhered to.
A. Tread =250 mm minimum

B. Riser =175 mm maximum
C. Slope of Ramp = Not steeper than 1:6
D. Ratio of Tread & Riser= 2 Riser + Tread= 600 to 648 mm
c) Windows/ventilators
Windows/ventilators shall be provided in all areas for natural lighting,

ventilation and visibility at working level.
For the purposes of ventilation, total openable area of the windows/

ventilators shall be as per Factory Act subjected to a minimum of 15% of the
floor area to be ventilated. However, for Control Room and in office areas
etc. where visibility from inside is of prime importance, increased window
area shall be provided. Areas accommodating panels/ equipments shall be
normally provided with ventilators at high level for unobstructed distributed
lighting.
CAPTIVE POWER PLANT
d) Shading Devices
Shading devices shall be provided over all windows, openable ventilators for
rain & sun protection. These devices shall be in the form of horizontal
projections, vertical projected fins or combination of both as per building
facade treatment. Minimum projection shall be 600 mm. Windows in closed
condition should not allow any rain water inside.
1.6 Specific Architectural Requirements
Only relevant clauses as applicable for each type of building shall be referred
1.6.1 Floor Finishing:

Floor finishing shall be based upon the occupancy or function of the particular area.
However the following parameters shall be adopted unless otherwise specified.
Panel dividers wherever required shall be provided as per specification.
a. Cellar area : 25 thk Cem conc. flooring
b. MCC Rm., A/C Plant Room. : 50 thk.Heavy duty Cem. Conc.

Flooring.
c. Battery Room : Vitrified Acid resistant tiles over

cem. conc. flooring.
d. Console Rm., Rack Rm. & UPS Rm :False flooring with antistatic
laminate top as/
e. Office areas, Corridors : Vitrified Porcelain Tile flooring
f. Toilets & D/W area : Ceramic tiles flooring & 2100

high ceramic tiles dado.
g. Skirting : 125mm high skirting in all areas

using same material as that of
floor.
Acid resistant tile dado 1500
high shall be provided in Battery
Rm.
h. Analyser room : Vitrified Porcelain Tile flooring
1.6.2 Doors, Windows, Ventilators
Doors, windows, ventilators shall be provided as per requirement. Their sizes shall
be according to requirements and equipment to be placed. All doors, windows shall
be provided with necessary approved quality fittings and fixtures and
painted/polished as per specifications. Doors and windows in air conditioned/
pressurised/equipment areas shall be airtight and provided with rubber beading all
around.
Equipment Entry Doors: Mechanically operated rolling shutter.

Pressed Steel doors with 2mm thk. sheeting as
per requirement.
CAPTIVE POWER PLANT
Doors: Entrance doors of Control room shall be

aluminium glazed doors with toughened
(shatterproof) glass. Doors in Office area, toilet
shall be teak veneered wooden flush doors
with pressed steel frames.
Windows And Ventilators: Powder coated aluminium windows &

ventilators using heavy duty aluminium
sections with toughened (shatterproof) glass
are to be provided in all areas.
Safety Bars: Aluminium safety grill shall be provided in

windows & ventilators where required.
1.6.3 Plastering And Pointing

Plastering : 12mm thick cement plaster in 1:6 on fair side of
all walls.
: 15mm thick cement plaster in 1:6 on rough

side of 230 thick brick walls.
: 20mm thick sand face plaster in two coats on

all external faces of brick walls.
: 6mm thick plaster in 1:4 in ceiling, chajjas & on

cols. etc.
: 15mm thick cement plaster mixed with water

proofing compound on inside surfaces of
R.C.C. gutter.
: 20 x 10mm groove in plaster as per

specifications to be provided wherever
required.
1.6.4 Roofing Treatment
Minimum slope of 1:80 shall be obtained in roof by providing lean concrete 1:3:6
over roof keeping 25mm min. concrete at disposal/gutter ends. Alternately roof shall
be laid to slope as desired. Roof tops shall have atactic polypropylene modified
bituminous membrane water proofing treatment as specified in Architectural
specifications.
R.C.C. rain water gutter shall be provided to collect roof water into it. Gutter shall be
provided with necessary slopes towards rain water pipes by means of cement
screed. 15mm thick water proof cement plaster shall be provided on inner surfaces
of gutter and 12mm thick water proof cement plaster shall be provided on outer
surfaces of gutter. Any sunk area, before cinder filling shall be finished with 15 mm
thk. water proof cement plaster. Rain water downtake pipes shall be PVC pipes
embedded in concrete.
1.6.5 White Washing, Colour Washing Distempering, Painting, Polishing
Ceiling : All ceilings of offices, corridors, analyser room ,

shall be finished with plastic emulsion paint , &
CAPTIVE POWER PLANT
ceiling of all other areas shall be finished with

three coats of white wash, canopy/porch ceiling
shall be finished with water proof cement.
Inside Walls :All office corridor, analyser room , control

room shall be finished with plastic emulsion
paint as per requirement. All other area walls
shall be finished with three coats of white
wash.
Outside Walls : All outside surfaces of building shall be

finished with water proof cement paint.
Doors And Windows : All steel doors, windows & ventilators shall be
finished with two coats of synthetic enamel
paint over a coat of primer.
1.6.6 Sanitary Fittings/Fixture
Battery room shall be provided with sink and Toilets shall be provided with all
necessary approved Indian standard fittings and fixtures .
1.6.7 Roofing
All sheds shall have precoated galvanised steel sheets for roofing and cladding. The
sheets shall be min. 0.50mm thick. The roofing system shall include all accessories
like ridges, north light curves, apron pieces, corner pieces, m.s. flat windties etc.
1.6.8 False Flooring, False Ceiling and Underdeck Insulation
Console Room, Rack Room, UPS Room, Operator’s Room , corridors & toilet areas
shall have Aluminium plank false ceiling with underdeck insulation. Wherever false
flooring is required, it shall be provided with lamination top, min.600 high from conc.
slab or hard floor .

DESIGN BASIS / PHILOSOPHY SECTION: C-2.2
GENERAL CIVIL 6782-380-16-47-DB-01
CAPTIVE POWER PLANT Rev. 1
C-2 DESIGN BASIS / PHILOSOPHY
C-2.2 GENERAL CIVIL
CAPTIVE POWER PLANT
JOB NO. : 6782
NOTE: Only the front sheet of this document (6782-380-16-47-DB-01) shows the Unit no. as
380.
1 28.11.2006 ISSUED WITH BIDS RKS UCJ VDS

Date Purpose
No by by by

DOCUMENT No.
ENGINEERING DESIGN BASIS 6782-00-16-47-DB-01
GENERAL CIVIL Rev. 1
Page 2 of 12
CONTENTS
1.0 SCOPE ............................................................................................................... 3

2.0 REFERENCE PUBLICATIONS ......................................................................... 3
3.0 DESIGN PHILOSOPHY / CRITERIA - GENERAL ............................................ 4
3.1 OVERALL PLOT PLAN ............................................................................................4
3.2 SITE GRADING........................................................................................................4
3.3 ROADS ....................................................................................................................4
3.4 CONCRETE PAVEMENTS ......................................................................................6
3.5 SITE FINISH.............................................................................................................6
3.6 STORM WATER DRAINAGE...................................................................................7
3.7 WATER SYSTEM.....................................................................................................8
3.8 SEWERS..................................................................................................................9
3.9 STORAGE TANK FOUNDATION AND DYKE WALLS:.........................................11
3.10 FENCING/COMPOUND WALL ..............................................................................11
3.11 PROCESS CONTROL ROOM SAFETY ................................................................12

2
DOCUMENT No.
Page 3 of 12
1.0 SCOPE
This specification covers design basis for overall plot plan and indicates major
parameters for location of different facilities and safe distances as per rules and safe
engineering practices.
The specification also covers the overhead and horizontal clearances provided in
units, requirements of maintenance platforms, access ways and ladders
The general practices followed for transportation and clearances required from
various statutory bodies are also covered.
2.0 REFERENCE PUBLICATIONS
• Environmental Guidelines for siting of Industry published by Ministry of
Environment and Forest.
• The Environmental Protection Act, 1986
• OISD Standard 108 (Recommended Practice on Oil Storage & Handling).
• OISD-109 (Process Design & Operating Philosophies on Blow Down & Sewer
System).
• OISD Standard 118 layout for Oil and Gas Installation
• OISD-150 (Design & safety requirement for Liquefied Petroleum Gas Mounded
storage).
• OISD Standard-163 (Process Control Room Safety)
• OISD Standard-164 (Fire proofing in oil & gas industry)
• Petroleum Rules, 2002
• The Static and Mobile Pressure Vessels (unfired) rules-1981
• Gas Cylinder Rules 2004
• Director General of Civil Aviation Rules.
• IS codes for various civil works (latest edition) as on NIT of tender
• IS-456-2000 code of Practice for Plain & Reinforced Concrete
• IRC codes for roads.
• CTI Blue book.
• CTI code ATC-105 Acceptance Test Code.
• CTI Technical Paper No. TP-88-05.
• Kelly's Handbook.
• Home Ministry Circular on Perimeter Wall.
• Manual for Water Supply and Treatment (by Ministry of Urban Development)
• Manual on Sewerage and Sewage Treatment (by Ministry of Urban
Development).
• Specification for Road & Bridge Works (Published by IRC on behalf of the
Government of India, Ministry of Road Transport & Highway).
• Process Licensors requirement, if any

3
DOCUMENT No.
Page 4 of 12
3.0 DESIGN PHILOSOPHY / CRITERIA - GENERAL

3.1 OVERALL PLOT PLAN
3.1.1 The Overall Plot Plan shall be developed based on good Engineering practice and
meeting the requirements of various statutory bodies and local authorities.
3.1.2 Additionally the Overall Plot Plan shall also meet as applicable the requirement of
OISD108, 118 and 163 depending upon the nature of the plant and process licensors’
recommendations.
3.1.3 The Overall Plot Plan shall be offered to the owner for approval after completing the in
house formalities. After receipt of the owner's approval only, the Overall Plot Plan
shall be valid for further engineering and statutory approvals.
3.1.4 The various statutory approvals shall be taken with the owner's assistance as and
when required.
3.2 SITE GRADING
3.2.1 All the tree roots and vegetation shall be grubbed up and removed from site.
3.2.2 The grading of the area shall be done by cutting and filling with the following:
a. Cutting area : Thoroughly rolled and compacted.
b. Filling area : Compacted in layers not exceeding 30 cm in
loose thickness to achieve min. 90% of standard
Proctor dry density as per IS:2720 Part-VII.
3.2.3 Site grading philosophy shall be based on following:
Minimum FGL : 10.0 M
The NGL at site varies from 5.0 m to 60.0m As per MRPL feed back flooding was
observed at level of 8.00m hence minimum FGL shall be kept at 10.00m. 1
The main Block levels have been fixed to optimize on cut / fill work. Unit blocks have
been kept at higher ground to have safe unit operation and also better soil condition.
As the site is undulating, step grading will be done to optimize on site grading
quantities. However, one single unit / utility / tank farm will be kept at one level only.
3.2.4 Slope in Graded Areas:
i General Site Grading 1:500 to 1:1000
ii Micro grading 1:200
iii Tank farms 1:200 to 1:300
End slopes of graded area shall be 1.5(H) to 1(V) for ordinary soil and 1(H) to 1(V) for
very stiff / stable soil / Rocky areas.
3.3 ROADS
3.3.1 Road Width
Location Road way Carriage way
i. Main roads for product movement 12.5m 10.5 m
ii. Road around unit 10.5m 10.5 m
iii. Secondary road 10.5m 8.5m
iv. Roads around tank farm 10.5m 8.5m

4
DOCUMENT No.
Page 5 of 12
v. Patrolling roads (along 6.0 m 4.0 m

boundary wall)
vi Access Road (Process Units) 6.0 m wide @ 20m c/c all-around from
the road around unit with pipe culverts /
box culvert on storm water drain
vii. Access road (secondary) 3.0 m
viii. Foot path 1.0 m
3.3.2 Camber 1:50
3.3.3 Radius of curve 12.0 m for 10.5m & 12.5m wide road
8.00 M for 6.0m wide roads.
3.3.4 CBR to be used for design As per soil data
3.3.5 Design standard IRC 37-2001 (using 2 msa & design CBR)
3.3.6 Road finish
Bituminous carpet with seal coat (50mm thick
Bituminous Macadam with 20 mm thick pre-mix
carpet over 3 layers of each 75 mm thick WBM
Gr.-II with 2 layers of each 100 mm thick WBM
grade-I below.)
Road Under Phase-I : - Upto 2nd layer of WBM Gr.-II .
Road Under Phase-II : - Repair of damaged portion of road during
construction and providing balance road work.
(Bituminous carpet & Bituminous Macadam shall be constructed employing
HOT mix plant and paver.)
3.3.7 Finished road top level above FGL:
a. Around hazardous units- 1.05m
b. When pipe way bridges are
provided for pipe ways - 1.60 m (based on 24” maximum pipe size)
at pipe way bridge location with a slope
(1:30) from 1.05 m to 1.60 m above FGL
- For higher pipe size, road level of 1.05m

shall be increased to restrict the hump at
PWB to ~0.5m
c. When overhead bridges

are provided for pipe ways - 1.05 m around hazardous units and 0.40 m
to 0.60 m for other areas
d. Other areas - 0.40 m to 0.60 m

5
DOCUMENT No.
Page 6 of 12
3.4 CONCRETE PAVEMENTS

3.4.1 Pavement slope 1 in 100
3.4.2 Type
a. Vehicular movement area
1. Process Unit Type-I (200 mm, thick) RCC M30
2. Utilities Type-I (200 mm, thick) RCC M30
b. Non vehicular movement areas
1. Unit Type-II (150 mm thick) RCC M25
2. Offsite pump station Type-III (100 mm thick) RCC M25
3. Utilities Type-II (150 mm thick) RCC M25
c. Pipe Rack/ Track PCC M20 (100thick)
d. Footpath Pre-cast interlock concrete
blocks (M-20)
NOTE:
i. Refer Standard drawing no. 7-65-0404, RCC pavement details

ii. Sub-Grade below RCC pavement shall be compacted to 90% of Standard
Proctor Dry Density as per IS:2720 Part-VIII and the slope of sub-grade shall
be same as top of the pavement slope.
iii. In case of poor soil treatment below base shall be carried out as per soil report
/ recommendation..
iv. Provide minimum number of expansion joints as per standard.
3.5 SITE FINISH
AREA CONCRETE ASPHALT STONE OTHER

PITCHING COMPACTED
EARTH
SURFACE
- OPERATING AREA √
(UNITS) Refer cl.3.4
- NON OPERATING √
(UNITS)
- ROAD √
- APPROACHES √

6
DOCUMENT No.
Page 7 of 12
AREA CONCRETE ASPHALT STONE OTHER

PITCHING COMPACTED
EARTH
SURFACE
- FOOTPATH √
(Precast
concrete
interlock blocks)
- TANK FARM (inside dyke) √
- BETWEEN UNIT & √

Roads (Except approach road (Precast
to units & approaches to fire Interlocking
hydrant) Tiles)
- PIPE WAYS √
(PCC M20)
- OPEN STORAGE / √
MAIN AREAS
ROAD EMBANKMENT SLOPE √

(if slope is
more than 1
m high)
3.6 STORM WATER DRAINAGE
3.6.1 Run off co-efficient
a. Paved area - Concrete - 1.0
- Bituminous - 0.9
b. Compacted area such as tank
farm/ offsite areas/expansion area - 0.6
c. Unusable open area/ Green Belt area - 0.4
3.6.2 Ditches
a. Type Rectangular type in and around units.
Other areas, ditches shall be rectangular
and/or trapezoidal type.
b. Construction
- Rectangular Ditches Stone masonry
with cement plaster in offsites. RCC in
units and other RCC paved areas (grade
of RCC drain shall be same as that of
pavement).
- Trapezoidal Ditches PCC (M20) lining
for both horizontal and sloped portion

7
DOCUMENT No.
Page 8 of 12
3.6.3 Culverts and Road Crossings

a. Pipe Culverts - Under Roads : RCC pipes (Class NP-3 as per IS:458)
b. Storm Water Box culverts : RCC Precast/ Cast-in-situ Construction
c. Cast-in-Situ Boxes for cable crossing : RCC construction
d. Electric Road Cable crossings : PVC pipe class-1 (IS 4985)
embedding in PCC
(All drainage culverts shall be RCC box culverts, wherever heavy crane movement is
envisaged.)
3.6.4 Tank farm drainage shall be provided in such a way that the storm water discharge
shall be either sent to storm water open ditch or to the oily sewer by providing sand
trap and valve pit.
3.6.5 An oil catcher with baffle wall type arrangement shall be provided on storm water
ditch before it leaves the battery limit of the complex.
3.7 WATER SYSTEM
3.7.1 Raw Water
a. Source
Water requirement for this project will be met from River Netravati. It is proposed to
construct a intake well and convey water to refinery by pipeline.
b. Storage
Type of reservoir Existing Rock quarry in the refinery area shall be further
developed and used as an open storage reservoir for
Raw Water. The reservoir shall have PE film lining with
concrete lining.
Capacity Based on reliability of source.
c. Storage (Filtered Water)
Type of reservoir RCC reservoir top covered..
Capacity As per Process Design Basis.
Treatment Treatment shall be done based on analysis of raw water
vis-à-vis requirement of process specification for water
quality of service water, cooling water makeup, DM
water and drinking water.
3.7.2 Drinking Water System
a. Rate of water supply - 30 gals/head/day (135 lpcd).
b. System - Underground ring main with G.I. pipes and
fittings.
c. Storage - Overhead tank of R.C.C Construction.
d. Treatment - Chlorination
3.7.3 Fire Protection System
Refer separate EIL design basis document no. 6782-00-16-47-DB-02

8
DOCUMENT No.
Page 9 of 12
3.7.4 Cooling Water System

Cooling water system (comprising of cooling Tower, CW Treatment, CW Sump and
Pumping) shall be as per process design basis.
3.7.4.1 Cooling Tower
a. Type - Induced Draft.
b. Construction - RCC Tower with PVC fill
c. Capacity and other parameters are based on process data sheet and design
data.
3.7.4.2 Cooling Water Treatment

The required treatment as per Process Data Sheets and Design Data shall be
provided.
3.7.5 DM Water Treatment
- D.M. Water plant shall be as per process design basis.
- The required treatment as per process data sheet and design data sheet shall
be provided for D.M. plant and condensate polisher.
3.7.6 Underground Piping
All underground C.S./M.S. pipes shall be provided with corrosion resistance
protection as per SMMS Specification.
3.8 SEWERS
3.8.1 General
a. Storm water drains shall not be combined with oily drains. However within the paved
area of the unit where rain water is likely to be contaminated with oil, the same shall
be discharged in the Contaminated Rain Water System (CRWS) oily drains. At unit 1
battery limit sealed manholes shall be provided.
b. Process waste (OWS) shall be discharged to waste water treatment facilities through
primary treatment plant if required. Otherwise to be discharged directly to the waste
water treatment plant.
c. Acidic waste shall be neutralized and discharged to disposal point or waste water
treatment plant.
d. Cooling tower blow down if contaminated shall be treated in WWTP.
e. All gravity sewers shall generally be laid underground.
f. All underground C.S. pipes shall be provided with corrosion resistance protection.
3.8.2 Types of Sewers and Disposal Method
Oily sewer - To Oil separator in WWTP
Contaminated Rain Water - Oil separator in WWTP 1
Chemical Sewer - Neutralisation pit and then pumped to
WWTP
Acidic and Alkali - Neutralisation pit and then pumped to
WWTP

9
DOCUMENT No.
Page 10 of 12
APH Wash - Neutralisation pit and then pumped to

WWTP
Closed Blow Down - To CBD Drum (RCC Pit)
Cooling Tower Blow Down - To WWTP
Sanitary Sewer - To WWTP
3.8.3 Design of CRWS and Oily Sewers
3.8.3.1 The Contaminated Rain Water System oily sewer shall be designed for the following
combinations :
- Contaminated rain water + Process Waste OR Fire water + Process Waste,
whichever is more.
3.8.3.2 The quantities of contaminated rainwater shall be worked out based on the 1
contaminated process area in the unit block.
3.8.3.3 The quantities of process waste shall be specified by Process / licensors. Consider
process waste from standby equipments also. OWS shall be routed to WWTP.
3.8.4 Design of Sanitary Sewer
The sanitary sewer shall be designed for 3 times the average flow flowing half
full in case of lateral sewer and flowing 2/3 full in case of Main Sewers.
3.8.5 Cover for Sewer Line
a. Minimum cover over sewer line shall be 600 mm.
b. Under road, sewer shall be protected by concrete encasement and minimum cushion
shall be 1200 mm.
3.8.6 Material of Construction for Manholes
Type and construction of manholes
a. In units areas - RCC Manholes / Catch Basin
(Liquid Retaining Specifications)
b. In Offsite areas - RCC Manholes (Liquid Retaining 1
Specifications)
c. Sanitary Sewer - Brick Manholes
Manhole Seal
For trapping of gas or prevention of spread of fire through is required, a liquid seal of
minimum 150 mm shall be provided at manhole along with suitable vents. Location of
sealed manholes shall be decided accordingly. All vent pipes of sealed manholes
shall be provided with flame arrestor.
3.8.7 Material of Construction for Sewers
3.8.7.1 CRWS Sewer
a. Within process units and Tankage areas - CS Pipes As per Piping Material
Specs
b. Offsite gravity sewer - RCC pipes class Pl (as per IS :
458) Socket and spigot, rubbering
joints (Suitable concrete supports
at all socket/ spigot joints of 1
underground piping shall be
provided.)
10
DOCUMENT No.
Page 11 of 12
c. Offsite pressure main - CS Pipes As per Piping Material

Specs
3.8.7.2 Oily Sewer
a. Within process units and Tankage areas - CS Pipes As per Piping Material
Specs
b. Offsite gravity sewer - RCC pipes class Pl (as per IS :
458) Socket and spigot, rubbering
joints (Suitable concrete supports
at all socket/ spigot joints of
underground piping shall be
provided.)
c. Offsite pressure main - CS Pipes As per Piping Material
Specs
3.8.7.3 Acidic and Alkali sewer - HDPE (as per IS:4984)
3.8.7.4 CBD Sewer - All CBD header and branch pipes
shall be laid in RCC trenches with
precast RCC covers. RCC Trench 1
shall be filled back with sand.
3.8.7.5 Chemical Sewer - CI Pipes as per (IS:1536 & 1537)
/ HDPE (as per IS:4984)
3.8.7.6 Sanitary Sewer
a. Toilet block up to inspection chamber HCI pipes (as per IS: 1729)
b. Gravity main & lateral RCC class Pl (as per IS:458) as
per IS : 458) Socket and spigot,
rubbering joints (Suitable
concrete supports at all socket/
spigot joints of underground
piping shall be provided.)
c. Pressure main CI Pipes (as per IS: 1536 and IS:
1537) / HDPE Pipes (Pressure
piping suitable for required
pressure)
3.8.7.7 Manhole for acid/ alkali sewer shall be provided with Acid/ Alkali proof lining.
3.9 STORAGE TANK FOUNDATION AND DYKE WALLS:
Foundation type:
a. Up to 10 m dia tank RCC Ring beam type.
b. Above 10m dia tank Sand tank pad
Anticorrosive layer 50 mm thick Bitumen sand mix for storage tank foundations
plus 50mm premix carpet outside the tank shell on the foundation only.
Storage Tank Dyke Walls
Construction Laterite Blocks /
1
Random Rubble Stone Masonry
3.10 FENCING/COMPOUND WALL
i. Protection of Land Acquisition Limit - Chain Link Fencing.

11
DOCUMENT No.
Page 12 of 12
ii. Protection of Main plant areas - Compound wall of Laterite Blocks

/ Random Rubble Stone Masonry
4.00m high with 600 mm barbed 1
wire over hang.
3.11 PROCESS CONTROL ROOM SAFETY
Control room shall be sized and designed meeting requirements of OISD-163
(Process Control Room Safety).

12
FIRE PROTECTION SYSTEM 6782-380-16-47-DB-02
C-2.2 FIRE PROTECTION SYSTEM
CAPTIVE POWER PLANT
JOB NO. : 6782
380.
1 23.01.2007 ISSUED WITH BIDS RKS UCJ VDS

Date Purpose
No by by by

DOCUMENT No.
FIRE PROTECTION SYSTEM Rev. 1
Page 2 of 14
CONTENTS
1.0 SCOPE .........................................................................................................................3
2.0 REFERENCE PUBLICATIONS....................................................................................3
3.0 FIRE PROTECTION SYSTEM .....................................................................................3
3.1 GENERAL .....................................................................................................................3
3.2 DESIGN PHILOSOPHY ................................................................................................3
3.3 DETAILED DESIGN BASIS ..........................................................................................3
3.3.1 Fire Water Hydrant System .......................................................................................3
3.3.2 Water Spray System..................................................................................................3
3.3.3 Foam System On Hydrocarbon Storage Tanks.........................................................3
3.3.4 CO2 Fire Extinguishing System..................................................................................3
3.3.5 Deleted Clean Agent Fire Extinguishing System for control room............................3
3.3.6 First Aid Fire Fighting Equipments.............................................................................3
3.3.7 Mobile Fire Fighting Equipments ...............................................................................3
3.3.8 Fire Fighting Appliances ............................................................................................3
3.3.9 Fire Station ................................................................................................................3
3.3.10 Codes & Standards....................................................................................................3
3.4 APPROVAL OF FIRE PROTECTION SYSTEM ...........................................................3
3.5 FIRE PROOFING..........................................................................................................3
4.0 FIRE DETECTION / ALARM SYSTEM ........................................................................3
5.0 COMMUNICATION ......................................................................................................3

DOCUMENT No.
Page 3 of 14
1.0 SCOPE
This standard covers design basis for basic philosophy and facilities for fire
fighting for plants. The provisions are as per statutory rules and safe
engineering practice.
2.0 REFERENCE PUBLICATIONS
.
• OISD RP - 108 Recommended practices on oil storage and handling.
• OISD STD - 111 Process design and operating philosophies on process
1
fired furnace.
• OISD GDN - 115 Guidelines on fire fighting, equipments and appliances
in petroleum industry.
• OISD STD -116 Fire Protection Facilities for Petroleum Refineries and
Oil / Gas Processing Plants
• OISD Standard 117 (Fire Protection Facilities for Petroleum Depots and
Terminal & Pipelines Installations.
1
• OISD STD - 118 Layout for oil and gas installations.
• OISD-RP-149 Design aspects for safety in electrical systems.
• OISD STD -150 Design & safety requirement for Liquefied Petroleum
Gas Mounded storage
• OISD STD-163 Process Control Room Safety
• OISD STD-164 Fire proofing in Oil & Gas industry
• OISD STD - 173 Fire Prevention and Protection System for Electrical
Installations
• Fire Protection Manual (Internal Appliances, Fire Engines/ Trailer pumps and
Hydrant Systems) by Tariff Advisory Committee (TAC).
• Rules of TAC for
a. Sprinkler System
b. Water Spray System
• BIS Codes for Fire Fighting Equipments.
• NFPA Codes for Clean Agent, CO2 System and Foam System.
• Process Licensors requirement, if any
3.0 FIRE PROTECTION SYSTEM
3.1 GENERAL
This functional specification described below gives design and functional
requirements for fire protection system for Phase III Refinery Project of MRPL
at Mangalore. The Fire Protection system shall be conceived to operate both
in prevention and fighting mode, depending on the relevant actions has been
DOCUMENT No.
Page 4 of 14
selected either manual or automatic. The fire fighting system shall be based
on the following fighting agents.
- Water
- Foam
- CO2
- Clean agent system 1
- Dry Chemical Powder (DCP)
3.2 DESIGN PHILOSOPHY
- Process plants, storages, utilities etc. shall be fully covered by hydrant system
as per OISD-116, Tariff Advisory Committee (TAC) manuals, NFPA standards,
design requirements, safe engineering practices and process licensor’s
requirements.
- Hydrant system shall be capable to fight two simultaneous major fires at a time
anywhere in the complex. The complex shall be considered as High Hazard
(B) category.
- For units, licensor’s recommendation shall also be taken care.
- Roof sinking case as per OISD shall be considered.
- The facilities like transformers, hydrocarbon storage tanks, mounded bullets,
etc. shall be protected with fixed installation e.g. water spray, foam system, 1
rim seal protection system only for crude oil tanks etc. as described in TAC
Spray Rules/ OISD as applicable.
- The fire hydrant network in and around hydrocarbon tank farm area shall be
designed for water demand assuming tanks to be protected by water spray &
foam system.
- For cable cellar water spray system shall be provided.
- Computer room, console room, UPS room, battery room, rack room etc of
1
control room shall be protected by clean agent system as per NFPA-2001.
- For process plants, OISD requirement and licensor’s recommendations
shall be followed.
- Fire protection facilities will be based on following:
- Monitoring and Alarm by alerting, locating fire and operating advise.
- Detection of fire, Toxic gas, Hydrocarbon vapor, H2S, Smoke, heat detectors
shall be included.
1
- Action by water/ foam/ Clean agent/ Dry Chemical Powder.

DOCUMENT No.
Page 5 of 14
- Design criteria for various facilities:-

i. Process Unit Handling Hydrocarbon
a. Water Application Rate for As per OISD 116 and TAC

process unit (General)*
* Hydrocarbon handling pump Water spray system as per OISD 116
& process licensor’s requirement
* Vessel : Un-insulated of holding Water spray system as per OISD 116
cap. over 50 m3 & process licensor’s requirement.
* Air Fin Coolers Located above pipe rack -Water spray
system as per OISD 116 & process
licensor’s requirement.
b. Water Application Rate for Refer OISD-116/ TAC & process
protected Equipment with deluge licensor’s requirement
system
c. Dry Risers Elevated platforms/ Tall towers.
d. Landing Valves On technological structures.
e. Hose Reels With each landing valves & at 40m
distance along pipe rack.
f. First Aid Eqpt. As per TAC/ OISD norms.
g. Remote Operated Long Range Remote controlled long range water
Monitor monitors (Aqua fog/ jet type) shall be
provided at elevated towers for all
columns/ vessels/ equipments above
25M height or inaccessible to normal
monitors.
(Long range monitor with adequate
boosting arrangement (boosting
arrangement shall be provided if
adequate pressure is not available
shall be considered.)
h. Spray System on columns The columns which are not covered
by remote operated long range
monitors.
- Water application rate: 10.2 lpm/m2
-Maximum spacing of ring: 5M
II. Offsite facilities

A. Hydro carbon Storage Tanks
Spray system -As per OISD 116 & TAC rules
Foam system -As per OISD 116 & TAC rules
In addition to above, provide linear heat detection system and automatic actuated
fixed foam system for all floating roof crude oil tanks.
B. Pressurised storage 1
Automatic deluge system -As per OISD/ TAC rules with

DOCUMENT No.
Page 6 of 14
Spray cooling of Process piping

within paved area or 15 m from
storage which ever is more.
C. Transformers & Cable Cellars
Automatic (deluge) high velocity water spray system shall be provided for
critical transformer of having oil capacity more than 2000 liters (each
transformer). Cooling water application rate of 10.2 lit / min / sqm shall be
provided as per OISD-173 and rules of TAC for Water spray System. Total
horizontal projected surface of the prism-enveloped plus 1m each side shall
be considered for cooling. Actuation of deluge valve shall be with the help of
Quartzoid bulb (QB).
Medium velocity water spray system shall be provided for cable cellars as per
OISD-173 and rules of TAC for Water Spray system, the same shall be
actuated through smoke detectors.
For unmanned sub stations fixed CO2 system shall be provided in addition to
medium velocity water spray system in the cable cellars. 1
D. Buildings & Other Miscellaneous Structures
- Fire hydrants and monitors shall be provided on elevated platforms of
technological structures, Process building/ structure with loop to feed from two
sides.
- Fire hydrant, for protection of pipe rack.
- Landing valves for multi storied buildings at first floor and above and at sub-
stations with cellars as per TAC rules.
- Hose reels near landing valves.
- First Aid Equipments as per TAC / OISD rules as applicable.
- Clean agent for control room as per NFPA 2001.
- Gaseous protection system on equipments recommended by suppliers.
1
- Hydrocarbon detection at AHU intake shall be provided along with interlock.
- Detection and actuation as per Electrical and Instrumentation specifications.
3.3 DETAILED DESIGN BASIS
3.3.1 Fire Water Hydrant System

A. Network sizing
i. TAC norms is to be followed for design and checked for OISD.

ii. Calculate the firewater demand as per TAC/OISD/ Licensor’s requirement.
iii Establish sizes of fire water network based on 150% of installed capacity
of pumps.

DOCUMENT No.
Page 7 of 14
a. Fire water network shall be analysed for 100% using “PIPENET”

software.
b. The velocity in the system should not exceed 5.0m/sec. with minimum
residual pressure at remotest point as 7.0kg/sqcm.
c. Two major fire with discharge of 50% of installed capacity at each fire
point shall be considered.
d. For floating roof tanks, a case of roof collapse shall be considered and
header around tank farm shall be sized accordingly.
iv. Refer TAC manual and OISD codes for details.
B. System description
- Underground ring main network system shall be laid at one meter earth cushion
and above ground ring main network laid on sleepers 500 mm above FGL /
Paved Area, independent of process lines near to road side.
- Flushing and pressure gauge points shall be provided on all headers and at
the remotest point in the network. 1
- Network shall be laid in a closed loops.
- The firewater header and branch lines shall be laid above ground on
independent sleepers for offsites and utilities areas. For road crossings and
crane / vehicle movement area the same shall be laid underground encasing
shall be provided as applicable. All firewater headers around units shall be
kept underground with suitable corrosion protection. All firewater headers and
branch lines in RCC paved areas shall be laid in RCC trenches with sand
1
filling and removable pre-cast cover with sealing. Headers should be laid in
such a manner that it should not touch the bed level of the RCC trench.
- The minimum header size for hydrant and monitor branches shall be as
under:
Hydrant connection - 4"
Water Monitor/Foam Monitor connection - 6"
Long Range Monitor Connection - 8”
Minimum Size of Network - 8”
- Radiography requirements as per TAC.
- All under ground FW headers shall be directly buried and provided with
corrosion protection coating as per SMMS specification.
- All under ground FW headers including the headers in RCC trench with sand 1
filling shall be provided with corrosion protection coating as per SMMS
specification Pipe shall be laid on 100mm thick sand in FW trench.

DOCUMENT No.
Page 8 of 14
- Above ground fire water piping shall be painted with Fire Red Paint to shade
No. 536 of IS:5 as per painting specification.
- All fire water network shall be hydro tested to a pressure shall be tested at 1.5
times the system design pressure of 18 Kg/cm2 (g).
1
- At least 10% of all welded joints shall be radiographed and shall be found in
order. At least 50% of welded joints selected for radiography shall be field
joints.
C. Restriction Orifice
- RO at Hydrant outlets to reduce the pressure to : 7kg/cm2

- RO at tappings of water spray system to keep the system pressure
in the range specified in the TAC/ OISD rules.
D. Isolation valves
- Isolation valves shall be provided in such a way that not more than 4 (four)
hydrants are isolated at a time and at crossings (Junctions) to ensure easy
maintenance and uninterrupted water supply in case of break down.
- Isolation valve shall also be provided below monitor and at all hydrants.
- Isolation valve shall be provided at all tapping points on firewater headers.
- Only carbon steel valves shall be used. CS valves shall be provided with
gear operations including equalizing lines for dia 8” 12” and above valve 1
sizes. No cast iron valves shall be used.
E. Hydrants, Monitors, Hose Reels & Hose boxes
Hydrant shall be BIS approved with following detail

Outlet : 63mm double headed
Pipe size : 4" CS
Capacity : 36 cum/hr
Type : Oblique angle type as per TAC
requirement
Monitor shall be BIS approved with following detail
Nozzle bore size : 38mm (Water– cum - foam diffuser type)
Pipe size : 6" CS
Capacity : 144 cum/hr
FM / UL listed High Volume Long Range water cum foam monitor shall be
provided around units / tankages
Capacity : 2000 GPM – 4000 GPM
Horizontal range : 80 m
DOCUMENT No.
Page 9 of 14
Hose reel shall be 40m long of 20mm bore size.

Hose shall be Reinforced Rubber Line (RRL) 2 nos 15m each kept in each
hose cabinet Hoses shall be as per Type –A of IS:636. Hose cabinet shall 1
have 2 Jet nozzles with branch pipe or 2 Universal branch pipes
Hose cabinet shall be BIS approved installed at every alternate hydrant
points and every landing valves.
F. Landing Valve
- Double headed
- To be provided on landings of first floor and above as per design criteria.
G. Material of Construction
Material used for fire protection system shall be in accordance with TAC
requirements and client specific requirement.
Broad specifications of material are as follows:
Pipe, fittings, valves - Carbon steel as per piping material
specification
- GI pipes for water spray (Down stream
of isolation valve)
Hydrant, Monitors, landing valves :Bureau of Indian Standards
Hose reels, hose Boxes and Accessories: (BIS) marked /TAC approved
H. Water Supply and Storage
a. Supply From Raw Water Reservoir.
b. Storage capacity Based on 6-hour storage of installed

capacity of pumps. Fire water reservoir shall
have 2 compartments with 3hrs. of installed 1
capacity of pumps.
c. Material of construction Open earthen reservoir lined with PE film

and concrete for raw water and fire water
reservoir
d. Make up water From Raw Water Reservoir through make

up Pump
e. Emergency connection From RW reservoir

DOCUMENT No.
Page 10 of 14
I. Fire Water Main Pumps
a. Capacity To fight two major fires simultaneously or as

per TAC rules, which ever is higher.
b. Type Vertical centrifugal.
Note: Pump capacity and head are to be finalised during detail

engineering.
c. Standby pumps 50% standby pumps
d. Drive Electrical / diesel engine as per OISD.
e. Power supply to To meet the requirement of the OISD.

Electrical driven pumps
f. Diesel Driven Pumps To meet the requirement of OISD
Diesel - day tanks capacity to meet

requirement of TAC and shall be placed
outside fire water pump house. (minimum12
Hour running storage)
Starting of DE with trickle charged battery
g. Mode of Operation
Starting of pumps Automatic through pressure switches and

manual. Pump actuation and running
indication shall be transmitted to Control 1
Room and Fire Station.
Stopping of pumps Manual only
h. Fire water Jockey

Pumps
-Capacity Based on OISD/ TAC requirements
-Head 0.5kg/cm2 more than main pump head
-Type Vertical
-Stand-by 100%
-Drive Electric (Normally)

To run on emergency power as well.

DOCUMENT No.
Page 11 of 14
Mode of operation Automatic through pressure switches with

provision to start and stop manually.
J. Fire Water Pump House

Firewater pump house shall be RCC frame construction having R.C.C.
roof with brick walls as per TAC norms. It shall have provision for separate
battery room, operator room and toilet block. A HOT/EOT crane shall be
provided for maintenance and erection. A local fire control panel in
operator’s room shall be provided for all controls of firewater pumps.
3.3.2 Water Spray System

¾ Water spray system provided on hydrocarbon tanks, transformers, process
equipment, etc. shall meet the requirements of TAC/ OISD. The rate of
water applications & mode of operation shall be as per Table-1 and as per
process licensor’s requirement.
¾ Water spray on every equipment, vessel, column, air fin cooler, tanks,
cable cellar and transformers shall have tappings from two sides of main
header. (But network design shall be done assuming only one tapping as
operational.)
¾ Water curtain shall be provided between heater and flow pass control
valve and as per process licensor’s recommendations.
¾ While providing water spray on equipments/ vessels, special care shall be
taken to provide water spray on flanges of nozzle connected to
equipments/ vessels.
TABLE 1
Rate of Water Application & Mode of Operation of Water Spray & Foam System
Facilities Mode of Operation Rate of application
Hydrocarbon Storage tanks Manual As per TAC & OISD whichever
is more
Process unit handling hydrocarbon

- On pumps Manual As per TAC & OISD whichever
is more
- Other equipments as per Manual As per TAC & OISD whichever
licensor is more
- Tall column Manual As per TAC & OISD whichever
is more
- Air Fin Coolers Manual As per TAC & OISD whichever
is more
DOCUMENT No.
Page 12 of 14
Transformers Auto (Deluge As per TAC & OISD whichever

system) is more
Cable Cellar Auto (Deluge As per TAC & OISD whichever
system) is more
NOTE: In case process licensor recommends for automatic deluge

system, manual system shall be changed accordingly.
¾ Material of Construction
Pipes, fittings CS for mains and MS-GI(HVY) screwed piping for

spray system
Valves and flanges CS.
Spray nozzles Cu Alloy
Deluge valves CS
Detector piping GI.
3.3.3 Foam System On Hydrocarbon Storage Tanks

- Type of foam -AFFF 1
- Operation -Manual
- System type -Semi fixed
- Application time -As per TAC
- Foam Solution -3% foam
Foam solution application rate
- 5 lpm/m2 of liquid surface - for fixed roof and cone cum floating roof tank
- 12 lpm/m2 of vapour seal area i.e. foam dam area for floating roof tanks.
- 8.1 lpm/m2 for roof collapse case for floating roof tanks.
Foam Compound Storage
- Foam compound requirement shall be considered to meet requirement of
foam fire protection system.
In addition to above for crude oil storage tanks automatic actuated by Linear Heat
Detection Rim Seal Foam Protection System designed to detect and extinguish
the floating roof Rim seal fire at its incipient stage shall also be provided as laid
down in OISD – 116. (The system is installed at the roof of tank and consist of
long foam line laid along the tank perimeter. The foam aspirating nozzles are 1
mounted on the line at an interval of 2.5 M. The premix foam is contained in a

vessel which is kept charged with nitrogen through a nitrogen cylinder. The
system is designed for minimum foam application rate of 18 LPM / M2 of rim seal
area.

DOCUMENT No.
Page 13 of 14
3.3.4 CO2 Fire Extinguishing System
- The system shall be as per NFPA-12.
3.3.5 Deleted Clean Agent Fire Extinguishing System for control room
Clean agent fire extinguisher system shall be provided in control rooms as per
NFPA 2001. The system shall be automatic and detection and actuation shall
1
also meet the requirement of NFPA 2001. Initial approval shall be taken from
client before proceeding with design and detailing.
3.3.6 First Aid Fire Fighting Equipments
This shall be provided as per OISD / TAC.
3.3.7 Mobile Fire Fighting Equipments

New mobile fire fighting equipments shall be provided in the new fire station as
per the provisions of OISD. Any specific requirements for mobile fire fighting 1
equipments for fire station shall be provided by MRPL.
3.3.8 Fire Fighting Appliances

Hoses & Hose boxes with accessories shall be provided as per OISD / TAC
requirements.
3.3.9 Fire Station

New fire station shall be located at safe location in the proposed Phase-III
Refinery Project.
3.3.10 Codes & Standards
a. Fire Protection Manual (Internal appliances, fire engines, trailer pumps,

and hydrant systems) (By Tariff Advisory Committee)
b. I.S. Codes For Fire Fighting Equipments.
c. Rules for water (For spray system design)
Spray system
d. NFPA 10 (Portable Fire Extinguisher)
e. NFPA 12 (CO2 Fire Extinguishing system).
f. NFPA 2001 (Clean Agent Fire Extinguishing System) 1
g. OISD standards
h. NFPA-11 Std. For Low Expansion Foam
i. NFPA-13 Std. For Installation of Sprinkler System
j. NFPA-17 Std. For DCP
k. Process licensor’s standards and recommended HSE Policy/ codes.

DOCUMENT No.
Page 14 of 14
3.4 APPROVAL OF FIRE PROTECTION SYSTEM

TAC Manuals describe procedure of submitting documents elaborating the
details of documents, drawings, scale of drawings, minimum contents in the
drawings. Based on their guidelines, documents / drawings shall be prepared.
Approval from TAC accredited agency shall be taken.
3.5 FIRE PROOFING
Fire proofing using vermiculite shall be provided for steel structures and
equipment supports that could collapse under fire condition and contribute to
the intensity of the fire shall be provided to meet the requirements of OISD
Standard 164 (Fire Proofing in Oil and Gas Industry).
4.0 FIRE DETECTION / ALARM SYSTEM

Refer Engineering Design Basis (Electrical) OISD Standards. 1
5.0 COMMUNICATION
Refer Electrical Specifications for details.

STRUCTURAL & ARCHITECTURE 6782-380-16-48-DB-01
C-2.3 STRUCTURAL & ARCHITECTURE
CAPTIVE POWER PLANT
JOB NO. : 6782
380.
1 24-11-2006 ISSUED WITH BIDS GOEL/JS MBL A KUMAR

Date Purpose
No by by by

STRUCTURAL & ARCHITECTURE 6782-380-16-48-DB-01
1.0 Please refer section C-3.2

JOB SPECS & DATA SHEETS SECTION: C-3.1
GENERAL CIVIL
6782-380-16-47-ID-01-B
CAPTIVE POWER PLANT
C-3 JOB SPECS & DATA SHEETS
C-3.1 GENERAL CIVIL
CAPTIVE POWER PLANT
JOB NO. : 6782
B 08.05.07 REVISED AND ISSUED WITH BIDS RAJEEV RKS NK
A 01.02.07 ISSUED WITH BIDS RAJEEV RKS UCJ

Date Purpose
No by by by

JOB SPECS & DATA SHEETS SECTION: C-3.1
GENERAL CIVIL
6782-380-16-47-ID-01-B
CAPTIVE POWER PLANT
JOB SPECIFICATIONS
S.No. TITLE SPECIFICATION NO. REV NO. OF

SHEETS
1. Job specifications for Cooling Tower 6782-380-16-47-SP-10 B 12

in CPP area
2. Job specifications for Cooling & Foam 6782-380-16-47-SP-11 B 11

System for Storage Tanks
3. Job specifications for High Velocity / 6782-380-16-47-SP-12 A 6

Medium Velocity Spray System on
Transformers / Cable Cellars
4. Job Specification for Fixed CO2 Fire 6782-380-16-47-SP-13 A 9

Extinguishing System
5. Specification for flexible pavements 6782-380-16-47-SP-14 A 7

with bituminous macadam and
bitumen premix carpet

SPECIFICATION NO.
JOB SPECIFICATION FOR
6782-380-16-47-SP-10 Rev B
COOLING TOWER
Page 1 of 12

COOLING TOWER
B 08.05.07 MRPL COMMENTS INCORPORATED & ISSUED FOR BIDS RAJEEV RKS NK
A 01.02.07 ISSUED FOR BIDS RAJEEV RKS UCJ

Date Purpose
No by by by
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
SPECIFICATION NO.
COOLING TOWER 6782-380-16-47-SP-10 Rev B
Page 2 of 12
TABLE OF CONTENTS
1.0 SCOPE ................................................................................................................................ 3

2.0 REFERENCE...................................................................................................................... 3
3.0 DESIGN BASIS.................................................................................................................. 3
4.0 STRUCTURAL COMPONENTS AND ACCESSORIES ................................................. 4
5.0 BASIN AND CHANNEL................................................................................................... 6
6.0 COOLING TOWER PIPING AND HOT WATER DISTRIBUTION SYSTEM .............. 7
7.0 MECHANICAL COMPONENTS ...................................................................................... 8
8.0 ERECTION, INSPECTION & COMMISSIONING ........................................................ 10
9.0 PERFORMANCE, GUARANTEE AND TESTS ............................................................ 11
10.0 SPECIFIC REQUIREMENTS.......................................................................................... 12
SPECIFICATION NO.
Page 3 of 12
1.0 SCOPE
This specification covers the general requirements for design, supply of material,
fabrication, erection, painting, testing and commissioning of mechanical induced
draught type cooling tower.
If any portion of this specification conflicts with any specific provisions contained in
the data sheets, the later shall govern.
2.0 REFERENCE
The cooling tower and its accessories shall comply with the stipulations laid down in
the latest editions of the following codes and documents and the relevant
specifications mentioned in these specifications:
i. AGMA American Gear Manufacturers Association

ii ASME American Society of Mechanical Engineering
iii CTI Cooling Towers Institute, USA
iv ATC Acceptance Test Code
3.0 DESIGN BASIS
The cooling tower shall be mechanical induced draught type having no. of cells with
fans, motors, gear reducers, piping distribution system, nozzles, valves, etc. The
water-air relationship may be “cross-flow“ or "Counter Flow" designed to meet the
best performance requirements given in the attached data sheet. Where a tower is
divided into cells, each cell shall be identified and so designed that each one of them
could be operated independently of the rest of the cells and can also be repaired,
maintained and cleaned while the other cells are in service.
The basin and channel shall be so designed that full flow conditions can be attained
even at minimum water level in the basin. The sluice gates should be able to
discharge full cell capacity at minimum water level and levels of gates shall be fixed
accordingly. The fill may be splash type or film type.
The design of the cooling tower shall generally be as per this specification and as per
relevant Indian and International standards to meet the performance requirements
given in the attached data sheet.
The information for structural design of the cooling tower furnished herein is for
general guidance of the bidder. He shall verify this information at site before taking
up the design of the cooling tower. The thermo dynamic design should be such that
SPECIFICATION NO.
Page 4 of 12
the difference between temperature of outgoing mixed air and hot water shall not be
less than 4oC. If the temperature selected is less than 4oC, complete thermodynamic
design justifying the same shall be furnished along with the bids.
4.0 STRUCTURAL COMPONENTS AND ACCESSORIES
The cooling tower shall be of following construction:
a. Reinforced cement concrete structure with PVC fill.
The contractor shall provide metal inserts of approved design on the tower structure
for fixing cable trays, pipe supports, lightning arrestors etc.
4.1 Frame Work

For RCC cooling tower, the frame work shall be of RCC construction. The concrete
shall be designed and constructed as per (IS:456, IS:3370 and other relevant IS
codes (latest edition) and as per enclosed set of specifications.
4.2 Casing
For RCC cooling tower, the casing walls shall be of reinforced cement concrete
constructions, conforming to IS:456 and other relevant IS codes and as per enclosed
set of specifications.
4.3 Air Inlet Louvers

Air inlet louvers shall be suitably designed, supported and arranged so that there will
be minimum restriction to air flow and prevent down coming water from splashing out
of tower. The material of construction shall be reinforced cement concrete as per
IS:456 for concrete tower.
4.4 Filling
Fill shall be pure film ‘or’ splash type made of PVC. The spacing of supports and the
thickness of splash bars shall be adequate to ensure that there is no sag and the
splash bars remain horizontal when supported.
4.5 Drift Eliminators

Drift Eliminator blades shall be of two pass zig-zag type arranged in herring bone
pattern. Drift eliminator blades shall be of concrete frame work and shall limit the drift
losses to a value not greater than 0.2% of the design water circulation rate.
SPECIFICATION NO.
Page 5 of 12
4.6 Partition Wall

Partition wall shall be provided from basin top to the bottom of fan deck to permit
each cell to be taken out of service without affecting the operations of the other cell.
RCC partition wall shall be provided for concrete tower.
4.7 Fan Deck

Fan deck for supporting the fan cylinder and for access to mechanical equipment and
distribution system shall be of adequate section to support any reasonable
combination of live and dead loads. Fan deck shall be of RCC of adequate thickness
for RCC tower.
Access doors shall be provided into each cell through the fan deck and drift
eliminators for easy access to the cooling tower interior for inspection and repairs.
4.8 Access doors

All parts subjected to periodical maintenance and inspection such as filling, drift
eliminators, fans etc. shall readily be accessible and easily removable. Access door
shall be provided at the basin level (through casing side) in each cell and in each fan
stack. The door shall have easily operable shutter of leak proof design and MS
construction with two coats of red oxide zinc chromate primer for RCC tower.
4.9 Fan Cylinder (Fan Stack)

Fan cylinder shall have an extended stack of venturi shape to attain conversion of
velocity pressure to static pressure. The height of stack shall be such that the
recirculation effects of air shall be reduced to minimum possible. Fan stack shall be
of RCC construction for concrete tower.
Rings for fan stacks shall be of the same material as that of fan stack and shall be
concentric with the fan.
4.10 Stairways
One staircase of width not less than 750 mm clear shall be provided on the casing
side from the ground level for access to the fan deck. The staircase shall be of RCC
for concrete tower.
The staircase shall be provided with handrails, knee rails and toe boards and suitable
landings shall be provided on the staircase at intervals of not more than 4M vertically.
Stairways shall be at 45o maximum with the horizontal. The riser shall not be more
than 200 mm. Construction details of the stairway shall be in accordance with the
Indian Standard.
SPECIFICATION NO.
Page 6 of 12
4.11 Escape Ladder

Removable escape ladders shall be provided for every 50 metre length for cooling
tower. The ladder may be of galvanised steel for concrete tower.
A 450mm minimum width galvanised steel or 600mm minimum width treated wood
escape ladder shall be provided from ground level to the top of the cooling tower. A
safety cage shall be provided to a point 2000mm above the top of the fan deck.
Ladder construction shall be in accordance with the safety laws of the state. Safety
cage shall be of MS and painted as approved by Engineer-in-charge.
4.12 Hand Rail

For RCC towers, GI pipe rail of 40 mm OD and of one metre height (clear) shall be
provided around fan deck, on stairway and on hot water distribution deck in double
rows with 40 mm dia G.I. pipe uprights at a spacing not more than 1.5 m interval. In
addition knee rails and toe boards shall also be provided. At ladder points a safety
chain or drop bar is to be provided. Knee rails and toe boards shall have one coat of
red oxide zinc chromate primer and two coats of approval enamel paint.
5.0 BASIN AND CHANNEL
The basin for cooling tower shall be of reinforced cement concrete construction. The
concrete structure shall be designed as per IS:456. IS:3370 (latest edition) other
relevant IS:codes and as per enclosed specifications.
The basin including channel shall have a holding capacity to retain 10 minutes of
recirculating water above minimum water level. A minimum of 300mm free board
shall be provided in the basin and channel. Depth of basin below min. water level
shall be 300mm minimum .The basin shall be divided into compartments by providing
concrete partition wall designed for pressure on one side only.
- The top of basin kerb shall be fixed by vendor depending upon size of basin & water
depth to suit 10 min. basin and channel capacity.
- The basin shall have adequate provision for the following and these facilities shall be
provided for each compartment.
- Drain off and sludge removal arrangement with piping valves and flanges etc.
- Pipe shall be CS pipe as per PMS A3A
- Overflow arrangement
- Necessary MS pipe with puddle flanges (150 lb ratings) and MS inserts wherever
required.
SPECIFICATION NO.
Page 7 of 12
- Access platforms of steel or concrete and MS rung ladders for operation (All MS
components shall have 2 coats of anticorrosive enamel paint over a coat of red oxide
zinc chromate primer).
- Sluice gates of isolation of each cell shall be as per IS:3042.
- Cooled water channel with necessary baffles shall also be provided by the contractor.
- Top of the cold water channel shall be covered with pre-cast cement concrete slabs
with lifting hooks.
- The screen at the outlet of the cold water channel shall be HD galvanised iron and
made up of small sections fitted with lifting hooks to facilitate section wise removal. A
suitable working platform with chain pulley block (Hot Dip Galvanised) and a monorail
(HDG) arrangement with ‘U’ clamp shall be provided for removal of screens. The
effective velocity through the screen shall not be more than 0.3m/sec.No. of screens
provided shall be two, in addition one spare screen shall also be supplied. The
velocity through the channel shall not be more than 1.0m/sec. considering depth
below minimum water level.
- The velocity through the sluice gates shall not be more than 1.2m/sec.
- Maximum, minimum and normal operating water levels in the basin shall be clearly
indicated in the data sheets.
- All design and calculations for civil works shall be submitted to the client/EIL for
approval.
- The basin and channel shall be hydraulicaly tested with water upto the top level as
per clause 10 of IS:3370 (Part-I) and if any leakage or defect is noticed, the same
shall be rectified and retested at contractor’s own cost.
6.0 COOLING TOWER PIPING AND HOT WATER DISTRIBUTION SYSTEM
Hot water distribution system, if trough type shall be suitably covered at the top to
minimise algae growth and dust and other foreign material getting into the
recirculating water
All underground pipes shall be provided with coating as per specifications enclosed
else where in the bid document.
Contractor shall have to provide the hot water piping as per PMS enclosed with bid.
The sizes of hot water headers will be based on the velocity at 2.0 to 2.5m/sec. and
shall be got approved by EIL. The pipes shall be painted with 2 coats of approved
anticorrosive paint.
Hot water distribution system at the top of the tower shall be of open through gravity
splash type or enclosed header type with low pressure nozzles and splash plates
made of either porcelain or suitable plastic material. The size of hot water headers
SPECIFICATION NO.
Page 8 of 12
shall be given in the offer. Each hot water riser shall be provided with isolation gate
valve. Nozzles and splash plates shall be easily cleanable and shall be so provided
as to result into even distribution of water over the entire tower cross section.
Headers or troughs must be arranged for easy and rapid cleaning and capable of
being flushed out by means of clean-out flanges located at the terminal end of each
header.
Contractor shall provide block valves on water inlet to each cell. All flanges within the
cooling tower battery limits shall be as per ASA 150 lb.standards, flat face, slip on
type flanges.
7.0 MECHANICAL COMPONENTS
All mechanical components of the cooling tower viz fans, hubs, speed reducers, drive
shafts etc. shall be designed to withstand the corrosive and moist environment in
which these are proposed to operate for the cooling tower service. The mechanical
equipment in the cooling tower will not give vibration of more than 0.0005". The gear
boxes and fans shall be capable to take this vibration.
7.1 Fans
Fans to induce air flow through the tower shall be axial flow type, multiblade,
adjustable pitch type designed for cooling tower services. The fan blades shall be of
glass reinforced or other corrosion resistant alloy.
Tip speed of the fan shall not exceed 3600 metre / minute (12,000 ft./minute). Each
blade shall be adjustable for angle or pitch and individually fastened to a common
hub. Fan hub shall be of Hot Dip galvanised steel. Combined Noise level of fans at
rated pitch angle and speed shall not exceed 85 decibels above threshold level at a
horizontal distance of 15M from the tower.
The bolts for fixing of the fan blades on the hub shall be 1041 SAE grade.
The fan assembly shall be statically balanced.
Equipment duly calibrated for testing decibel level shall be arranged by the
contractor, at his own cost.
7.2 Gear Reducers

Speed reducing gear shall be of heavy duty, right angle, self lubricating type
designed for continuous operation under extreme conditions of heat and humidity.
SPECIFICATION NO.
Page 9 of 12
The speed reducer shall be designed as per AGMA specifications for right angle
gears and shall have a minimum service factor of 2 at rated driven horse power.
The lubrication system shall be of simple design. Lubricating oil shall be drainable
and refillable from outside the fan rings. Oil level shall be readable from the same
point. Gear case shall be vented outside of fan ring. The slow speed shaft shall have
double oil seals.
7.3 Drive Shaft

Drive shaft connecting motor and the speed reducer shall be of hot dip galvanised
carbon steel for outdoor operation in highly humid atmosphere.
The drive shaft shall have flexible couplings on either end to absorb any
misalignment during operation, the bushes of the flexible coupling shall be of
neoprene material and bolts shall be of galvanised steel.
The entire rotor assembly including drive shaft shall be dynamically balanced.
7.4 Support and Guards

The motor and the speed reducers shall be supported on a single hot dip galvanised
structural steel frame with all necessary bracings to prevent deflections,
misalignment or excessive vibrations. The motor and the speed reducer shall be
accurately aligned on the supports and securely bolted to it with galvanised steel
bolts, nuts, split washers and steel washers.
All moving parts of fan and motor assembly shall be properly guarded for safety
reasons.
7.5 Motor
Each fan shall be driven by a single speed, totally enclosed, fan cooled weather proof
chemical plant type, squirrel cage induction motor of class `B' insulation conforming
to relevant IS specifications. The motor shall be located outside the exhaust air
stream at the top of cooling tower and connected to the reduction gear by means of
fan drive shaft. Refer ELECTRICAL SPECIFICATIONS for details. Motor rating shall
be min. 15% more than BKW.
7.6 Hardware
All cooling tower hardware shall be of corrosion resistant material.

All bolts, nuts and washers shall be of galvanised steel.
All nails shall be of stainless steel (SS-304).
SPECIFICATION NO.
Page 10 of 12
The anchors for the frame work posts shall be of cast iron. Joints connector and / or
connector plates shall be of malleable iron, cast iron or galvanised steel.
No hardware shall be of copper or copper based alloy.
7.7 Lifting Devices

(i) One set of lifting tackles complete shall be provided on top of the fan deck for
the removal of gear assembly and fan from the stack, for maintenance or
repairs.
(ii) One set of lifting tackles (mono rail with chain pulley block) to be provided
near basin / channel for slug dosing of chemicals.
The chain pulley block, tripod and dolly if provided for this purpose shall be of hot dip
galvanised steel and the track assembly shall be of aluminium. A movable wooden
platform shall be supplied for use as access platform through the fan stack for
handling mechanical equipments.
7.8 Vibration Cut-off Switch

One vibration cut-off switch with adjustment for sensitivity for each fan shall be
provided and they shall be of weather-proof construction mounted in a weather proof
box. This shall be mounted on the fan motor gear supports, outboard of fan ring.
7.9 Oil Recovery Arrangement

The vendor shall provide an oil skimming arrangement to be installed in cooling water
channel for recovery of oil from the recirculating water. The maximum velocity in
channel shall not exceed 0.3m/sec. at the oil skimming apparatus. Adequate
arrangement for lifting the weir plate shall also be made.
8.0 ERECTION, INSPECTION & COMMISSIONING
8.1 Contractor shall be fully responsible for the complete and satisfactory supply and
erection of all portions of the cooling tower including concrete basin, channel and
ancillary structures. The contractor shall furnish the following to complete the job.
a. All labours
b. All tools and related equipment
c. All hoisting equipment
d. All necessary scaffoldings
e. All necessary transporting equipment
f. Testing and commissioning responsibility
g. Necessary metal inserts for supporting cable trays and lightning arrestors.
SPECIFICATION NO.
Page 11 of 12
On completion of the work, the contractor shall remove and dispose off, all rubbish
and other unsighty materials caused by his working and thereby leaving the premises
and the cooling tower in good, clean, safe and operatable condition.
Owner or his authorised representative will have the right to inspect at any stage of
manufacture and construction, all materials, components and workmanship and
testing of material. The contractor shall provide all facilities for inspection and testing
without any extra cost to the owner.
9.0 PERFORMANCE, GUARANTEE AND TESTS
The completed cooling tower shall be guaranteed to meet the design performance
conditions when tested in accordance with the cooling tower Institute Acceptance
Test Code ATC-105.
The contractor shall furnish performance curves based on constant L/G ratio under
the following conditions:
a. For water rate at design condition and+10% variation.

b. For cooling range at design condition +20% variation.
c. For wet bulb temperature +3oF(+1.67oC) and -7oC (-3.9oC) of design wet bulb
temperature.
The completed cooling tower in operation shall also be guaranteed to meet the
following requirements.
- The approach shall not be greater than that specified in the cooling tower data sheet.
- Motors driving the fans shall be amply sized for total BHP required including gear
losses. The power consumption for running the fan should not exceed the rated BHP.
- There shall be no leakage of water through sides or ends of the tower.
- Motors, speed reduction gears and fans shall be of adequate design and construction
and properly protected for operation in all adverse climatic conditions.
- Water tightness of basin, piping, valves, sluice gates, etc. is to be ensured.
- Test for cooling capacity to meet design parameters.
- Test for tripping level of vibration switch.
- Drift losses and power consumption shall be within the guaranteed limit mentioned in
data sheets.
SPECIFICATION NO.
Page 12 of 12
- Motors and fans shall operate satisfactorily in continuous operation with no injurious
vibrations and the sound intensity shall not exceed 85 decibels above threshold level
when measured at a horizontal distance of 15M from the nearest face of the tower
and 1.5 M above ground level.
- Return water header in contractor’s scope shall be hydraulically tested for a pressure
of 5kg/cm2.
10.0 SPECIFIC REQUIREMENTS
a. Contractor shall provide one spare screen to facilitate maintenance and repairs.
b. The drive shafts shall be hot dip galvanised after fabrication.
c. Contractor shall specify the type of resin for all G.R.P. materials. The Contractor shall
also indicate the tensile strength of GRP materials used and it shall be noted that the
materials shall be tested for strength.
Detailed design calculations for arriving at power consumption shall be submitted.
Fulkerson method shall be used for contour flow towers & KELLY’ method for cross
flow tower.
JOB SPECIFICATION COOLING & SPECIFICATION NO.
FOAM SYSTEM FOR STORAGE 6782-380-16-47-SP-11 Rev B
TANKS Page 1 of 9
JOB SPECIFICATION
COOLING & FOAM SYSTEM
FOR STORAGE TANKS
B 08.05.07 REVISED AND ISSUED FOR BIDS RAJEEV RKS NK

Prepared Checked Approved
Rev. No Date Purpose
by by by
Format No. EIL 1641-1924 Rev. 1 Copyrights EIL – All rights reserved
TANKS Page 2 of 9
INDEX
1.0 SCOPE
2.0 CODES AND STANDARDS
3.0 SYSTEM DESCRIPTION
4.0 SCOPE OF WORK AND SPECIFIC REQUIREMENTS
5.0 DESIGN AND CONSTRUCTION
6.0 ERECTION
7.0 TESTING AND COMMISSIONING
8.0 PAINTING
9.0 CIVIL WORKS
ANNEXURE-A
GENERAL ARRANGEMENT FOR WATER SPRAY SYSTEM
GENERAL ARRANGEMENT FOR SEMI-FIXED FOAM SYSTEM
TANKS Page 3 of 9
1.0 SCOPE
This specification covers the requirements of design, supply, fabrication, erection,
testing and commissioning of cooling and semi fixed foam systems for the protection of
storage tanks containing inflammable hydrocarbon liquids.
2.0 CODES AND STANDARDS

2.1 Design Codes:
i) OISD - 116
ii) Fire Protection Manual (Issued by TAC)
iii) IS codes
2.2 Reference codes
National Fire Codes by NFPA.
3.0 SYSTEM DESCRIPTION

The hydrocarbon storage tanks shall be provided with either one or both of the following
fire protection systems as per Project requirement.
a) Water Spray System
b) Semi Fixed Foam System
The General Arrangements of these two systems are indicated in Annexure - A.
4.0 SCOPE OF WORK AND SPECIFIC REQUIREMENTS
4.1 General
The scope of work for fire protection system for storage tanks shall in general be as but
not limited to the following:
a) Design, supply of all materials, fabrication and installation of complete system
for water spray and foam systems including all spray nozzles, foam makers,
vapour seal chambers, foam couplings, pipe fittings supports including pipe
sleepers, revolving heads, deflector plates on wind girders, platforms and
ladders etc complete as per specifications and drawings.
b) Hydrostatic testing, flushing and painting of complete piping work.
c) Testing and commissioning of the complete system.
d) Coating of pipes passing through dykes as per EIL standard specification
including encasing at dyke locations with PCC M20.
e) Taking approval from TAC/TAC authorized agencies.
TANKS Page 4 of 9
4.2 Drawings and Documents

The drawings accompanying the tender document are indicative of scope of work and
issued for tendering purpose only. These drawings indicate the general scheme as well
as the layout to enable the contractor to make an offer in line with the requirements of
the owner. Final construction shall be as per approved construction drawings released
during the course of execution of work to be prepared by the contractor and approved
by EIL. Tenderers should submit detailed drawing along with calculations, engineering
and construction drawings and document submission/issue schedule along with their
offer.
Detailed design calculations and drawings to explain all salient features of their design
shall be submitted along with their offer, failing which the tender shall be liable for
rejection.
The cost of all such design, calculations, documents and drawings to be furnished shall
be included in the price quoted for the work. The term "drawing" in the detailed
specifications shall imply the drawings prepared by the contractor and approved by EIL.
Advance certified final drawings/calculations submitted by the contractors shall be
reviewed by EIL/Owner. During such review, the Engineer-in-Charge may suggest
certain comments necessitating some modifications in these documents. The contractor
shall incorporate all such modifications.
4.3 Specific Requirements

The work shall be executed as per scope of the package and attached drawings and
documents. The routing / location / sizes shown in the scope drawings are indicative
only. There is a possibility that during execution of the work the scope might change
especially in the piping portion on grade from roadside to the tank bottom or on account
of comments from TAC/TAC authorized agencies.
The lump sum price indicated shall be inclusive of cost of mandatory and
commissioning spares, all consumables, lubricants etc., for the total job as detailed in
the bid document.
4.4 Statutory Approval

Contractor shall take TAC/TAC authorized agency approval of the system. Drawings
and documents as required by TAC/TAC authorized agency authorities complete in all
respects shall be prepared by the Contractor well ahead of time so that the actual
commissioning of the works is not delayed for want of inspection by the concerned
authorities. The bidder shall give assistance and cooperation to the inspection
authorities for inspection works at various stages.
TANKS Page 5 of 9
Any change/addition required to be made to meet the requirements of the statutory

authorities shall be carried out by the Contractor. The Inspection and acceptance of the
work by statutory authorities shall, however, not absolve the Contractor from any of his
responsibilities under this contract.
5.0 DESIGN AND CONSTRUCTION

5.1 Cooling System
5.1.1 Cooling system for storage tanks shall consist of medium velocity water spray nozzles
mounted on cooling ring around the tank for shell side cooling and revolving head at the
roof of tank to cool the roof portion. Cooling system of each tank shall be connected to
fire water ring main on roadside through two supply headers. The two supply headers
shall preferably be located in such a way that they are connected to different sections of
the ring main. Each supply header shall be sized for 100% flow requirement of the
Tank. An Isolation valve shall be provided on each supply header near fire water ring
main. Pressure available in fire water ring main at header tapping points shall be
considered at 7.0 kg/cm2 for design purposes. The flow velocity in the pipes shall be as
per TAC requirements.
5.1.2 In case of floating roof tanks the cooling ring shall be located about 1.0M below the top
wind girder. Where more than one wind girders are envisaged, the location of the
cooling ring shall be decided as per table in clause no. 5.3.1. All wind girders except the
top one shall be provided with deflector plate to channelise the water along the shell.
In case of cone and floating-cum-cone roof tanks the cooling ring shall be provided at
the highest possible location on tank shell to provide maximum coverage to the tank
shell. Where more than one wind girders are envisaged, the location of cooler ring shall
be decided as per table in clause no. 5.3.1. All wind girders shall be provided with
deflector plates to channelise the water along the shell.
5.1.3 To cool the roof portion of cone and floating cum-cone roof tanks a revolving (sprinkler)
head conforming to IS:906 shall be provided. The branch feeding the revolving head
shall be connected to the same supply header which is feeding to cooling ring.
5.1.4 Minimum pipe size shall be restricted to Dia 80mm.
5.2 Semi Fixed Foam System
5.2.1 Semi fixed foam system for storage tanks shall consist of foam makers mounted on
tank shell at top. Each foam maker shall be connected with an independent foam
supply dry piping which shall be extended to the roadside. Protein based foam solution
with 3-6% proportion shall be pumped into foam lines at a pressure of 7.0 kg/cm2 from a
mobile foam tender.
TANKS Page 6 of 9
5.2.2 Foam makers for cone and floating cum cone roof tanks shall be provided with vapour
seal chambers to prevent escape of hydrocarbon vapours through dry foam piping to
the roadside.
5.2.3 Suitable foam deflectors shall be provided inside tank shell on foam outlets to guide the
foam smoothly along the tank shell. Platform and approach ladder from rooftop shall be
provided for each foam maker for maintenance and testing work.
5.3 Hydraulic Design
The design requirements of water spray and foam system are indicated in Annexure A.
and hydraulic design shall be performed using ‘PIPENET’ or equivalent software.
5.3.1 Cooling System:
A cooling application rate of 3 lit/min/m2 of tank shell area shall be considered for design
purposes.
For cone and cone cum floating roof tanks (dia> 10m) where two or more cooling rings
are envisaged, the cooling rate for these rings and number of shall be as given in table
No. 1
TANKS Page 7 of 9
TABLE NO-1
(FOR FLOW OF WATER AND NO. OF RINGS)
Detail of No. of Rings %Flow Ring Position on Tank
Tanks of water
Floating Roof Tanks
Height < 10.0M One 100% Below top wind Girder
Ist Ring 30% Below Top wind Girder
Height > 10.0M 2nd Ring 70% 4M from top of tank (in case this
Two
< 15.0M location is fouling with 2nd wind
girder, the ring shall be placed
below the 2nd wind girder.)
Ist Ring 25% Below top wind Girder
2nd Ring 25% 4M from top of tank (in case this

location is fouling with 2nd wind
Height > 15.0M girder, the ring shall be placed
Three
< 20.0M below the 2nd wind girder.)
3rd Ring 50% At mid height of the tank (in case
this location is fouling with 3rd
wind girder, the ring shall be
placed below the 3rd wind girder.
Cone & Cone cum Floating Roof Tanks
Height < 10.0M One Revolving Head 100% At top of Tank
Revolving 25% At top of Tank

Head
One Ist Ring 25% Below top wind girder
Revolvi
Height> 10.0M ng
< 15M Head + 2nd Ring 50% 4M from top of tank (in case this
2 Rings location is fouling with 2nd wind
girder, the ring shall be placed
below the 2nd wind girder.)
Revolving 25% At top of tank
Ist Ring 20% Below top wind girder
One
Revolvi 2nd Ring 20% 4M from top of tank (in case this
Height> 15.0M ng location is fouling with 2nd wind
< 20.0M Head + girder, the ring shall be placed
3 Rings below the 2nd wind girder.)
3rd Ring 35% At mid height of the tank (in case
this location is fouling with 3rd
wind girders, the ring shall be
placed below the 3rd wind girder.
TANKS Page 8 of 9
The spray nozzles shall be so selected that their individual spray pattern shall at least
meet each other without leaving any portion of tank shell unwet and shall provided
uniform cooling. A minimum overlap of 400mm between two nozzles shall be provided.
5.3.2 Orifice Plate

In the cooling rings, the residual pressure shall be minimum 1.4 kg/cm2g in the ring
based on design pressure 7.0 kg/cm2g of available in fire water at header tapping,
suitable orifice plate shall be provided in both the vertical risers for each tank.
5.3.3 Semi Fixed Foam System:

For cone roof tanks, a foam solution rate of 5 lit/min/m2 of liquid surface area shall be
considered for design purposes. For floating roof tanks, foam solution delivery rate shall
be 12 lit/min/m2 . The nos. and capacities of foam makers shall be as indicated in the
enclosed design requirements.
For floating roof tanks the foam application shall be restricted to foam seal area by
providing a foam dam. The foam dam shall be located about 800mm away from tank
shell. The height of foam dam shall be sufficient to retain foam upto the top of the
weather shield. Suitable drain spouts shall be provided to drain the degenerated foam
liquid from the foam dam area. The rate of application of foam shall be 12 lpm/m2 of
foam dam area for floating roof tank.
5.4 Equipment and Materials Specification

5.4.1 All equipment and materials in contractor's scope for fire protection systems shall be as
per specifications and drawings.
5.4.2 The details and material specs of foam makers, vapour seal chambers, spray nozzles,
revolving sprinkler head, foam coupling, pipes and fittings shall be submitted to
Owner/EIL for approval before placing the order on sub vendors. Various fire fighting
equipments shall have either BIS certification mark wherever applicable or shall be TAC
approved.
6.0 ERECTION:
Fabrication and erection of piping shall be done as per the approved detailed drawings
and enclosed specifications with following specifications with following specific
requirements:
6.1 Foam Piping at grade level shall be sloped towards the drain valves at all the lowest
elevations.
6.2 Drain valve assembly shall be provided at low points in the dry piping system. Suitable
strainers shall be provided in cooling water headers.
TANKS Page 9 of 9
6.3 Suitable guides shall be provided on the piping wherever required to keep the pipes in
position.
6.4 Vendor shall design, fabricate and provide all pipe supports on tankages. Pipe sleepers
for grade level piping (sleeper height upto 500mm above finished grade level) shall be
as per EIL standard drg. enclosed. In case where the sleeper height is more than 500,
special structural supports shall be designed and provided by the Contractor.
6.5 The portion of piping passing through dykes shall be coated as per EIL standard
specification and encased in M20 concrete 100mm thick all around. The pipe shall be
embedded in the dyke to make it water tight. The dyke shall be cut to lay the pipes and
dyke made good after laying the pipes.
6.6 10% of all the welded joints shall be radiographically tested and half the joints
radiographed shall be field joints.
7.0 TESTING AND COMMISSIONING

7.1 The complete piping shall be tested to a hydrostatic test pressure of one and a half
times the working pressure for a period of 2 Hrs.
7.2 Commissioning
The complete cooling and foam system shall be tested for satisfactory performance as
per design requirements by the contractor. Any modification required for achieving such
performance shall be done by the contractor without any extra cost. (Owner shall
arrange for necessary water and foam solution required for performance testing of the
system). The system shall be deemed to be complete after the above tests are
conducted by the bidder to the satisfaction of the owner.
8.0 PAINTING
8.1 After hydraulic testing of the system all exposed steel piping, equipment, fixtures and
supports shall be painted with two coats of fire red paint over a coat of primer
conforming to shade No.536 of IS:5 as per shop and field painting specification
attached in the bid.
8.2 All other components shall be suitably painted and identified.
9.0 CIVIL WORKS

All civil works shall be done as per relevant IS codes and good engg. practice.
JOB SPECIFICATION FOR SPECIFICATION NO.
HV/MV SPRAY SYSTEM ON
6782-380-16-47-SP-12 Rev A
TRANSFORMERS / CABLE
CELLARS Page 1 of 6
JOB SPECIFICATION FOR HIGH

VELOCITY / MEDIUM VELOCITY
(HV/MV) SPRAY SYSTEM ON
TRANSFORMERS / CABLE CELLARS

Date Purpose
No by by by
TRANSFORMERS / CABLE 6782-380-16-47-SP-12 Rev A
CELLARS Page 2 of 6
TABLE OF CONTENTS
1.0 SCOPE .................................................................................................................................... 3

2.0 TECHNICAL SPECIFICATION ........................................................................................... 3
2.1 REFERENCE PUBLICATIONS:........................................................................................... 3
2.2 TRANSFORMER ................................................................................................................... 3
2.3 CABLE CELLARS................................................................................................................. 5
3.0 APPROVAL OF THE SYSTEM............................................................................................ 6
CELLARS Page 3 of 6
1.0 SCOPE
This specification covers the general description, material of construction and test for
the High Velocity / Medium Velocity (HV/MV) Spray system on Transformers / Cable
cellars
2.0 TECHNICAL SPECIFICATION
2.1 REFERENCE PUBLICATIONS:
1. OISD-STD-116 (Fire Protection Facilities for Petroleum Refineries and Oil

/Gas Processing Plants
2. Fire Protection Manual (Internal appliances, Fire Engines/ Trailer pumps and
Hydrant Systems) by Tariff Advisory Committee (TAC).
3. OISD Standard-173 (Fire prevention and protection system for electrical
installation).
4. Rules of TAC for
a. Water spray systems.
5. I.S. Codes for Fire Fighting Equipments.
2.2 TRANSFORMER
2.2.1 General:
Transformers shall be protected by Auto actuated High Velocity water spray system
as per OISD-173. The system shall be automatically actuated by deluge system
through Quartzoid bulb detectors (QBD) on airline.
The system shall be designed completely as per “Rules for Water Spray System”
(published by TAC). Each transformer shall be provided separate high velocity water
spray network consisting of isolation valves, Deluge valve assembly, by pass valve
strainers, drain valves, high velocity spray nozzles etc.
2.2.2 System Design:
System shall be designed by using “Pipenet” or internationally recognized equivalent

software conforming to “Rules for Water Spray System” published by TAC and as per
OISD-173.
2.2.3 Hydraulic Specification:
Application Rate: 12.5 LPM/ M2 (Minimum) of the surface area of the entire
transformer including the bottom surface, radiators, conservators etc.
Minimum Pressure: 3.5 Bars (in case of an outdoor transformer)
(This is the pressure at the hydraulically most remote Sprayer)
Maximum Pressure: 5 Bars (for any Projector)
Maximum Velocity in the Feed Pipe: 10 M/second
CELLARS Page 4 of 6
2.2.4 Deluge Valve Assembly:
The Water Spray System shall be provided with Deluge Valve assembly actuated by
QBD (Quartzite Bulb Detector) on air line. Deluge valve shall be as per attached EIL
specification for Deluge Valve.
The deluge valve assembly shall comprise of solenoid valve, by pass valve, pressure
switch, pressure gauge, inlet/ outlet valve, drain valve, priming valve, vent valve
including alarm motor gong, all tubing for actuation, fittings etc. The system shall be
provided with isolation valve & strainer on the up stream of deluge valve including
providing drain valve at downstream.
Deluge valve shall be housed with brick masonry walls (3 sides) and with RCC roof.
2.2.5 Spray Nozzles:
High Velocity Water spray nozzles shall have discharge pattern as 90-100 degree
angle uniform full cone spray pattern and shall be provided as per attached EIL
specification for nozzles. The nozzle placing shall conform to the requirements of
“Rules for Water Spray System”. Nozzles on the rings shall be located at not less
than 500mm and not more than 800mm from the Transformer surface.
2.2.6 Detection System:
The detection system for transformers shall confirm to cl. 3.2.4 of “Rules for Water
Spray System”. QBD on air line shall be provided for detection of fire.
2.2.7 Supporting of Pipes:
Piping shall be individually supported as far as possible. In no case, shall the piping
be supported on the body of the Transformer. Terminal pipes longer than 300mm
shall be supported separately.
2.2.8 Piping Material Specification:
Spray Piping Upstream of Deluge Valve: A33A (A/G)

A94A (U/G)
Spray Piping Down Stream of Deluge Valve: J2A (Screwed / threaded)
Detection Piping: J2A
All A/G fire water spray pipes shall be painted Fire Red confirming shade no.536 as
per IS:5.
Corrosion protection tape coating shall be provided on all U/G pipes as per attached
specification.
Break up flanges shall be provided in spray piping for easy removal during
maintenance of transformers.
2.2.9 Radiography
10% of welded joints shall be radiographed out of which 50% shall be field joints
CELLARS Page 5 of 6
2.3 CABLE CELLARS
2.3.1 General:
Cable cellars shall be protected by Medium Velocity water spray system. The control
shall be manual, local and remote from control room. Necessary drainage
arrangement shall be provided in cable cellar room for drainage of sprayed water.
The detection shall be through smoke detection system (smoke detection system
refer elsewhere in bid document).
The system shall be designed completely as per “Rules for Water Spray System
(published by TAC) and OISD-173. Each cable cellar shall be provided with suitable
no. of segments. Each segment shall be provided with isolation valves, Deluge valve
assembly, by pass valve strainers, drain valves, high velocity spray nozzles etc. In
case of fire all the segment of a particular cable cellar shall operate simultaneously.
Suitable interface shall be incorporated for simultaneous operation of all segments.
2.3.2 System Design:
System shall be designed by using “Pipenet” or internationally recognized equivalent

software conforming to “Rules for Water Spray System” (published by TAC) and
OISD-173.
2.3.3 Hydraulic Specification:
Application Rate: 12.2 LPM/ M2 (Minimum) of the exposed area of the cable
racks.
Minimum Pressure: 2.8 Bars
(At the hydraulically most remote Nozzles)
Maximum Pressure: 3.5 Bars (for any Nozzle)
Maximum Velocity in the Feed Pipe: 10 M/second
2.3.4 Deluge Valve Assembly:
The Water Spray System shall be provided with Deluge Valve assembly. Deluge
valve shall be as per attached EIL specification for Deluge Valve and as per “Rules
for Water Spray System”.
The deluge valve assembly shall comprise of solenoid valve, by pass valve, pressure
switch, pressure gauge, inlet/ outlet valve, drain valve, priming valve, vent valve
including alarm motor gong, all tubing for actuation, fittings etc.
The system shall be provided with isolation valve & strainer on the up stream of
deluge valve including providing drain valve at downstream.
Deluge valve shall be housed with brick masonry walls (3 sides) and with RCC roof.
2.3.5 Spray Nozzles:
Medium Velocity Water spray nozzles shall be provided as per attached EIL
specification for nozzles. The nozzle placing shall conform to the requirements of
“Rules for Water Spray System”. Nozzle/ pipe spacing shall be as per Cl. 4.8.4 of
“Rules for Water Spray System”.
CELLARS Page 6 of 6
2.3.6 Detection System:
The detection system for cable cellar shall confirm to cl. 4.8.7 of “Rules for Water
Spray System”.
2.3.7 Supporting of Pipes:
Piping shall be supported as per guidelines of “Rules for Water Spray System” by the
contractor.
2.3.8 Piping Material Specification:
Spray Piping Upstream of Deluge Valve: A33A (A/G)

A94A (U/G)
Spray Piping Down Stream of Deluge Valve: J2A (Screwed / threaded)
All A/G fire water spray pipes shall be painted Fire Red confirming shade no.536 as
per IS:5.
Corrosion protection tape coating shall be provided on all U/G pipes as per attached
specification.
2.3.9 Radiography
10% of welded joints shall be radiographed out of which 50% shall be field joints
3.0 APPROVAL OF THE SYSTEM

Drawings & documents as required by authorities (TAC accredited agency) in all
respect shall be prepared and submitted by the Bidder. The Bidder shall make
arrangement for inspection & testing for TAC accredited agency & other statutory
authorities at various stages of the work. Any changes, additions required to meet the
requirement of TAC shall be carried out by the CONTRACTOR without any extra
cost.
SPECIFICATION NO.
FIXED CO2 FIRE EXTINGUISHING 6782-380-16-47-SP-13 Rev A
SYSTEM
Page 1 of 9

FIXED CO2 FIRE
EXTINGUISHING SYSTEM

Date Purpose
No by by by
FIXED CO2 FIRE EXTINGUISHING 6782-380-16-47-SP-13 Rev. A
SYSTEM
Page 2 of 9
TABLE OF CONTENTS
1.0 SCOPE .................................................................................................................................... 3

2.0 REFERENCE CODE.............................................................................................................. 3
3.0 GENERAL DESCRIPTION OF SYSTEM ............................................................................ 3
4.0 THERMO SWITCHES........................................................................................................... 3
5.0 CHARACTERISTICS OF FIXED INSTALLATION ........................................................... 3
6.0 CHARGING ........................................................................................................................... 4
7.0 DISCHARGE HEADS ........................................................................................................... 4
8.0 MANIFOLDS WITH CONNECTIONS TO DISCHARGE HEADS .................................... 4
9.0 DISCHARGE NOZZLES ....................................................................................................... 4
10.0 CO2 SYSTEM CONTROL PANEL....................................................................................... 4
11.0 MATERIAL SPECIFICATIONS ........................................................................................... 5
12.0 STATUTORY APPROVAL............................................................................................... 5
13.0 TESTING AND MARKING .................................................................................................. 5
14.0 PAINTING.............................................................................................................................. 5
15.0 SPARES.................................................................................................................................. 5
SYSTEM
Page 3 of 9
1.0 SCOPE
This specification covers the general description, material of construction and test for
the fixed type carbon dioxide fire extinguishing system designed to be actuated by
electronic control/ thermo electric process.
2.0 REFERENCE CODE
i. NFPA –12 – Carbon Dioxide Extinguishing System

ii. SMPV (unfired) Rules by Petroleum And Explosives Safety
Organisation (PESO) formerly known as CCE
3.0 GENERAL DESCRIPTION OF SYSTEM
3. 1 The CO2 system shall be designed and supplied strictly as per the requirements of
NFPA-12 and the criteria given herein below:
3.2 The system shall be a high pressure (850psi) and shall be such that it is
a. Extremely quick in action

b. Non poisonous
c. Safe and
d. Clean
3.3 Fire shall be extinguished by the total flooding of the space with CO2 gas to render the
atmosphere inert and non supporting to combustion.
3.4 CO2 gas cylinder’s capacity provided shall be sufficient to discharge CO2 gas,
equivalent to 50 per cent of the cubical content of the space involved, depending on
the floor area of the enclosure. Consideration of extra requirement due to opening in
the enclosure shall also be given.
3.5 All the mandatory requirements of NFPA-12 shall be fully complied.
3.6 The vendor shall fill the required data in the Technical data sheet (Annexure- 1) on
page no. 6 of 9 and submit along with the offer.
4.0 THERMO SWITCHES

Thermo switches for releasing the CO2 gas by temperature shall be of vapour proof,
single pole, open circuit and designed to close at 220 volts. A.C. / 110 volts DC/I
independent battery when the surrounding air reaches 77oC / or any other desired
temperature. Each thermo switch shall be mounted on half inch conduit box. These
shall be provided around the place to the protected against fire hazard. The range of
thermo switch is from 0 oC – 100 oC.
5.0 CHARACTERISTICS OF FIXED INSTALLATION
5.1 Carbon dioxide shall be stored in the high pressure steel cylinders, and when released
it shall travel in the same form through the pipe work to the discharge nozzles. The
release of pressure allows the liquid to turn partly to snow emerging at a temperature
of –110 oF (-79 oC). A battery of CO2 cylinders fitted with the above device shall be
connected to the main manifold of the pipe work.
SYSTEM
Page 4 of 9
5.2 The storage cylinders shall be located in a dedicated room for the building for which
protection is envisaged.
5.3 The time to reach the specific concentration of CO2 shall be clearly mentioned. The
system shall be interlocked with the air conditioning/ ventilation system wherever
applicable. In case of CO2 injection into the rooms, the relevant air handling units shall
be automatically shutoff.
5.4 The distribution piping shall have to clear the RCC beams and ribs which criss cross
the ceiling, path of air ducts and electrical conduits. All supports, hangers and clips etc.
required for supporting the distribution piping, cylinders, manifolds etc. shall also be
supplied with the system. The number of supports, hangers and clips etc. shall be as
per the drawings approved by the Owner/EIL.
6.0 CHARGING
Each CO2 cylinder shall be equipped with a valve permitting refilling of cylinder. The
cylinder shall be sealed with a puncturable diaphragm and shall be provided with a
safety pressure relief for abnormal pressure formation.
7.0 DISCHARGE HEADS
Each cylinder the CO2 battery shall be equipped with a discharge head for automatic
piercing of the sealing diaphragm. One or two cylinders in the multiple cylinder
discharge group shall have discharge heads operated directly from the control panel
and the others shall be operable by the gas pressure discharged from the first one or
two.
8.0 MANIFOLDS WITH CONNECTIONS TO DISCHARGE HEADS
The pressure manifold shall be designed in such a way that it shall collect the gas from
all the cylinders and discharge collected quantities of the gas in the main manifold
which shall be connected with the discharge of outlets in the rooms.
9.0 DISCHARGE NOZZLES
9.1 Suitable number of distribution nozzles shall be properly located within the enclosures
to be protected for assuring a uniform distribution of the carbon dioxide.
9.2 The nozzles for discharging CO2 gas into the hazardous areas, shall be of such shape
as to spread the gas without freezing. The nozzles shall be made of heat resisting
material and threaded to fit standard pipes, or pipe fittings.
9.3 A suitable arrangement shall be made in room for effective removal of CO2 being
released.
10.0 CO2 SYSTEM CONTROL PANEL
10.1 The control panels shall be located in individual buildings and shall be wall mounted
type. The control panels shall be provided for manual actuation and shall be designed
to accommodate relays, auxiliary switches, pilot and signal lamps. The control panels
shall be also be provided with the facility of audio alarm and on receipt of fire alarm
signal from fire alarm panel, audio alarm shall be initiated from CO2 control panel with
necessary signal to shut off air conditioning / ventilations system, if any. Manual push
SYSTEM
Page 5 of 9
button for discharge of CO2, in each protected area (after audit alarm and 30 seconds
time delay) shall be provided near exit of the room.
10.2 Sign boards, caution boards, illumination board, alarm, given as per requirements of
NFPA- 12 shall be provided in and around building protected with CO2 system.
11.0 MATERIAL SPECIFICATIONS
11.1 Material for cylinder body, valve, nozzle shall conform to clause 5 of IS:287. CO2 gas
quality shall conform to IS:307.
11.2 All piping, spray nozzle shall be as per NFPA-12.
12.0 STATUTORY APPROVAL

Approval from ‘Chief Controller of Explosives’ for CO2 system for handling, storage,
disposal shall be taken by contractor.
13.0 TESTING AND MARKING
13.1 Every CO2 cylinder shall be made and tested, approved, equipped and marked in
accordance with IS:2878
13.2 CO2 piping shall be hydrotested as per NFPA-12.
13.3 Each cylinder shall be clearly and permanently marked with the following information:
a. Manufacturer’s name and trade mark.
b. Year of manufacture.
c. Cylinder marking as per IS:2872
14.0 PAINTING
Painting and colouring of pipelines, nozzles, CO2 cylinders, supports, etc. shall be
done as per standard practice including supply of all paints and consumables and
other items required for carrying out painting and colouring.
15.0 SPARES
15.1 The bid must include in the quoted price, the mandatory spares to be supplied with the
CO2 system.
15.2 In addition to the above spares, vendor shall recommend the list of spares required for
two years trouble free operation with unit rates and quantity along with the offer.
SYSTEM
Page 6 of 9
TECHNICAL DATA SHEETS ANNEXURE-1

DETAILS TO BE FURNISHED BY THE BIDDER ALONG WITH THE
OFFER
C : Means Bidder to furnish data/details
1.0 Type of system : Fixed CO2 Fire Extinguishing

System
2.0 Design code/standard to which design/ : NFPA-12 and SMPV

manufacture/testing conforms. : Rules (PESO) for cylinders
3.0 System designed to protect risks in the

building as specified. : C
3.1 Design Concentration : C

3.1.1 Amount of gas required. : C
(Attach separate sheet, if required).
(List out gas supplied, number of cylinders
etc. for working and standby requirements,
risk wise.) :
3.2 CO2 storage cylinder details
a) Manufacturer : C
b) Design Code : C
c) Capacity in litres : C
d) Gas Holding Capacity (Kg) : C
e) Total Number supplied : C
f) Approving Agency FM/UL/LPC/

VdS & TAC
(This must be acceptable to TAC). : C
g) Approved by PESO : YES
h) Working pressure (kg/cm2) : C
i) Design Pressure (kg/cm2) : C
j) Dimension of Cylinder Dia x

length x thickness : C
3.3 Pipes, valves and fittings.
a) Manufacturers
i. Pipes : EIL approved vendor
SYSTEM
Page 7 of 9
ii. Fittings : EIL approved vendor
iii. Valves : EIL approved vendor
b) Material for Construction
i. Pipes : As per spec
ii. Fittings : As per spec
iii. Valves : As per spec
c) Design Code
i. Pipes : As per NFPA
ii. Fittings : As per NFPA
iii. Valves : As per NFPA
d) Type of joints : As per NFPA
e) Hydraulic test Pressure of

manifold/supply lines(kg/cm2). : As per NFPA
f) Discharge Nozzles
i. Manufacturer and Type : C
ii. Material of Construction : C
iii. Number Supplies : C
iv. Approved by FM/UL/VdS/FOC

& TAC (Yes/No) : C
3.4 Painting and colouring of pipeline,

nozzles, cylinder supports included
(2 coats of red oxide and synthetic enamel): C
3.5 Operating Devices
3.5.1 Push Button Station

i. Type : C
ii. Manufacturer : C
iii. Model, numbers offered : C
iv. Overall dimensions : C
3.5.2 Control Cables

i. Manufacturer : C
SYSTEM
Page 8 of 9
ii. Code/ Standard : C
iii. Type : C
iv. Size : C
v. Rating : C
3.6 Main Control Panel

i. Manufacturer :
ii. Mounting Detail : C
iii. Number of entries : C
iv. Sheet Thickness : C
v. Cable Entry : C
vi. Total heat load predicted for air

conditioning, if any. : C
vii. No. of AC/DC feeders and their

rating. : C
3.6.1 Additional Requirements for Control Panel
a) Whether housing all the necessary

relays indicating lamps, push
buttons, switches, etc. for the
efficient operation of the system,
(Yes/No). : C
b) Input power supply requirement for

operation of panel. (AC/DC Volts) : C
c) Panel Signal Voltage(AC/DC Volts) : C
d) Type/APM Capacity of the battery : C
e) Interconnecting cabling between

battery and panel. : C
f) Power supply unit incorporated in

the panel. (Yes/No). : C
g) Audio visual alarm on panel provided

Battery low conditions (Yes/ no) : C
h) Change over from AC Main supply

to standby power supply fully
automatic in either direction
(Yes/No). : C
SYSTEM
Page 9 of 9
i) Following push buttons provided
i) Alarm : C
ii) Reset : C
iii) Test (Yes/ No) : C
j) Audio visual indication for AC

supply failure provided (Yes/No). : C
k) Pilot lamp for system ‘ON’ supply

(Yes/No). : C
l) Dual tone hooter for fire/fault alarm

Provided & range of the same : C
m) Painting (External/Internal) : C
4.0 Material of Construction selected in

accordance with NFPA-12 (Yes/No) : C
5.0 Inspection and Testing
a) Visual inspection of installed : C

system & hazard area.
b) Check of labeling of devices. : C
c) Check for mechanical tightness of

piping & associated equipments : C
d) Non-destructive operational
tests for all devices included. : C
6.0 Weighing system (EIL approved) : C
SPECIFICATION FOR FLEXIBLE SPECIFICATION No.
PAVEMENTS WITH 6782-380-16-47-SP-14 Rev A
BITUMINOUS MACADAM AND
BITUMEN PREMIX CARPET Page 1 of 7
SPECIFICATION FOR
FLEXIBLE PAVEMENTS WITH
BITUMINOUS MACADAM AND
BITUMEN PREMIX CARPET
A 01.02.07 ISSUED WITH BIDS. RAJEEV RKS UCJ
Rev.
Date Purpose Prepared by Checked by Approved by
No
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

PAVEMENTS WITH BITUMINOUS 6782-380-16-47-SP-14 Rev. A
MACADAM AND BITUMEN
PREMIX CARPET Page 2 of 7
CONTENTS
1.0 SCOPE
2.0 CODES & STANDARDS
3.0 BITUMINOUS MACADAM
4.0 BITUMEN PREMIX CARPET
5.0 PAYMENT
6.0 REMOVAL OF SURPLUS EARTH

MACADAM AND BITUMEN
1.0 SCOPE
This specification establishes the material and construction requirements for the flexible
pavement with bituminous macadam and bitumen premix carpet.
2.0 CODES & STANDARDS
IS: 73 Paving bitumen

IRC: 27 Tentative specification for bituminous macadam (Base & Binder Course)
NOTE:- Latest Edition of all Codes and Standards shall be followed.
3.0 BITUMINOUS MACADAM
Bituminous Macadam shall consist of construction of one or more courses of compacted

crushed aggregates, pre-mixed with a bituminous binder, laid immediately after mixing.
3.1 Material
3.1.1 Aggregates
The aggregates shall consist of crushed stones of clean, hard, tough, durable rock of uniform
quality and shall be clean, free from excess of dust, flat or elongated pieces, soft or
disintegrated stone, clay or other deleterious matter.
The aggregates shall satisfy following physical requirements:
Aggregate impact value - 30 percent

Los Angeles abrasion value maximum - 40 percent
Loss with sodium sulphate for five cycles - Maximum 12 percent
Flakiness index - Maximum 15 percent
Stripping test (CRRI) * - Maximum 25 percent
* Test shall be as described in IRC: 27.
3.1.2 Grading of Aggregates
The aggregates for bituminous macadam shall conform to the grading as specified below:
50 mm compacted thickness for binder course

___________________________________________________________________________
Percent passing Sieve No. Grading 1 Grading 2 Grading 3
50 mm 100 100 -
40 mm - 95-100 -
25 mm 50-95 60-95 100
20 mm - - 75-100
12 mm 5-20 15-35 -
10 mm - - 50-85
4.75mm - - 20-40
2.36mm 0-8 - 5-20
75 micron 0-5 0-5 0-5
Binder content percent by wt. of mix 3-6 percent

MACADAM AND BITUMEN
3.2 Quantities of materials required for 10m2 of road surface
3.2.1 Aggregates
The approximate quantity of aggregates required for 10 m2 of area of bituminous macadam

shall be 0.60 to 0.75 m3 for compacted thickness of 50mm.
3.2.2 Binder
3.2.2.1 Premixing
The bituminous binder required for premixing of bituminous macadam shall be at the rate
specified depending on the gradation of the aggregates. The upper limit may be raised when
absorptive type of aggregates are used, and the exact rate shall be specified by the Engineer-
in-Charge.
3.2.2.2 Tack Coat
The bitumen shall be heated in asphalt boilers to 1770 - 1880 C and shall be spread uniformly
at the rate of 1 kg/ m2 by means of sprayers. The applied binder shall be evenly brushed.
The tack coat shall be applied just ahead, keeping pace with laying of premix carpet.
3.2.3 Construction Methods
3.2.3.1 Weather and Seasonal Limitations
Bituminous macadam shall not be laid or placed during rainy weather or when the sub grade
or base course is damp or wet unless emulsion is used or normally when the atmospheric
temperature in the shade is 160 C or below.
3.2.3.2 Equipment
All equipment necessary for the proper construction of work shall be on the site of work in
good condition.
3.2.3.3 Preparation of Underlying Course
The underlying course on which bituminous macadam is to be laid shall be prepared, shaped
and conditioned to a uniform grade and section as specified. Any depressions or pot-holes
should be properly made up and thoroughly compacted sufficiently in advance. The surface of
the underlying course shall be thoroughly swept and scraped clean and free from dust and
foreign material
3.2.3.4 Application of Tack Coat
The bitumen shall be heated in asphalt boilers to 1770 - 1880 C and shall be spread uniformly
The tack coat shall be applied just ahead of the spreading of pre-mixed macadam.

MACADAM AND BITUMEN
4.0 BITUMEN PREMIX CARPET
4.1 Material
4.1.1 Coarse aggregate

The aggregate shall consist of crushed stones of clean, hard, tough, durable rock of uniform
quality and shall be clean, free from excess of dust, flat or elongated pieces, soft or
disintegrated stone, clay or other deleterious matter. The size of aggregate shall be as
mentioned in the schedule of quantities.
4.1.2 Sand
The sand shall consist of clean, hard, durable, uncoated, coarse dry particles and shall be free
from injurious amounts of dust, soft or flaky particles, organic matter or other deleterious
substances.
4.1.3 Binder
The binder shall be bitumen of penetration 80/100 conforming to IS: 73. The bitumen shall be
collected on road side drums. Any leaking or damaged drum shall not be accepted.
4.2 Quantities of material (premix carpet)
For Premix Carpet 25mm thick

________________________________________________________________________
1 2 3
________________________________________________________________________
1) Coarse Aggregate
12mm and down size 3.5m3 -
2) Bitumen 80/100 185 kg 68.3 kg
3) Coarse sand as
sealing compound - 0.6m3
4.3 Laying
4.3.1 Preparation of Road Surface
The existing surface shall be thoroughly cleaned, swept & scraped clean of dust, loose
materials, caked mud and other foreign matter with the help of wire brush, chisel, picks etc.
before laying the tack course. The cleaning shall be carried out in such a manner as to expose
the stone metal to a depth of 1 to 2mm without dislodging the interlocking of the metal. All
dust and other material thus removed shall be disposed as directed by the Engineer-in-Charge.
4.3.2 If pot holes or ruts are found on the existing road surface, these irregularities must be filled in
with premix chippings and well rammed about a week before the carpet is laid.
4.4 Tack Coat
4.4.1 The bitumen shall be heated in asphalt boilers to 1770 - 1880 C and shall be spread uniformly
4.4.2 The tack coat shall be applied just ahead, keeping pace with laying of premix carpet.

MACADAM AND BITUMEN
4.5 Preparation of Premix
4.5.1 Mechanical mixers shall be generally used for preparation of premix. Improvised hand mixing
drums may be used, if permitted by the Engineer-in-charge.
4.5.2 Stone chippings of specified size shall be thoroughly mixed dry in the mixer at the rate
indicated above. Binder heated at temperature suitable for the grade of bitumen is added to the
mixer drum at the specified rate per 100m3 of surface and thoroughly mixed till the stone
chips are completely coated with the binder.
4.5.3 The premix shall be emptied on to wheel barrows or stretchers and carried to work site.
4.6 Spreading of Premix
Immediately after applying the tack coat, the premix shall be spread with rakes to the required
thickness and distributed evenly by means of a drag spreader. The camber shall be checked by
means of camber board and the unevenness shall be rectified.
4.7 Rolling
4.7.1 When the premix has been laid for a length of 15-20 meters, rolling shall be commenced with
tandem rollers (8 to 10 tonnes). Rolling should commence from edges and proceed towards
centre longitudinally.
4.7.2 The wheels of roller shall be continuously moistened to prevent the premix adhering to the
wheels and being picked up.
4.7.3 After the preliminary rolling and honeycombing, high spot or depressions shall be rectified by
adding or removing the premix as per requirements and the surface shall be rolled again to
compaction. Camber shall be checked at every stage and any defects found shall be rectified.
Excessive rolling shall be avoided.
4.8 Seal Coat (For low rainfall areas- under 150 cm/yr)
4.8.1 A premix seal coat, mix preferably in a mechanical mixer after heating the sand should be
applied immediately after laying the carpet and rolled. Materials required for this seal coat are
as per clause 4.
4.8.2 Seal Coat (For high rainfall areas - over 150 cm/yr)
The material requirement for seal coat in high rainfall areas is as under:
Binder 80/100 = 98 kg/ 100m2 of road surface

Coarse aggregates
6.3mm passing IS 10mm
Square mesh retained on

IS sieve 2.36mm = 0.9m3/ 100m2 of road surface.
A liquid seal coat, preferably with chippings as above (though coarse sand can also be used)
should be applied after laying the carpet. The binder after being heated to permitted
temperature, should be applied to the cleaned surface, blinded with chippings and rolled.
Traffic may be allowed on the road preferably 24 hours after providing the seal coat.

MACADAM AND BITUMEN
5.0 PAYMENT *
Payment shall be made on sq.m. basis of finished surface including all labour & materials as
per above specifications.
6.0 REMOVAL OF SURPLUS EARTH
6.1 Surplus earth and soil from excavation shall be removed from construction area to the area
demarcated by the Engineer-in-Charge.
6.2 Payment shall be made only for lead beyond initial 50m from construction areas. Rate shall
include loading, transportation, dumping, stacking the surplus earth and soil in the area
demarcated. Payment shall be made on cubic meter basis by measurement of number of
trucks.
* FOR LSTK CONTRACTS PAYMENT CLAUSES STAND DELETED.

Document No.
SITE SPECIFIC SPECTRA FOR 6782-9-2554-DB-01
MANGALORE Rev. No.0
Page 1 of 3
SITE SPECIFIC SPECTRA FOR

MANGALORE
1.0 SITE SPECIFIC SPECTRA
0 15-12-2006 ISSUED FOR IMPLEMENTATION

Prepared
Rev. No Date Purpose Reviewed by Approved by
by
Template No. 5-0000-0001-T1 Rev. 1 Copyrights EIL – All rights reserved

Document No.
MANGALORE Rev. No.0
Page 2 of 3
Spectral Acceleration Coefficients (Sa/g) for Design Basis Earthquake (DBE)

(numerical values tabulated below)
DAMPING %
0.70
0.5
0.60 1.0
2.0
0.50
Spectral accln. in "g"
3.0
0.40
4.0
0.30
5.0
7.0
0.20
0.10
0.00
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0
Time Period in seconds
Spectral Acceleration Coefficients (Sa/g) for Design Basis Earthquake (DBE)
Time Percentage of critical damping

Period
( sec) 0.5 1.0 2.0 3.0 4.0 5.0 7.0
0.000 0.085 0.085 0.085 0.085 0.085 0.085 0.085

0.050 0.353 0.309 0.219 0.205 0.192 0.178 0.163
0.100 0.561 0.460 0.259 0.237 0.216 0.194 0.178
0.130 0.572 0.473 0.274 0.249 0.224 0.199 0.182
0.200 0.577 0.478 0.280 0.253 0.226 0.199 0.183
0.270 0.573 0.475 0.279 0.252 0.226 0.199 0.183
0.300 0.566 0.470 0.278 0.251 0.225 0.199 0.183
0.400 0.505 0.424 0.263 0.237 0.210 0.184 0.170
0.500 0.438 0.373 0.243 0.216 0.188 0.161 0.149
0.600 0.369 0.321 0.224 0.197 0.171 0.144 0.134
0.800 0.268 0.238 0.177 0.160 0.142 0.124 0.114
1.000 0.204 0.184 0.144 0.132 0.120 0.107 0.098
1.200 0.164 0.149 0.119 0.110 0.100 0.091 0.082
1.400 0.134 0.124 0.104 0.096 0.088 0.080 0.072
1.600 0.116 0.107 0.090 0.083 0.076 0.070 0.062
1.800 0.098 0.092 0.080 0.073 0.066 0.060 0.054
2.000 0.089 0.084 0.074 0.068 0.062 0.056 0.049
2.400 0.073 0.069 0.060 0.056 0.052 0.049 0.044
2.800 0.062 0.060 0.055 0.050 0.046 0.042 0.039
3.000 0.057 0.055 0.050 0.046 0.043 0.040 0.037
The spectral acceleration values for periods greater than 3.0 seconds may be considered
same as that for 3.0 seconds.

Document No.
MANGALORE Rev. No.0
Page 3 of 3
NOTE :
1. Categorization of structures shall be as per IS 1893 (Part 4). Structures in Category 1

shall be designed for seismic forces calculated from maximum considered earthquake
MCE (which is twice the forces calculated from DBE). Structures in Category 2,3 and 4
shall be designed for seismic forces from DBE.
2. For methodology of calculation of seismic forces and other seismic design criteria, refer
latest revisions of the following codes:
IS 1893 (Part 1) : General provisions and buildings
IS 1893 (Part 4) : Industrial structures including stack-like structures
3. Values of R for elements not covered in IS 1893 may be taken same as in NEHRP1
provisions according to which R is 1.5, 2.5 and 3.5 for low, limited and high deformable
structures respectively. In general R=2.5 for boilers, furnaces and piping systems. For
flat bottomed, ground supported steel tanks or vessels which are mechanically
anchored, R may be taken as 3.0 and if the same kind of tanks are self anchored R may
be taken as 2.5.
4. Z/2 factor shall be considered as unity. In other words, zone factor shall not be
considered when using site specific spectra.
REFERENCES
1. NEHRP : National Earthquake Hazards Reduction Program - Recommended

provisions for seismic regulations for new buildings and other structures : Part 1 -
Provisions, Building Seismic Safety Council, FEMA 368, 2001, National Institute of
Building Sciences, Washington, DC

SECTION: 3.2
JOB SPECIFICATIONS
STRUCTURAL& ARCHITECTURAL 6782-380-16-48-JS-01 Rev.A
CAPTIVE POWER PLANT
C-3 JOB SPECS & DATA SHEETS
C-3.2 STRUCTURAL & ARCHITECTURAL
CAPTIVE POWER PLANT
OWNER : MANGALORE REFINERY AND PETROCHEMICALS

LTD.
JOB NO. : 6782
A 23-01-2007 ISSUED FOR BID PACKAGE

GANESH VGOEL MBL
Rev.
Date Purpose Prepared by Checked by Approved by
No

JOB SPECIFICATIONS
STRUCTURAL& ARCHITECTURAL 6782-380-16-48-JS-01-Rev. A
CAPTIVE POWER PLANT
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL - All rights reserved

JOB SPECIFICATIONS
CAPTIVE POWER PLANT
CONTENTS
1.0 GENERAL
2.0 REFERENCED STANDARDS AND PUBLICATIONS
3.0 DESIGN CRITERIA- GENERAL
4.0 DESIGN REQUIREMENTS FOR SPECIFIC APPLICATIONS
5.0 MATERIAL REQUIREMENTS
6.0 CONSTRUCTION REQUIREMENTS
ENCLOSURE – I FACTORS OF SAFETY FOR FOUNDATION DESIGN
ENCLOSURE – II SITE SPECIFIC SPECTRA FOR MANGALORE

JOB SPECIFICATIONS
CAPTIVE POWER PLANT
1.0 GENERAL
1.1 The design considerations given hereunder establish the minimum basic requirements
of reinforced cement concrete (RCC) structures, structural steel works and masonry
structures. All structures shall be designed for satisfactory performance and functions
for which the same are to be constructed.
a) All codes referred in this document pertain to BIS (Bureau of Indian Standards)
publications and bearing the prefix IS.
b) Whenever any reference to BIS code is made, the same shall be taken as the
latest revision (with all amendments issued there to) on the notified date of
submission of tender.
c) Apart from the BIS codes mentioned in particular in the various clauses of this
document, all other relevant codes related to the specific job under
consideration and/or referred to in the above-mentioned codes, shall be
followed wherever applicable. Reference to some of the codes in the various
clauses of this document does not limit or restrict the scope of applicability of
other relevant codes.
d) In case of any variation/contradiction between the provisions of BIS codes and

the requirements given hereunder, the provisions given in this document shall
have precedence over all others. In absence of relevant BIS codes, reference
to corresponding British/American codes may be made (in that order of
preference).
All designs, detailing and construction shall strictly conform to the enclosed
standards, specifications and ‘Specific Requirements’. Only if relevant
information is not available in this document, reference to relevant BIS code
shall be made.
1.2 The Contractor shall do the structural designing of all structures and prepare complete
set of civil and structural drawings needed for correct and accurate construction. The
design shall be strictly in accordance with ‘Design Criteria’ given herein.
1.3 Detailed list of drawings/documents [including design calculations, design drawings,

bar bending schedules (for RCC works) and fabrication drawings (for structural steel
works)] and structure-wise quantity statements (showing anticipated, released and
balance quantities of concrete, structural steel and piles) shall be prepared by the
Contractor and submitted monthly for review by Owner/Owner’s representative. This
list shall also indicate the document/drawing category (approval, review or information
as applicable) together with the scheduled and actual dates of submission of the
documents.
1.4 Before proceeding with design and drawing preparation the Contractor shall submit
detailed general philosophy of design of various parts of (all) the structures and
equipment foundations along with explanatory sketches for review by Owner/Owner’s
representative. Only after the review and incorporation of comments on the general
philosophy, as offered during the review, the Contractor shall submit any design
document and/or drawing for review or information or issue the same for construction.
Design and detailing of the structures and foundations shall fulfill all functional
requirements for which the same is intended and it shall be ensured that adequate
accesses, clearances, clearing of interferences, provision of cutouts, etc. have been
provided to make the structure/foundation fully operational.
JOB SPECIFICATIONS
CAPTIVE POWER PLANT
1.5 The design and AFC drawings shall strictly adhere to the reviewed design basis and
architectural/structural general arrangement and shall incorporate all the comments/
suggestions given by Owner/Owner’s representative without any extra cost to the
Owner and any implication of time-schedule for completion of works.
1.6 Construction of units/structures identified for design/drawing review (as referred in

Specific Requirements attached in this document) by Owner/owner’s representative
shall not be taken up at the site till these documents are reviewed by Owner/owner’s
representative and comments/suggestions given by Owner/owner’s representative are
incorporated. For all other foundations and structures the Contractor shall directly
submit the AFC drawings to Engineer-in-Charge and construction of such works shall
be taken up immediately. Requisite number of prints of design and drawings for such
foundations/ structures shall also be simultaneously sent to Owner/owner’s
representative for their information and record. In the event Owner/owner’s
representative offers any comment on documents/drawings of Information category it
shall be ensured by the Contractor that these comments are duly incorporated in the
documents/ drawings and revised set of document/drawing is issued to site for
construction and simultaneously to Owner/owner’s representative for records.
Wherever review is carried out the same shall be restricted to following:
a) Conformance of general arrangement of the structure to already reviewed

design philosophy and design basis.
b) Overall framing of the building/conceptual foundation system.
c) Detailed design and drawings including input/ output of computer analysis and
design vis-à-vis actual drawing.
Irrespective of the identified structures requiring review, the Contractor shall

submit complete sets of design and drawings of all structures/foundation
systems.
1.7 (i) Structural design/drawings for any structure/foundation shall be submitted for
review only if referenced input (e.g. architectural drawing, piping GAD,
equipment data sheet, vendor drawing, etc.) have been reviewed by the
concerned Owner’s specialist in approval/review code-2 or 1.
(ii) To facilitate an overall systematic review the Contractor shall submit the design
and drawings for each independent building/structure, together with a copy of
the referenced reviewed input data, in one lot.
1.8 Submission of all identified documents including design calculations and drawings for
review and/or information/record to the Owner/Owner’s representative by the
Contractor shall be in requisite (as mentioned elsewhere) number of prints. To ensure
accuracy, correctness and completeness of documents before submission to
Owner/Owner’s representative, the Contractor shall ensure that all such submitted
designs and drawings are complete in all respects, thoroughly checked, stamped
APPROVED FOR CONSTRUCTION (AFC), and signed APPROVED by the
Contractor's own responsible Civil/structural graduate (minimum) engineer (irrespective
of the fact that the same are prepared in the Contractor's own design office or by an
approved agency).

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Incomplete, unchecked, unsigned and unstamped documents/drawings and

designs shall not be accepted for review/construction and shall be returned
forthwith.
1.9 The accuracy/correctness of all designs and drawings shall be the sole responsibility of
the Contractor and any delay/loss/damage incurred by the Owner in respect of any
mistake/discrepancy/anomaly in such designs and drawings shall be entirely borne by
the Contractor.
1.10 Owner/Owner’s representative reserves the right to review any/all or none of the
designs and drawings. Review by Owner/Owner’s representative shall not relieve the
Contractor of his responsibility for correct design and execution of the works.
1.11 All revisions shall be clearly marked and clouded for easy identification. Subsequent
review of such revised documents shall be limited to revision as clouded.
1.12 All fabrication/erection drawings and bar bending schedules shall be prepared by the
Contractor and shall be directly issued for construction to his work site. Also, six copies
of such drawings together with design calculations for all splices, joints and gusset
plates shall simultaneously be submitted to Owner/owner’s representative at site
(Resident Construction Manager) for review. The Owner/owner’s representative at site
at his discretion may review all or some or none of these designs & drawings.
Wherever such review is carried out the same shall be restricted to the following:
a) Structural layouts, orientation, elevation of structural members.
b) Section/size of members.
c) Adequacy of few critical connections and joints for their required strength.
1.13 Internationally accepted commercial software viz. STAAD, STAADPRO, COSMOS, GT

STRUDEL, NISA only shall be permitted for analysis and design. STAAD shall not be
allowed for use in dynamic analysis of machine foundations.
In case software packages other than listed above are intended to be used for analysis
and design, the same shall be informed in writing to Owner/owner’s representative.
Calculations and relevant computer files containing input and detailed output (also
refer clause 1.14) shall be submitted by the Contractor for checking and validation of
the software package. Only after getting written approval from Owner/owner’s
representative, to this effect, such intended software be put to use for detailed analysis
and design.
1.14 Soft copies of all input files and the following documentation as hard copy shall be
submitted for computer aided analysis and design:
(i) Complete print out of input and output files.
(ii) Relevant sketches with node and member numbering, loading, etc.
(iii) Summary of member end forces, support reactions, stress ratio, deflections,
etc.
Reviewing of designs/drawings is not obligatory on the part of Owner/Owner’s

representative and complete correctness/soundness of the designs/drawings
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and their execution at the site shall be the sole responsibility of the Contractor
irrespective of the fact whether the same has been reviewed by Owner/Owner’s
representative or not. Any defect observed during construction or till the defect
liability period of works' shall be rectified and removed by the Contractor. The
Contractor shall carry out whatever modification or reconstruction is needed for
the purpose, to the entire satisfaction of the Engineer-in-Charge/Owner without
any extra cost and/or time implication to the Owner.

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2.0 REFERENCED STANDARDS & PUBLICATIONS
Sl. No. CODES
1. Code of practice for plain & reinforce concrete IS: 456

2. Code of practice for general construction in steel IS: 800
3. Code of practice for use of cold-formed light gauge steel
structural members in general building construction IS: 801
4. Code of practice for use of structural steel in overhead
transmission line towers IS: 802
5. Code of practice for use of steel tubes in general building
construction IS: 806
6. Covered electrodes for manual metal arc welding
of carbon and carbon manganese steel IS: 814
7. Code of practice for use of metal arc welding for general
construction IS: 816
8. Code of practice for design loads IS: 875
9. Code of practice for construction of stone masonry IS: 1597
10. Fillers for expansion joints IS: 1838
11. Criteria for earthquake resistant design of structures IS: 1893
12. Code of practice for structural use of unreinforced masonry IS: 1905
13. Recommended practice for hot dipped galvanizing on iron and
steel IS: 2629
14. Methods for testing uniformity of coating of zinc coated articles IS: 2633
15. Code of practice for design & construction of raft foundations IS: 2950
16. Code of practice for design & construction of machine foundations IS: 2974
17. Code of practice for concrete structures for storage of liquids IS: 3370
18. Code of practice for design and construction of foundation
for transmission line towers and poles IS: 4091
19. Code of practice for earthquake resistant design
and construction of buildings IS: 4326
20. Criteria for blast resistant design of structures for explosions
above ground IS: 4991
21 Criteria for design of RC bins IS: 4995
22. Criteria for design of RCC chimneys IS: 4998
23. Code of practice for anti-termite measures in buildings IS: 6313
24. Code of practice for design & construction of steel chimney IS: 6533
25. Method for determination of mass of zinc coating IS: 6745
26. Chlorpyrifos emulsifiable concentrates IS: 8944
27. Criteria for design of steel bins for storage of bulk materials IS: 9178
28. Recommendations for metal arc welding of carbon and carbon
manganese steel IS: 9595
29. Two parts polysulphide based sealants IS: 12118
30. Code of practice for ductile detailing of reinforced concrete structures
subjected to seismic forces IS: 13920
31. Fire Proofing in Oil and Gas Industry
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(A publication of Oil Industry Safety Directorate) OISD-STD-164

32. Code of practice for Design and construction of Pile foundations IS: 2911
33. Code of practice for structural safety of buildings - Shallow
foundations IS: 1904
34. Code of practice for determination of bearing capacity
of shallow foundations IS:6403
35. Code of practice for calculation of settlements of
foundations IS: 8009(Pt I, II)
36. Determination of dynamic properties of soil IS: 5249
37. Process Control Room Safety OISD-STD-163
38. Code of practice for cement and colored paints IS:5410
Note The above list is suggestive and not exhaustive. Apart from these basic codes any
other code referred-to in this document and/or any other related code shall also be
followed wherever required.

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3.0 DESIGN CRITERIA - GENERAL
Pipe racks, technological structures1, compressor sheds and other shed-type

structures shall completely be of steel construction. All other buildings shall be of RCC
(frame-type) construction.
All structures shall be checked and designed to satisfy the worst load combination
(refer IS:875) that produces maximum forces and effects and consequently maximum
stresses. Wind and earthquake (or blast) loads shall not be considered to act
simultaneously.
The design and detailing of all structures, whether concrete or steel, shall suffice a
minimum fire rating of greater of 2 (two) hours or as specified by licensor. Norms as
defined in OISD-STD-164 and IS: 456 shall be strictly adhered to for structural steel
and concrete works, respectively.
3.1 DESIGN LOADS
3.1.1 These loadings shall be applicable to all structures irrespective of the material
employed for construction.
a. Dead Loads
The weight of all permanent construction including walls, fire proofing, floors, roofs,
partitions, stairways and fixed service.
b. Equipment Loads
The empty weight of process equipment including all fixtures, platforms, ladders
and attached piping but excluding contents shall be considered. If piping weight is
not indicated separately or included in the weight of the equipment, the same shall
be taken as 10% of the weight of the equipment.
c. Live Loads
Live loads shall, in general, be as per IS: 875. However, the following minimum live
loads shall be considered in the design of structures:
i. Process Building/Technological Structure
Operating area - 5.0 kN/m2

Maintenance area - 7.5 kN/m2
ii. Compressor House/TG house
Operating area - 7.5 kN/m2

Maintenance area - 7.5 kN/m2
iii. Service Platform
Vessel/Tower - 3.0 kN/m2

Isolated platform - 2.5 kN/m2
1 Uncladded-open type structure housing process equipments.

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(for valve operation)

Access way - 2.5 kN/m2
Cross over - 2.0 kN/m2
iv. Substation/Control Room
Panel floor - 10.0 kN/m2

Unknown partition2 - 1.0 kN/m2
v. Office building
Office area - 3.0 kN/m2

Lobby - 5.0 kN/m2
Exit way - 5.0 kN/m2
Unknown partition - 1.0 kN/ m2
vi. Laboratory
Upper floors - 4.0 kN/ m2
vii. Cooling Tower
Operating platform/
Hot water basin cover slab - 3.0 kN/m2
viii. Staircase
Process Building/
Technological Structure - 5.0 kN/m2
Office - 5.0 kN/m2
Substation/Control Room - 3.0 kN/m2
Laboratory - 3.0 kN/m2
Service platform - 2.5 kN/m2
ix. Walkway
Gantry girder - 3.0 kN/m2
In absence of any suitable provision for live loads for any particular type of floor or
structure as given above (or in BIS Codes), the assumed loading shall be got
approved by the Owner/owner representative.
Live load on various types of roofs shall be as per the requirements given in IS:875.
d. Operating Loads
Operating loads shall include maximum design loads sustained by the equipments
during plant operation.
2 For definition of unknown partitions refer clause 3.1.2 of IS: 875 (Part 2).
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e. Wind Loads
Wind loads shall generally be as per IS:875 except for switch yard structures &
transmission towers for which IS:802 shall be applicable.
The basic wind speed of the site is taken as 39 m/s.
Values of coefficients k1, k2, k3 shall be as:

k1= 1.0 .for permanent structures and 0.73 for Temporary Facilities.
k3 = 1.0 .
k2 = shall be taken ( as IS : 875 ) for relevant class of structure with Category-2 terrain
with respect to the actual height of the structure.
The design life span of all structures (units & offsite) shall be taken as 50 years.
Temporary structures shall be designed for a design life span of 25 years. Design
life span for boundary wall/barricading structures shall be 5 years.
To account for surface area of piping, platforms and other attachments fixed to the
equipment the surface area of the equipment (vessel/column) exposed to wind
shall be increased by 20% or as specified in the mechanical data sheet of the
equipment.
f. Seismic Loads
Seismic forces shall be as per site specific spectra for Mangalore document no.
6782-9-25-54-DB-01.
g. Impact & Vibratory Loads
Structures subjected to impact or vibratory loads shall be designed as per the

provisions of IS:875 & IS:2974. Requirements for overhead cranes and monorails
shall be as per IS:800.
h. Blast Forces
All structures subjected to blast forces generated due to accidental blasts from
hydrocarbon ignitions shall be designed to withstand a minimum pressure of 3psi.
i. Bundle Pull
Bundle Pull for different types of Exchanger shall be taken as under:
Fixed type - Nil

Kettle type - 0.30 x Bundle weight
All other types - 0.86 x Bundle weight or 30N/mm of diameter
whichever is greater
Total Bundle Pull shall be considered on fixed pedestal alone.

Monorails for exchangers (in Technological Structures) shall be designed for the
weight of the Bundle PLUS 7.0MT (7.0MT being the weight of EXTRACTOR)
j. Soil and Hydrostatic Pressure
Pressure on basement walls - In the design of basement walls or similar

(approximately vertical) structures below grade, provision shall be made for
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resisting lateral pressure of the adjacent soil. If a portion or whole of the adjacent
soil is below free water surface, pressure computations shall be based on the
diminished weight of the soil (due to buoyancy) plus full hydrostatic pressure. Due
allowance shall also be made for possible surcharges from fixed or moving loads.
Uplift on Floors - In the design of basement floors and similar (approximately

horizontal) constructions below grade, the upward pressure of water shall be taken
as full hydrostatic pressure applied over the entire plan area. The hydrostatic head
shall be measured from the underside of construction. The downward load due to
over burdens shall be calculated only for the volume over projected plan area (i.e.,
the volume of overburden beyond projected plan area shall not be considered).
Factors of safety against uplift shall be 1.2.
k. Other Loads
Apart from the specified live loads, any other equipment load or possible
overloading during construction/hydro-test/ maintenance/erection shall also be
considered in the design. Under hydro test condition the wind force shall be taken
as 25% of normal loading.
Design of all structures shall also consider any other relevant and consequential
load/stress imparted to the structure.
All liquid retaining/storage structures shall be designed assuming liquid upto the full
height of wall irrespective of provision of any over flow arrangement. Pressure relief
valves or similar pressure relieving devices shall not be made in underground water
retaining/storage RCC structures. Hot water basin in Cooling tower shall be
designed for the weight of water upto top of parapet wall.
All buildings/structures shall be designed to resist the worst combination of the

above loads.
3.2 SOIL INFORMATION FOR FOUNDATION DESIGN
For soil information reference shall be made to the Geo-technical data.
Type of cement, grade of concrete, minimum cement content and maximum water
cement ratio (for concrete), minimum cover to reinforcing steel to be used in
foundations and substructures and any other remedial actions required for foundations
due to aggressiveness of sub soil/water shall be as per the Geo-technical data.
3.3 ANTI-TERMITE TREATMENT
No anti-termite treatment shall be provided inside the unit areas.
Offsite and utility buildings shall be provided with anti-termite treatment as per IS: 8944
and IS: 6313.
3.4 FOUNDATIONS
3.4.1 NGL (Natural ground level) and FGL (Finished ground level) shall be marked on all
drawings showing foundation/sub-structure details and related design documents.
3.4.2 Machine/static equipment foundations shall be separated from adjoining parts of

buildings, other foundations and floor/pavement slabs. Joints at floor/pavement slabs
shall be suitably sealed.
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3.4.3 Foundations and structures for machines subject to vibrations shall be so proportioned
that the amplitude and frequency of the foundation/structure are within the permissible
limits as per relevant BIS codes (or as required by the machine vendor).
3.4.4 Machine foundations shall be designed and detailed as per IS: 2974. All appendages
to such foundations shall be reinforced suitably to ensure integral action.
3.4.5 Safe bearing pressure (allowable net safe bearing capacity) shall be based on the
following minimum criteria under Dead Load + Live Load (or with Operating) condition:
- Foundations in unit areas, utility areas

and foundations for Plant buildings. 25mm settlement.
- Non Plant buildings. 40mm settlement.
- Raft Foundations 40mm settlement
- Foundations for Storage Tanks:
a) Cone/Dome roof tanks. 300mm edge settlement.

b) Floating roof tanks. 150mm edge settlement
For transient loadings viz. with wind/seismic loads, settlement shall not be the
criteria and safe bearing capacity based on shear criteria shall be considered.
3.4.6 Structures supported on RCC strip footings shall be provided with suitable tie beams
connecting all footings at foundation level. Minimum width of footing shall be 1000 mm.
3.4.7 Raft foundations shall be designed as per IS: 2950.
3.4.8 Masonry walls shall be supported on continuous plain cement concrete mats/plinth
beams. Top of plinth beams shall be located minimum 300mm below the finished
grade level. Fouling of plinth beams with cable trenches, drains, pipe ducts, service
lines etc. shall not be acceptable.
3.4.9 Factors of safety for the design of foundations shall be as per Enclosure-I of this
document.
3.4.10 For the design of foundations for vertical vessels and process columns under hydro
test condition minimum 25% wind load shall be considered acting on the equipment.
3.4.11 Minimum depth of foundation for all structures shall be as per Geo-technical data.
Depth of ground water level shall be as per the Geo-technical data and hydrostatic
pressure shall be adequately accounted for in the design.

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3.5 FLOORING DETAILS FOR BUILDINGS
TABLE-1 FLOORING DETAIL
SNo DESCRIPTION FLOORING TYPE
I II III
1(a) Sub Earthfill base

Grade compacted to 95% dry
density.
1(b) Compacted layer of 200 THICK 200 THICK 150 THICK
boulder soling over
thoroughly compacted
Earth fill (in mm)
2(a) Strl Lean concrete 1:5:10 50 THICK 50THICK 50THICK
Grade over sand layer (in mm)
Slab
Strl non suspended slab 150 THICK 150 THICK 100 THICK
in M20 Grade concrete
(Reinforced with 8mm
dia bars @200 c/c both
ways) over lean
concrete.
2(b) R/F placed R/F placed in No reinforcement
centrally two layers at required.
top & bottom
3 Finish Floor finish As/Architectural As/Architectural As/ArchitecturalDetail
Detail Detail
Type I: Plant Buildings such as Sub-Stations, Control Rooms, Pump Houses,

Utility Compressor Houses, Parking Areas, Stores, Porches.
Type II: Ware Houses, Workshops, Cement Godowns, Fire Stations, Process
Compressor Houses.
Type III: Non Plant Buildings (viz. Administration, Laboratory, Canteen, Time
Office, Gate House, Training Centre, Guest House, Residential
buildings).

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3.6 SPECIAL CONSIDERATIONS FOR REINFORCED CONCRETE STRUCTURES
3.6.1 General
a) All buildings, structures, foundations, machine/equipment foundations, liquid

retaining/storage structures, pipe/cable trenches, pits etc. shall be designed
based on referenced BIS Codes in general and other relevant BIS Codes as
applicable. It shall be ensured that the skin temperature of concrete at no time
exceeds 800 C.
b) All concrete structures exposed to atmosphere (including fireproofed

surfaces) shall be painted with anti fungal paint.
c) Minimum cement content and the maximum water-cement ratio for concrete in
super structure shall be as given in Table-2.
TABLE-2 MINIMUM CEMENT CONTENT AND MAXIMUM WATERCEMENT RATIO FOR

DURABILITY
Exposure Plain concrete Reinforced concrete Remarks
condition
severe Grade of Minimum Maximum Grade of Minimum Maximum
Concrete cement free water- Concrete cement free water-
content cement content cement
(kg/m3) ratio (kg/m3) ratio
M20 250 0.5 M30 350 0.45
The requirement of grade of concrete, type of cement, minimum cement

content and maximum water-cement ratio for concrete to be used in piles shall
be as per the requirements given in Geo-technical data attached.
Note : Generally the use of one of the following cements shall be considered :
i) Grade 53 & Grade 43 ordinary Portland Cement conforming to IS 12269 & IS

8112
ii) Sulphate Resistance Cement As per IS 12330 shall be used only for Sulphur pit
and Sulphur yard of Sulphur unit, or any other area.
d) All structures shall be of frame-type construction. Detailing shall be as per

provisions of IS: 13920.
e) Unless otherwise specified elsewhere in this document only Limit state method
as per IS: 456 shall be followed in the design.
f) All machine/equipment foundations, cable/pipe trenches shall be of RCC

construction only. Cable/pipe trenches shall be suitably sloped and adequate
provision shall be made for draining out of accumulated water.
g) Cable and pipe trenches shall be provided with precast (300mm wide) covers,
adequately designed for the anticipated traffic movement (Cranes/Hydra etc.).
Trenches of different category of loading shall be clearly identified for design.
The covers shall, however, be designed for a minimum uniformly distributed

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load of 2.0T/m. The walls of cable trenches shall be designed to resist a

minimum surcharge load of 1.0 T/m².
h) High strength deformed (HSD) TMT steel bars of minimum grade Fe 415,
conforming to IS:1786 shall be used.
i) Foundations placed at varied depths shall be designed considering bearing

capacity at that particular level with due consideration of an uplift/subsoil water
table.
j) Minimum embedment of piles in pile caps shall be 100mm.
k) If the specified design depth of ground water table so warrants all underground
pits, tunnels, basements, cable trenches etc. shall be provided with leak-proof
treatment.
l) Intermixing of different grades of concrete in the same structure/structural

element (excepting columns, walls, etc. with element extending in sub and
super structure both) shall not be accepted.
m) Intermixing of different grades of steel (main reinforcement) in the same

structure shall not be accepted.
n) RCC pits, tanks etc. for storage of corrosive liquids shall be provided with
suitable anticorrosive treatment.
o) All liquid retaining/storage RCC structures shall be leak-proof and designed as

uncracked section as per IS: 3370 and shall be designed assuming liquid up to
the full height of the wall irrespective of provision of any over flow arrangement.
Parts of such structures not coming in contact with liquid may be designed in
conformance to IS: 456 except ribs of beams of suspended floor slabs &
counter forts of walls (located on the side remote from the liquid) and the roof
which shall be designed as uncracked section. No increase in permissible
stresses in concrete and reinforcement shall be allowed under wind or seismic
conditions for such structures.
p) PVC water bars (230mm wide, 5mm thick) shall be provided at each
construction joint of all liquid retaining structures. Water bars shall be
embedded in the concrete as per manufacturers’ recommendations. All pipes
embedded in concrete elements shall be provided with welded puddle flange
with 8mm thick plate and diameter as “pipe dia + 200mm”. Pipes shall be
placed in position prior to concreting. The sequence of construction shall be
clearly shown on the drawing.
q) The walls and slabs of liquid retaining/storage structures shall be provided with
reinforcement on both faces.
r) Provision of pressure relief valves or similar pressure relieving devices shall not
be permitted in underground liquid retaining/storage RCC structures.
s) Primary framing members and/or any other member which remains constantly
in contact with water or enclosed water vapour shall be designed as uncracked
section.

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t) RCC storage/process tanks located above floor or roof shall not rest directly on
slab/beam but shall have independent supporting structures which in turn shall
rest on (primary or secondary) beams and/or columns.
u) Liquid storage structures shall be tested for its water-tightness/leak-proofness

as detailed hereunder:
i) The structure shall be tested strictly in accordance with IS: 3370 for
water-tightness. The total drop in water surface level shall not exceed
6mm in 24 hours in case of covered reservoirs and 12mm in 24 hours in
case of open reservoirs.
ii) If the test proves structure to be defective the same shall be repaired.
The repaired structure shall again be tested as stated above. If the
structure is still found unsatisfactory it shall be dismantled and rebuilt.
iii) Testing after construction and remedial treatments shall conform to

provisions of IS: 6494.
v) Backfilling around underground liquid storage structures shall be allowed only

after successful hydro-testing and when so certified by the Owner/Owner’s
representative’s at site.
3.6.2 Minimum Cover to Main Reinforcement
Clear cover shall be considered over links / stirrups, unless otherwise specified the
minimum clear cover provided to super structures for R.C.C. works for slab and beam
shall be 30 mm. For column and pedestals the minimum cover from longitudinal
reinforcement shall be 40 mm. The clear cover for foundations and substructures shall
be greater of as recommend in IS : 456 (latest ) or required as per the geo-technical
recommendations. Clear cover for liquid-retaining structures shall be minimum 30 mm
or as required as per the geo-technical recommendations.
3.6.3 Minimum Thickness of Structural Concrete Elements
The following minimum thickness shall be followed:
- Footings (All types I With without beams) 300mm

(Note: Tapered footings shall not have thickness less than
150mm at the edges. Minimum average thickness shall
not be less than 300mm)
- Slab thickness in Raft foundations

with beam & slab construction 150mm
- Pile Cap 500mm
- Basement
- A) Wall 150mm
- B ) Base Slab With Beams 200mm
- C ) Base slab without Beams 300mm
- Floor/Roof Slab, Walkway, Canopy Slab 150mm

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- Cable/Pipe Trench/Launder Walls & Base Slab 125mm
- Parapet 100mm
- Louvres / Fin. 100mm
- Pre-cast Trench Cover/Floor Slab
- Louvre ( in contact with liquid ) 125mm
Liquid Retaning / Leak Proof Structure

A) Walls 150mm
B) Base slab with beams 200mm
C) Base slab without beams 300mm
- Underground Pit
- A) walls 150mm
- B) Base Slab with beams 200mm
- C) Base slab without beams 300mm
3.6.4 Minimum Cover to Foundation Bolts
Minimum distance from the centerline of foundation/anchor bolt to edge of pedestal

shall be the maximum of the following:
i) Clear distance from the edge of the base plate/base frame to the outer edge
of the pedestal shall be minimum 50mm.
ii) Clear distance from the face of pocket to the outer edge of the pedestal shall be
75mm.
iii) Clear distance from the edge of the sleeve or anchor plate to the edge of
pedestal shall be 75mm.
3.6.5 Minimum Height of Pedestals
The minimum projection of outdoor/indoor pedestals supporting equipment/structures

shall be 300mm and 150mm respectively above the high point of pavement/finished
grade level/finished floor level, whichever is higher. The maximum projection of
pedestals for staircase/ladder shall be 200mm.
3.6.6 Concrete Mix
a) Reinforced Cement Concrete (RCC)
Unless otherwise noted, reinforced concrete conforming to IS: 456 shall be used
using 20mm and down size graded crushed stone aggregate.

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b) Lean Concrete
Mud mat of minimum 75mm thickness of lean concrete mix 1:5:10 (by weight, using
40mm and down size grade crushed stone aggregate) shall be provided under all
RCC foundations except under base slabs of liquid retaining structures for which
the mix shall be 1:3:6 (by weight) and minimum thickness of mud mat shall be
100mm. Mud mat shall extend 75mm on all sides beyond the edges of base slabs
in case of liquid retaining/storage structures and 50mm in case of other
foundations. The exposed surface of mud mat layer in case of liquid
retaining/storage structure shall be finished smooth.
Lean concrete of grade1:5:10 (by weight) shall be used as filler material wherever
loose sub grade exists by removing the loose soil/fill.
c) Plain Cement Concrete (PCC)
Plain cement concrete mud mat of grade M20 (by weight) of minimum 150mm
thickness (using 40mm and down size graded crushed stone aggregate) shall be
provided under all masonry wall foundations.
Plain cement concrete of grade M 20 (by weight) of minimum 40mm thickness

(using 10mm & down size graded aggregates) shall be provided as damp proof
course at plinth level of all masonry walls.
Making-up of levels for placing the foundation at a shallower depth from the
NGL/FGL (from that as specified in the Geo-technical recommendations) by
means of filling of lean concrete is not acceptable.
3.6.7 Grouting & Minimum Grout Thickness
The minimum thickness of grout shall be 25 mm.
All anchor bolt sleeves/pockets and spaces under column bases, shoe plates etc. shall
be grouted with free flow, non-shrink (premix type) grout with 28-day minimum cube
crushing strength of 40N/mm2. Ordinary cement sand (1:2) grout shall only be used
under the base plates of crossover, short pipe supports (not exceeding 1.5 m height)
and small operating platforms (not exceeding 2.0m in height) not supporting any
equipment.
3.6.8 Movement Joints
Expansion and/or separation joints in non-suspended ground floor slab shall be filled
with sand for the full depth of slab except the top 12mm which shall be filled up with
approved two part liquid polysulphide sealing compound conforming to IS: 12118.
Joints in basement slabs shall be made leak proof by providing PVC water stops.
Joints in the super-structure shall be provided by means of gap between two

consecutive structural members. The gap shall be based on the design requirements
and shall be treated to a minimum as under:
a) When the vibrating equipment is separately supported on a structure, a clear air

gap shall be provided between the vibrating equipment supporting structure
and the surrounding floor with provision of suitable moulding/kerb to stop any
leakage/overflow of any floor wash to the next lower floor.

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b) In normal floors, expansion and/or separation joints shall be covered both on

top and bottom with 3mm thick Aluminium sheet fixed on both sides of the joint
with brass screws. Provision of movement on one side shall be kept with proper
slotted holes. Similar cover plates shall be provided for all exterior columns on
both interior and exterior faces. The edges of these plates shall be properly
chamfered. Bitumen impregnated fibre board (as per IS:1838) shall be used
between the gap of the two members on either side of the joint for the full depth
in such movement joints. The top 12mm depth shall be filled up with two part
liquid polysulphide sealing compound (as per IS:12118).
c) For all liquid retaining structures expansion joints shall be filled up with non-
absorbent compressible sheet/bitumen impregnated fibre board (as per
IS:1838) except the top 12mm depth on the water faces which shall be filled
with two part liquid polysulphide sealant (as per IS:12118). In case of
contraction and/or construction joints, such polysulphide sealant shall be used
for 12mm depth on the water faces after forming suitable grooves in concrete.
PVC water bars 230x5mm thick shall be invariably used at suitable location in
all types of joints in liquid retaining structures.
3.7 SPECIAL CONSIDERATIONS FOR STEEL STRUCTURES
3.7.1 General
Structural steel work shall include the following structures in general, but not limited to:
- Steel buildings/open structures

- Guide structures (for stacks, towers/columns)
- Platforms & walkways
- Ladders, staircases & hand railing
- Pipe racks/pipe supports/cable racks
- Crane gantry girders & monorails
- Switch yard structures
Design, fabrication and erection of the above works shall be carried out in accordance
with the referenced BIS Codes in general and other relevant BIS codes as applicable
to the specific structure.
Basic consideration of structural frame work shall primarily be stability, ease of
fabrication/erection and overall economy satisfying relevant Indian Standard Codes of
Practice. Simple and fully rigid design as per IS:800 shall be used. Where fully rigid
joints are adopted they shall generally be confined to the major axis of the column
member.
Structural elements continuously exposed to temperatures above 2000 C shall be
designed for reduced stress as per Table 4 of IS:6533 (Part 2). The expected
temperature of steel components shall not be allowed to exceed 4000 C.
Where required by OISD-STD-164 and UL-1709 norms structural steel members shall
be fire-proofed by Vermiculite based material. Vermiculite thickness shall be 28mm
generally, however it shall suitable for 2 hours fire rating with maximum temperature of
steel as 550° C.
Crane gantry girders shall generally be of welded construction and of single span
length. Chequered plate shall be used for gantry girder walkway flooring.

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Steel staircases shall have channels provided as stringers with minimum clear width of
750mm and slope of 41 degree. The vertical height between successive landings shall
not be less than 2.6 m nor exceed 4.0 metres. Treads shall be minimum 230mm wide
made of grating (with suitable nosing) spaced equally so as to restrict the rise to
maximum 200mm.
Handrails, 1000mm high, shall be provided to all walkways, platforms, staircases. Toe
plate (100mmx5mm) shall be provided for all handrailing (except for staircases).
Spacing of uprights shall be 1500mm (maximum). Two types of handrailing shall be
provided.
a) For walkways, platforms (except platform around circular vessels), staircases:

Top rail, mid-rail and upright shall be 32mm dia (NB) MS tubes.
b) For platforms around circular vessels: Top rail shall be 32mm dia (NB) MS
tubes but mid-rail and upright shall be of structural steel.
Electro-forged hot dipped galvanized welded MS Gratings shall be minimum 25mm

deep. The maximum size of voids in the grating shall be limited to 30mm x 55mm.The
minimum thickness of galvanizing shall be 120 microns.
Welded connections shall be adopted as far as practicable except for cases where
bolted connections are required viz. (Galvanized) electrical switchyard structures and
transmission towers. Structural connections shall have minimum two bolts of 16mm
dia. unless otherwise limited by the size of members.
Minimum two nuts shall be used for all anchor bolts.
3.7.2 Steel Grade
Structural steel shall be of yield stress of 250 MPa conforming to grade A of IS:2062.
Tubular steel shall conform to Yst 240 of IS:1161.
3.7.3 Permissible Stresses
- Permissible stresses in structural members shall be as specified in:
IS: 800 Hot rolled sections (excluding switchyard structures).

IS: 801 Cold formed light gauge sections
IS: 802 Switchyard structures
IS: 806 Tubular structures
- Permissible stresses in bolts shall be as specified in:
IS: 800 Hot rolled sections

IS: 801 Cold formed light gauge sections.
IS: 802 Switchyard structures.
- Permissible stresses in welds shall be as specified in:
IS: 801 Cold formed light gauge sections.

IS: 816 Hot rolled sections

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- Structural elements continuously exposed to temperatures above 200ºC shall be

designed for reduced stress as per Table-4 of IS:6533 (Part 2). The expected
temperature of steel components shall not be allowed to exceed 400ºC.
3.7.4 Limiting Deflection
a) The limiting permissible vertical deflection for structural steel members shall be as
specified below:
- Gantry girder for electric overhead crane

(Capacity upto 50T) : L/750
- Gantry girder for electric over head crane

(Capacity over 50T) : L/1000
- Gantry girder for manually operated crane : L/500
- Girder/beam for supporting dynamic equipment/hoist : L/450
- Grating/Chequered plate : L/200 or 6mm

whichever is
minimum.
- Purlins supporting any type of roofing
material under (dead load+live load)
or (dead load+wind load) conditions : L/200
- Other structures/structural components : As specified in

relevant BIS
Codes
Where 'L' represents the span.
b) The limiting permissible horizontal deflection for multi storeyed steel

structure/building shall be Height/325.
c) The limiting permissible horizontal deflection for structures supporting two-phase

fluid flow piping shall be limited to 25mm or H/325 (H is the height of support above
the pedestal top), which ever is lower.
3.7.5 Design Criteria
i) Basic consideration of structural frame work shall primarily be stability satisfying

relevant Indian Standard Codes of Practice and specifications given herein.
Simple and fully rigid design as per IS:800 shall be used. Where fully rigid joints
are adopted they shall be confined to the major axis of the column member.
ii) Where required by OISD-STD-164 norms structural steel members shall be

fireproofed. All such structural steel members shall be provided with one coat of
primer compatible with fire proofing material.
iii) Crane gantry girders shall be of welded construction and of single span length.
Splicing in the girder shall not be permitted. Chequered plate shall be used for
gantry girder walkway flooring.

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iv) All steel staircases shall have channels (minimum size MC150) provided as
stringers with minimum clear width of 750mm and slope of 41 degrees. The
vertical height between successive landings shall not exceed 4.0 metres.
Treads shall be minimum 230mm wide made of grating (with suitable nosing)
spaced equally so as to restrict the rise to maximum 200mm.
v) Ladders shall be provided with safety cages when the top of the ladder is more
than 4.5m above the landing level. Safety cages shall start 2.5 metres above
the lower landing level. Ladders shall be of 450mm clear width with 20mm
diameter MS rungs spaced at 300mm (maximum). Ladders shall preferably be
placed vertical. In no case shall the angle with the vertical exceed five degrees
(bottom of the ladder to be farther from the top to provide a positive slope).
vi) Hand rails, 1000mm high, shall be provided to all walkways, platforms,
staircases. Toe plate (100mmx5mm) shall be provided for all hand railing
(except for staircases). Spacing of uprights shall be 1500mm (maximum). Two
types of hand railing shall be provided.
a) For walkways, platforms (except platform supported on vessels),

staircases:
Top rail, mid rail and upright shall be 32 (M) NB galvanized MS tubes.
b) For platforms supported on vessels:
Top rail shall be 32 (M) NB galvanized MS tubes but mid rail (flat 50x6)
and upright (angle 50x50x6) shall be of structural steel.
vii) Floor gratings shall be fabricated from mild steel and shall be minimum 25mm
thick. These shall either conform to type-II or III (based on application) of EIL
standard 7-68-0561 or could be made from electro-forging process. If EIL
standard is not adopted, the maximum size of voids in the grating shall be
limited to 30x55mm. Deflection shall not be more than 6mm or span/200, which
ever is lower. Floor gratings shall be hot dip galvanised in accordance with
IS:2629 and tested as per IS:2633 and IS:6745. Quantity of zinc coating shall
2
be minimum 900 g/m of surface area (0.12mm uniform thickness).
It shall be mandatory that a prototype of the grating fulfilling the following is

demonstrated satisfactorily to the Owner/owner’s site representative prior to
placement of bulk order(s):
a) above defined requirements.
b) for gratings manufactured using electro-forging process, the unfused

joints are not in excess of 5% of the total joints. If unfused joints found
are in excess of 5%, the prototype shall stand rejected and a fresh
prototype shall be prepared with revised welding parameters clearing the
requirement of unfused joints limited to 5% of the total joints.
c) the projection of secondary member above the main member is not more
than 1.5mm.
d) the unfused 5% joints of b) above are welded by SMAW/GMAW process.

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e) the joints are able to sustain a minimum pull out load of 1.2 times the
allowable shear capacity of the secondary member.
f) gratings made by electro-forge process shall be subjected to a third party

inspection as per Owner/owner’s representative approval.
viii) Unless otherwise permitted in writing by Owner/owner’s representative only

welded connections shall be adopted. All permanent and erection connections
shall have at least two 20mm diameter and 16mm diameter bolts respectively.
ix) All connections shall be designed for full moment carrying capacity of the
connecting members together with 60% full shear carrying capacity for sections
with depth 200mm and above and 50% full shear carrying capacity for sections
with depth less than 200mm or for the actual design forces, whichever is more.
x) All fabricated structures (except electrical switchyard structures and

transmission towers) shall be given one shop coat of primer compatible with the
final paint system. The paint system shall conform to the painting specification.
xi) Minimum two nuts shall be used for all anchor bolts.
xii) Gusset plates of different thicknesses shall not be used in the same truss or
girders. Gusset plates for all bracing shall be of same thickness as that used for
truss/girders unless a higher thickness is required by design.
xiii) If so required by piping support detail, minimum 20mm diameter plain round MS
rod shall be welded on the top flange for full length on all transverse beams and
at locations where pipes are supported on longitudinal beams of pipe racks,
pipe supporting structural members.
3.7.6 Minimum Thickness
3.7.6.1 The minimum thickness of various structural components (Hot rolled sections) shall be
as given:
a) General Construction
Trusses, purlins, side girts & bracings 6mm
Columns, beams 7mm
Gussets in trusses & girders
i) Upto and including 12m span 8mm
ii) Above 12m span 10mm
Stiffeners 8mm
Base plates 10mm
Chequered plate 6mm (on plain)
Grating 3mm
Insert plates 12mm

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The minimum thickness of structural components (except gratings & chequered

plates), which are directly exposed to weather and inaccessible for repainting,
shall be 8mm.
b) Switchyard Structures
The minimum thickness of various structural components shall be as per

IS:802.
Note: The minimum thickness for rolled beams and channels shall be the mean
flange thickness regardless of the web thickness.
3.7.6.2 The minimum thickness of tubes shall be as specified in IS:806.
3.7.6.3 Structural members exposed to marked corrosive action shall be increased in

thickness or otherwise suitably protected against corrosion.
3.7.7 Electrical Switch yard Structures
3.7.7.1 All electrical switch yard structures shall be of structural steel and designed on the
basis of IS:802. All structural connections shall be with bolts.
3.7.7.2 Structural steel members including bolts, nuts and washers shall be hot dip galvanized
in accordance with relevant BIS Codes. The zinc coating on tower members shall not
2
be less than 900g/m of the surface area.
3.8 SPECIAL CONSIDERATIONS FOR MASONRY WORKS
3.8.1 General
All masonry works shall be designed in accordance with the latest revision of
referenced BIS Codes in general and other relevant IS codes as applicable to the
specific structure.
3.8.2 Cement Mortar
All masonry work shall be constructed in cement sand mortar 1:5 for load bearing walls
and 1:6 cement sand mortar for non-load bearing walls except half brick partition walls
which shall be constructed in 1:4 cement sand mortar with two numbers of 6mm
diameter MS bars provided at every fourth course properly anchored with cross walls
or pillars.
3.8.3 Fire Walls
All masonry fire walls shall be of minimum 345mm thickness.
4.0 DESIGN REQUIREMENTS FOR SPECIFIC APPLICATIONS
4.1 PIPE RACK
For designing the pipe rack superstructure and foundation the following loads shall be
considered.

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Vertical Loading
At each tier a uniformly distributed load (udl) shall be placed. The magnitude of this udl
per unit length of the span shall be calculated as per the gross actual loading from
pipes at that tier level, including the actual weight of empty pipe, the weight of content
and insulation, if any, divided by the actual extent of the span covered by these pipes.
3
A minimum density as 2600N/m shall be considered for insulation. The material
content shall be taken as one-third volume of pipe filled with water for gas/steam
2
carrying pipes. The minimum loading for any tier shall not be less than 1.25kN/m . If
2
the calculated loading is higher than 1.25kN/m , this shall be rounded off to the next
2
higher multiple of 0.25 (ie 1.50, 1.75, 2.0kN/m ). This udl shall be assumed to be
spread over the entire span.
Vertical loads of flare pipes shall be taken as one-third full of water for Process Unit
piping and one-sixth full for Off site piping.
Friction Force (Longitudinal & Transverse)
Where the pipes are of similar diameter and service conditions, the friction force at
each tier on every portal both in longitudinal and transverse directions shall be 10% of
the design vertical loading of the pipes for four or more pipes supported on a tier, and
30% of the design vertical loading of the pipes for single to three pipes supported on a
tier. Longitudinal friction force shall be considered as uniformly distributed over the
entire span of the beam at each tier and transverse friction force shall be considered
as a concentrated load at each tier level. Friction force on T-supports and trestles shall
be taken as 30% of the vertical loading in longitudinal direction and 10% of vertical
loading in transverse direction, both acting simultaneously, and/or vice versa.
For two-phase fluid flow/transfer lines the frictional force shall be minimum 50% of the
weight of pipe including contents and insulation, acting simultaneously in transverse
and longitudinal directions.
Anchor and Guide Force (Thermal load)
a) Longitudinal → As per piping inputs

b) Transverse → As per piping inputs
Live Load
Live loads on pipe rack platforms are imposed loads such as personnel loads, tools
and tackles loads etc. Live loads on pipe rack platforms shall be 300 Kg/m2.
Wind Force
Transverse wind loading shall be calculated depending on the width of the Pipe Rack
as follows:
a) Basic wind pressure shall be considered as per IS: 875.
b) To calculate wind load in transverse direction of piperack, a projected height of

1.25m/1.5m/2.0m shall be considered on all tiers irrespective of height between two
tiers of rack widths of 4m/6m/8m and 10m respectively. For piperacks of widths
greater than 10m, the above projected height shall be taken as 0.8[diameter of
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largest pipe including insulation (m)] + tan 10°[width of rack (m)]. However, this
shall not exceed the height between consecutive tiers.
c) For flare header or any other line supported on extended leg of piperack, the wind
force shall be considered separately.
Loading on Longitudinal Beams
Unless otherwise required from pipe support loadings, the longitudinal beams
connecting portal columns shall be sufficiently strong to sustain a minimum of 25% of
the load on transverse beams. This total load shall be placed as two equal
concentrated loads acting at 1/3 rd span. This load shall be in addition to the piping
loads transferred from the intermediate beams. Other longitudinal axial forces coming
on it from the design of the supporting system shall also be simultaneously taken into
account in the design of the longitudinal beam. Friction & Anchor Forces as per piping
requirements shall also be considered in the design. If beams support monorails, all
such loads shall also be considered to be acting simultaneously along with other loads
mentioned above.
Cable Tray and Walkway Loads
The estimated actual load from electrical, instrumentation trays shall be considered at
the specified locations, together with walkways, if provided.
Earthquake Force
Seismic forces shall be based on IS:1893 (Latest Revision) considering site spectrum.
(Site spectra will be provided later). The important factor shall be taken as 1.5.
Equipment Loads
Equipment loads of surge drums, deaerators, silencers, etc. when supported on pipe
rack shall be considered on actual load basis derived from the data sheets for the
design of foundation and super structure.
Maintenance Loads
Maintenance loads such as loads due to the use of monorail, davit etc. shall be
considered in design only on specific requirement furnished by the user group.
Snow Load
Snow loads wherever applicable shall be as per IS:875.
4.2 RCC AND STEEL CHIMNEYS
RCC and Steel chimneys shall be designed as per the requirements of IS:4998,
IS:6533 and Standard specification no. 6-68-0053.
4.3 MACHINE FOUNDATIONS
Machine foundations shall satisfy the following requirements:
a) The minimum grade of concrete to be used shall be as per clause 3.2 & 3.6.

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b) Minimum reinforcement as per requirements of IS:2974 shall be provided

unless required otherwise by design.
c) All units of the foundation system, except foundation raft shall be provided with
symmetric reinforcement on opposite faces, even if not required by design
considerations.
d) The soil stress below foundations under dead loads shall not exceed 80% of
the allowable soil bearing capacity, or safe load on pile, for static loading.
e) The combined center of gravity of the machine and foundation system shall, as
far as possible, pass through the center of area of the foundation raft or
centroid of the pile group. Where unavoidable, eccentricity shall be less than
5% for block foundations and 3% for frame foundations.
f) Foundations shall be so designed that natural frequency of the foundation

system shall not resonate with the following:
i) Operating speed of the motor.

ii) Operating speed of the machine.
iii) 2 x Operating speed of the machine.
iv) Critical speed of the machine (for centrifugal machines).
Natural frequency of the foundation shall preferably be + 20% away from the
above-mentioned frequencies. However, amplitudes of vibration of the
foundation block shall always be checked to be within permissible limits.
g) Amplitudes of vibration shall be less than values specified by the machine

manufacturer. If not specified, provision of IS:2974 shall be followed.
h) The foundation and its superstructure shall be separated from adjacent
foundations and platforms. Clear air gaps shall be provided in the
superstructure to avoid transmission of vibration to adjacent structures. Special
note shall be given on the drawing in this respect, and suitable details shown as
required.
i) Foundations resting partly on rock and partly on soil shall preferably be

avoided. However, if unavoidable, the soil area shall be replaced by lean
concrete (1:4:8). However, Owner/owner’s representative concurrence shall be
obtained for such cases.
j) Foundations shall not rest on previously backfilled or sensitive soils.
k) For frame foundations, base raft shall be cast in a single concreting operation.
A properly designed construction joint shall be provided between the base slab
and columns. The entire superstructure of columns and upper deck shall be
cast in a continuous concreting operation.
l) If height of the frame columns above raft level exceeds 8.0m, an additional
construction joint at the junction of columns/top-deck may be provided.
m) Block foundations shall be cast in a single concreting operation.

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4.4 BLAST RESISTANT CONTROL ROOMS
a) The structure shall be designed on shear wall concept with roof acting as a
diaphragm that transfers the transverse loads to the side shear walls and
columns in proportion to their stiffness. Internal partitions and division walls
shall not be designed as shear walls.
b) Thickness of reinforced concrete walls shall be 230mm (to meet the criteria of
Tariff Advisory Committee).
c) RCC wall shall be taken up to 1.5m below FGL or up to top of footing whichever
is shallower, maintaining the wall thickness and R/F same as in superstructure.
d) All superstructure members shall be designed for reversal of stresses.
e) Minimum R/F in wall in each face shall be 1% (as total % in both directions) of
gross cross sectional area as calculated from structural design considerations.
The maximum R/F in each face however shall not exceed 2%.
f) Roof slab shall be doubly reinforced. Minimum R/F on top and bottom shall be
1% of gross cross sectional area (as total % in both directions).
g) Maximum spacing of bars in walls and roof slab shall not exceed 150mm c/c.
Minimum bar diameter shall be 12mm.
h) In addition to load combinations of IS:875, the structure shall also be checked

for:
(i) 1.0 (Dead load + Blast load) for flexure considerations
(ii) 1.2 (Dead load + Blast load) for shear considerations

i) For blast load combinations the design bearing pressure of soil shall not
exceed twice the allowable static bearing pressure of soil. For piles under blast
conditions, the permissible increase shall be one-and-a-half times the allowable
capacity of pile in horizontal and vertical (compression and uplift) directions.
4.5 TANK FOUNDATIONS
Storage tanks up to 10.0 metres diameter, shall be supported on ring wall type of
foundations.
4.6 SUPPORTING ARRANGEMENTS FOR TRANSFER LINE
Structures supporting transfer lines and other two phase flow lines:
A list of piping with two-phase fluid flow shall be developed by the Contractor. Pipe
routing and structures supporting such lines shall be drawn. Only piping with diameter
more than 6" shall be considered critical and governed by this clause. Smaller diameter
piping shall be governed by relevant clauses for pipe rack.
4.6.1 Design loads
Horizontal force not less than 50% of the pipe weight (empty and contents) shall be
considered, acting simultaneously in two orthogonal directions (along the pipe and
across it) at that support.
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4.6.2 Piping supported on Pipe racks
4.6.2.1 Pipe racks supporting two phase flow lines above 6" diameter shall have all portals and
longitudinal beams encased in structural grade concrete. Encasing shall be in all
shapes (excluding profile shapes) with a minimum 50mm cover over the largest
dimension of the steel section. Minimum reinforcing steel as shrinkage/temperature
reinforcement shall be provided as welded wire fabric conforming to IS:1566 with mesh
size of 50mm x 50mm and wire thickness 3mm.
4.6.2.2 Between all successive portals supporting such lines, plan bracings shall be provided.
These shall be provided at least at their supporting elevation (bottom level in case of a
line with spring hangers). Longitudinal bays connecting portals shall be braced
vertically, from supporting level downwards, at least in one bay.
4.6.2.3 If the level difference between two phase fluid piping support and normal pipe
supporting tier of pipe rack is 3 metres or more, additional vertical bracing shall be
provided above the pipe rack level in all such transverse frames.
4.6.3 Isolated trestles
Vertical bracing shall be provided on all faces and horizontal bracing at least at pipe
support level. All members including bracing shall be encased in concrete for the entire
height of the trestles and the fundamental frequency of the structure shall be isolated
from the most critical range which is 4 to7 Hz. The weight of pipe shall not be
considered for dynamic analysis. Encasing details shall be same as mentioned in
clause 4.6.2.1.
4.6.4 Supports from technological structures
Structural members supporting transfer lines from technological structures shall be

adequately braced. Floors shall have plan bracing to effectively transfer horizontal
forces to vertical frames of the structure.
Supports on/from cantilevers shall be avoided. However, if unavoidable, adequate plan

bracing shall be provided.
4.6.5 Permissible stresses
No increase in permissible stresses shall be allowed except in load combination with

wind and seismic, as permitted by IS codes.
4.6.6 Permissible deflections
The deflection at the top of the structure, with all the horizontal forces acting together,
shall be limited to 25mm or height/325, whichever is less.
4.7 COMPRESSOR HOUSE, PUMP HOUSE AND OTHER SHED TYPE STRUCTURES
Roofs of all shed type structures shall have 1:3 slope. MS wind ties (40mm x 6mm)
painted as per painting specifications shall be provided over roof sheeting on the last
purlin towards eaves and the first purlin at ridge, on each slope of the roof. Cladding
shall be provided on all sides starting at 3 metre height from FFL/HPP and continuing
up to roof level. Provision for equipment entry and drop out area shall also be made as
per approved equipment layout.
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Daylight, natural ventilation and rain protection shall be ensured by providing

continuous louvers and roof monitors along the longitudinal sides of the shed. Louvers
shall be provided at various levels of the cladding to act as necessary air inlet/outlet,
and for daylight and rain protection. One louver shall be provided at 3.5metre height
from FFL/HPP, for rain protection of the opening below. Similarly, one louver shall be
provided at eaves level for ventilating the stagnant air, at that level. Sufficient number
of louvers shall also be provided at all intermediate working and equipment levels for
achieving proper day-lighting and ventilation in the sheds as per Factory Act and
National Building Code of India.
Continuous steel ventilator consisting of fixed glass and weld mesh with bird screen
net and sufficient overhang shall be provided on the longitudinal sides of the roof
monitor. Rain water gutters and PVC pipes shall be provided for proper roof drainage.
Gutters shall be of Mild Steel sheets (minimum 3mm thick) painted as per painting
specifications.
5.0 MATERIAL REQUIREMENTS
5.1 General
5.1.1 The minimum requirements of various materials to be used in Civil and Structural
works are as below:
5.2 Water
5.2.1 Water used in construction for all civil & structural works shall be clean and free from
injurious amounts of oil, acids, alkalies, organic matters or other harmful substances
which may be deleterious to concrete, masonry or steel. The pH value of water
sample shall be not less than 6. Potable water will be considered satisfactory. All
requirements of IS:456, have to be met.
5.2.2 Tests on water samples shall be carried out in accordance with IS:3025 and these
shall fulfill all the guidelines and requirements given in IS:456.
5.2.3 Water for curing shall be of the same quality as used for concreting and masonry
works.
5.3 Aggregate (For Concrete)
5.3.1 General
- Coarse and fine aggregates for Civil and Structural Works shall conform in all
respects to IS:383 (Specification for coarse and fine aggregates from natural
sources for concrete). Aggregates shall be obtained from an approved source
known to produce the same satisfactorily. Aggregates shall consist of naturally
occurring (crushed or uncrushed) stones, gravel and sand or a combination
thereof. These shall be chemically inert, hard, strong, dense durable, clean and
free from veins, adherent coatings, injurious amounts of alkalies, vegetable
matter and other deleterious substances such as iron pyrites, coal, lignite, mica,
shale, sea shells etc.
- Aggregates which may chemically react with alkalies of cement or might cause
corrosion of the reinforcement shall not be used.

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- The maximum quantities of deleterious materials in the aggregates as

determined in accordance with IS:2386 - Part II (Methods of Test for
aggregates for concrete), shall not exceed the limits defined in IS:383.
5.3.2 Coarse Aggregates
- Coarse aggregates are the aggregates, which are retained on 4.75mm IS

Sieve. It shall have a specific gravity not less than 2.6 (saturated surface dry
basis).
- These may be obtained from crushed or uncrushed gravel or stone and may be
supplied as single sized or graded. The grading of the aggregates shall be as
per IS:383 or as required by the mix design, to obtain densest possible
concrete.
5.3.3 Fine Aggregates
- Fine aggregates are the aggregates which pass through 4.75mm IS sieve but
not more than ten percent (10%) pass through 150 micron IS sieve. These shall
comply with the requirements of grading zones I, II and III of IS:383. Fine
aggregates conforming to grade zone IV shall not be used for reinforced
concrete works.
- Fine aggregates shall consist of material resulting from natural disintegration of

rock and which has been deposited by streams or glacial agencies, or crushed
stone sand or gravel sand. Sand from sea shores, creeks or river banks
affected by tides, shall not be used for filling or concrete works.
5.3.4 Sampling and Testing
The Contractor shall carry out all tests including mix designs of concrete, at the start of
work as well as during any stage of construction as per the requirement. Tests shall be
carried out in accordance with IS:516-Methods of test for strength of concrete and
IS:2386-Methods of test for aggregates for concrete. The method of sampling shall be
in accordance with the requirements given in IS:2430.
5.3.5 Storage of Aggregates
- Storage of all types of aggregates at the site of work shall be as specified in IS:
4082. Aggregates shall in no case be stored near excavated earth or directly
over ground surface.
- Fine aggregates delivered at the site in wet condition or becoming wet due to
rain or any other means, shall not be used for at least 24 hours. For the use of
such aggregates the contractor shall adjust the water content in accordance
with IS:2386 to achieve the desired mix.
5.4 Sand (For Masonry & Filling)
5.4.1 Sand for Masonry Mortars
- The sand shall consist of natural sand, crushed stone sand or crushed gravel
sand or a combination of any of these. The sand shall be hard, durable, clean
and free from adherent coatings and organic matter and shall not contain the
amount of clay, silt and fine dust more than specified in IS:2116
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- The sand shall not contain any harmful impurities such as iron pyrites, alkalis,
salts, coal or other organic impurities, mica, shale or similar laminated
materials, soft fragments, sea shells in such form or in such quantities as to
affect adversely the hardening, strength or durability of the mortar.
- The maximum quantities of clay, fine silt, fine dust and organic impurities in the
sand, when tested in accordance with IS:2386, shall not be more than 5% by
mass in natural sand, or crushed gravel sand or crushed stone sand. For
organic impurities, when determined in accordance with IS:2386, colour of the
liquid shall be lighter than that indicated by the standard solution specified in
IS:2386.
5.4.2 Grading of Sand
The particle size grading of sand for use in mortars shall be within the limits as
specified below:
Grading Of Sand For Use In Masonry Mortars
IS Sieve Designation IS:460 Percentage Passing Reference To Method

(Part I) By Mass
4.75 mm 100
2.36 mm 90 to 100
1.18 mm 70 to 100
IS:2386 (Part-I)
600microns 40 to 100
300 microns 5 to 70
150 microns 5 to 15
In case of sand whose grading falls outside the specified limits due to excess or
deficiency of coarse or fine particles, this shall be processed to comply with the
standard by screening through a suitably sized sieve and/or blending with required
quantities of suitable sizes of natural sand particles or crushed stone screening which
are by themselves unsuitable. The various sizes of particles of which the sand is
composed shall be uniformly distributed throughout the mass.
5.4.3 Sampling and Testing
The method of sampling shall be in accordance with IS:2430. The amount of material
required for each test shall be as specified in relevant parts of IS:2386. All tests shall
be carried out in accordance with the relevant parts of IS:2386.
If further confirmation as to the satisfactory nature of the material is required,

compressive test on cement mortar cubes (1:6) may be made in accordance with
IS:2250 using the supplied material in place of standard sand and the strength value
so obtained shall be compared with that of another mortar made with a sand of
acceptable and comparable quality.
5.4.4 Sand for Filling
Sand for filling shall meet the requirements of IS:383 and shall be natural sand, hard,
strong, free from any organic and deleterious materials. Sand obtained from sea
shores, creeks or river banks affected by tides, shall not be used for filling. Fine
aggregates suitable for concreting works shall be suitable for filling also. No sand
below grading zone-III as per IS:383 shall be allowed for filling.
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5.5 Cement
3
Unless otherwise specifically called for, cement for RCC and PCC/lean concrete
works shall be one of the following:
33 grade ordinary or low heat Portland cement IS:269
43 grade ordinary Portland cement IS:8112
Portland slag cement IS:455
Portland Pozzolana cement (fly ash based) IS:1489 (Part-1)
Portland Pozzolana cement (calcined clay based) IS:1489 (Part-2)
Sulphate resisting Portland cement IS:12330
High alumina cement IS:6452
For masonry applications the use of Masonry cement (conforming to IS:3466) can be
made.
5.6 Steel
5.6.1 General
All steel bars, sections, plates, and other miscellaneous steel materials, etc. shall be
free from loose mill scales, rust as well as oil, mud, paint or other coatings. The
materials, construction specifications such as dimensions, shape, weight, tolerances,
testing etc, for all materials covered under this section, shall conform to respective BIS
codes.
5.6.2 Reinforcement Bars
High strength deformed (HSD) TMT steel bars of minimum grade Fe 415, conforming
to IS:1786 shall be used.
5.6.3 Structural Steel
Structural steel sections shall conform to following BIS codes:
Steel tubes for structural purposes IS:1161
Mild Steel Tubes, tubular and other wrought steel fittings IS:1239
Steel for general structural purposes (Grade A). IS:2062
Hollow steel sections for structural use. IS:4923
3 The type of cement selected shall be appropriate for the intended use.
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5.6.4 Miscellaneous Steel Materials
Miscellaneous steel materials shall conform to the following BIS codes:
Expanded Metal Steel Sheets for General purposes. IS:412
Specification for mild steel and medium tensile

steel bars and hard drawn steel wire for concrete
reinforcement (Grade I)
(For mild steel bars of anchor bolts, rungs, metal inserts,
grating etc.) IS:432
Hexagonal head bolts, screws & nuts of product Grade C. IS:1363
Cold formed light gauge structural steel sections. IS:811
Technical supply conditions for threaded steel fasteners. IS:1367
Plain washers IS:2016
Steel wire ropes for general engineering purposes IS:2266
Thimbles for wire ropes. IS:2315
Bulldog grips. IS:2361
Mild Steel Tubes, tubular and other wrought steel

fillings. (For Hand rail tubular sections) IS:1239
Drop forged sockets for wire ropes for general

engineering purposes. IS:2485
Steel chequered plates. IS:3502

Hexagonal bolts and nuts (M42 to M150). IS:3138
5.6.5 Anchor Bolts
Material for Anchor Bolts such as MS bars, washers, nuts, pipe sleeves and plates etc.
shall be as per relevant BIS codes mentioned above under Clauses 5.6.4.
5.7 Brick
5.7.1 General
Bricks for masonry works shall conform to IS:1077 - Specification for common burnt
clay building bricks and shall be variety of class 5.0 (with minimum compressive
2
strength of 5.0 N/mm ). Physical requirements, quality, dimensions, tolerances etc. of
common burnt clay building bricks shall conform to the requirements of IS:1077.
Bricks shall be hand-moulded or machine-moulded and shall be made from suitable

soils. The bricks shall have smooth rectangular faces with sharp corners and shall be
well burnt, sound, hard, tough and uniform in colour. These shall be free from cracks,
chips, flaws, stone or humps of any kind.

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Testing of the bricks shall be done as per IS:5454 and IS:3495. Water absorption shall
not be more than 20% by its dry weight when soaked in cold water for 24 hours.
Locally available bricks of non modular size (230x115x75mm) in place of bricks of

modular size (190x90x90mm) can be used in case the bricks satisfy the other
requirements of IS:1077 (corresponding class as defined above).
5.8 Stone
5.8.1 General
All Stones used for masonry works shall conform to the requirements of following BIS
codes.
Method of identification of natural building stones IS:1123
Recommendations for dimensions and workmanship

of natural building stones for masonry work IS:1127
Recommendations for dressing of natural building stones IS:1129
5.8.2 Quality of Stones
Stones shall be hard, dense, strong, sound, durable, clean and uniform in colour. They
shall also be free from veins, adherent coatings, injurious amounts of alkalies,
vegetable matters and other deleterious substances such as iron pyrites, coal, lignite,
mica, sea shells etc. As far as possible stones from one single quarry shall be used for
anyone work. The strength of stones should be adequate to carry the imposed load
and shall meet all the requirements of IS:1905, taking into account the appropriate
crushing strength of stone and type of the mortar used. The percentage of water
absorption, when tested in accordance with IS:1124, shall not exceed 5 percent.
The length of the stone shall not exceed 3 times the height. Width of stone on base
shall not be less than 150mm and in no case exceed 3/4 th thickness of the wall.
Height of the stone shall not be more than 300mm.
5.9 Admixtures
5.9.1 General Requirements for Admixtures
- All concrete admixtures shall comply with the following Indian standards:
Specification for integral cement water proofing compounds. IS:2645
Specification for other admixtures for concrete. IS:9103
In case of non-availability of any IS code for testing and acceptability criteria,

relevant American, British or German Code shall be applicable.
- No admixture shall impair the durability of the concrete nor combine with the
ingredients to form harmful compounds nor increase the risk of corrosion of
reinforcement. Use of admixtures shall not reduce the dry density of concrete.
Once the proportion of admixtures have been established, strict check shall be
maintained not to alter the proportions of ingredients and water-cement ratio of
the Design Mix during execution.
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- The chloride contents in admixtures shall not exceed 2% by mass of the

admixture or 0.03% by mass of the cement.
- Admixtures which do not meet the requirements stipulated in this document

shall not be used.
5.9.2 Water Proofing Compounds
- The permeability of the specimen with the admixture shall be less than half of
the permeability with a similar specimen without the use of these compounds.
These compounds shall be used in such proportion as recommended by
manufacturer but in no case it shall exceed 3% by weight of cement.
- The initial setting time of the cement with the use of these compounds shall not
be less than 30 minutes and final setting time shall not be more than 10 hours.
Tests shall be carried out in accordance with IS:4031.
- Compressive strength of the specimen at 3 days shall not be less than

2
160kg/cm nor 80% of the 3 days compressive strength of mortar cubes
prepared with same cement and sand only, whichever is higher. Similarly
2
compressive strength at 7 days shall not be less than 220 kg/cm nor less than
80% of the 7 days compressive strength prepared with the same cement and
sand only, whichever is higher. The test to determine the compressive strength
shall conform to IS:4031.
5.10 Water Bars (Water Stops)
5.10.1 PVC water bars shall be used in reinforced concrete construction of liquid retaining
structures or any other structure to safeguard them from hydrostatic pressure and
water leakage and any relative movement between two parts of the structure due to
thermal loading shrinkage or differential movement of foundations. These shall be
preformed and shall provide a permanent water tight seal along the entire joint in the
poured concrete structures. These shall also be flexible enough to withstand deflection/
displacements at joints arising due to variation of temperatures or settlement of
foundations.
5.10.2 Performance requirements of PVC water bars shall meet the requirements of IS:12200.
These shall be of an approved make and of ribbed/serrated/plane type with a bulb at
the centre. The thickness and width of water bars shall in no case be less than 5mm
and 150mm respectively. However, for concrete sections greater than 300mm thick,
the width of water bars shall not be less than 230mm.
5.11 Bitumen/bituminous Materials
Bitumen to be used for various types of work shall meet all the requirements of
relevant BIS codes as given below:
Specification of Paving Bitumen. IS:73
Specification for bitumen mastic for flooring (Grade IV) IS:1195
Specification for Bitumen felts for water proofing and damp proofing. IS:1322
Specification for Bituminous compounds for water proofing

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and caulking purposes. IS:1834
Specification for preformed fillers for expansion joint

in concrete pavements and structures. IS:1838
Specification for bitumen mastic for use in water proofing of roofs IS:3037
Specification for bitumen primer for use in water proofing

and damp proofing. IS:3384
Specification for Bitumen Mastic for Tanking and Damp proofing. IS:5871
Specification for Glass fibre base coal tar pitch & bitumen felts IS:7193
Code of practice for damp proofing using bitumen mastic IS:7198
Specification for bitumen Mastic, Anti Static and

electrically conducting grade. IS:8374
Tests and acceptable criteria shall be as per relevant BIS codes.
5.12 PVC Pipes
PVC Pipes shall conform to the requirements of IS:4985.
5.13 Wood/timber
5.13.1 Wood recommended for platforms of cold vessels or below cold vessels/ exchangers
shall be hard and shall be of group A, grade I, and shall have safe permissible stress of
2
7N/mm in compression, perpendicular to grains on outside location as per IS:883.
General characteristics like durability, treatability etc. shall conform to IS:883 and
IS:3629.
5.13.2 Timber required to be used for form work shall be fairly dry before use. It should
maintain its shape during the use and even when it comes into contact with moisture
from the concrete. Storage of Wood/Timber shall be as per the requirements of
IS:4082.
For proper identification and selection of suitable timber for form work, following codes
shall be referred.
Classification of commercial timbers and their zonal distribution IS:399
Specification for ballies for general purposes IS:3337
Specification for Ply wood for concrete shuttering work IS:4990
5.14 Anti-termite Compounds
5.14.1 Chloropyrifos emulsifiable concentrates (1%) conforming to IS:8944 shall be used for
treatment of soil for protection of buildings against attack by subterranean termites.

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5.15 Polysulphide Sealants
5.15.1 All Polysulphide Sealants shall conform to IS:12118. Test conditions and requirements
shall be as given in the above referred BIS code.
6.0 CONSTRUCTION REQUIREMENTS
6.1 Construction
6.1.1 All concrete works shall be carried out as per the provisions of IS:456, IS:3370,
IS:2974 and other relevant BIS Codes. Concrete mix proportioning and design mix;
sampling and strength test of concrete, production and control of concrete, tolerances
and placing of reinforcement and for cover; transporting, placing, compacting and
curing etc, inspection and testing of structure (including requirement of non-destructive
testing) shall be as specified in IS:456.
6.1.2 Continuous concreting shall be done for structures supporting dynamic equipment as
per the provisions of IS:2974.
6.1.3 The damp proof course shall be laid in two layers of equal thickness and each layer
given two coats of hot bitumen on top (grade A90/S90 conforming to IS:73) at the rate
of 1.7 kg/m2. Dry sharp sand shall be sprinkled evenly over the top layer of bitumen
before hardening.
6.1.4 Form work and stripping of form work shall be as per the provisions of IS:456.
6.1.5 Assembly of reinforcement in RCC structures shall conform to IS:456.
6.1.6 Fabrication of all structural steel works shall be carried out as per the provisions of
IS:800/801/802/806 and other relevant BIS codes. Fabrication shall include cleaning,
straightening, cutting, bending, holding, bolting, welding, machining, painting, marking,
assembling, erecting, inspecting and testing etc. Welding procedure and welder
qualification shall be as per IS:800 and/or referenced BIS codes only.
6.1.7 Erection of all structural steel works including supply of plant & equipment, storing and
handling, setting out, field connections, field welding and security during erection shall
conform to IS:800/801/802/806.
6.1.8 All masonry works shall be carried out as per the provisions of IS:1597/2212/4326 and
other relevant BIS codes.
6.1.9 The limits of dimensional tolerances for all works shall be as given below:
For Plain and Reinforced Cement Concrete Structures:
(a) Deviation from specified dimensions - 6mm to +12mm

of cross section of columns and beams.
(b) Deviation from dimensions of footings

(see Note below)
(i) Dimensions in plan -12mm to +50mm

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(ii) Eccentricity 0.02 times the width of the footing in

the direction of deviation but not more
than 50 mm.
(iii) Thickness +0.05 times the specified thickness.
Note: Tolerances apply to cast-in-situ concrete dimensions only, not to positioning of vertical
reinforcing steel or dowels.
(c) Deviation in length (major dimension of single unit)
up to 3m ± 6mm
3m to 4.5m ± 9mm
4.5m to 6m ±12mm
additional deviation for every subsequent 6m ± 6mm
(d) Deviation in straightness or bow (deviation from specified line) for a single or
continuous member), e.g, beam, column or slab edge.
Up to 3m 6mm
3m to 6m 9mm
6m to 12m 12mm
additional for every subsequent 6m 6mm
(e) Deviation in squareness shall be measured taking the longer of two adjacent
sides as the base line.
The shorter side shall not vary in its distance from a perpendicular so that the
difference between the greatest and shortest dimensions exceeds 6mm. For
this purpose, any error due to lack of straightness shall be ignored. Squareness
shall be checked with respect to the straight lines that are most nearly parallel
with the features being checked. When the nominal angle is other than 90
degrees, the included angle between check lines shall be varied accordingly.
(f) Deviation in twists shall be within a limit such that any corner shall not be more
than the limit given below from the plane containing other three corners:
Up to 600mm wide and up to 6m in length 6mm
over 600mm wide and for any length 12mm
(g) Maximum deviation in flatness from a 1.5m straight edge placed in any position
on a nominally plain surface shall not exceed 6mm.
For Steel Structures:
(a) Columns and tower-type structures
- Deviation of column axes at foundation top level with respect to true axes.
i) In longitudinal direction ±5mm
ii) In lateral direction ±5mm

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- Deviation in the level of bearing surface of columns at foundation top

with respect to true level. ±5mm
- Out of plumb (verticality) of column axis from true vertical axis measured at top:
i) Up to and including 30m height ±H/1000 or ±25mm

whichever is less.
ii) Over 30m height ±H/1200 or ±35mm

whichever is less.
- Deviation in straightness in longitudinal & transverse planes of column at any

point along the height . ±H/1000 or ±10mm
whichever is less
- Difference in the erected positions of adjacent pairs of columns along length or

across width of building prior to connecting trusses/beams with respect to true
distance. ±5mm
- Deviation in any bearing or seating level with respect to true level

±5mm
- Deviation in difference in bearing levels of a member on adjacent pair of

columns both across & along the building ±5mm
Note 1) Tolerance specified for out-of-plumbness should be read in conjunction with

‘Deviation in straightness....’ & ‘Difference in the erected positions.....’.
Note 2) 'H' is the column height in mm.
Note 3) Tolerance limits as given under clause (a) above for steel structures are
applicable to concrete columns/pedestals also.
(b) Trusses
- Shift at the centre of span of top chord member with respect to the vertical
plane passing through the centre of bottom chord. ±1/250 of height of
truss in mm at center
of span or ±15mm
whichever is less
- Lateral shift of top chord of truss at the centre of span from the vertical plane
passing through the centre of supports of the truss ±1/1500 of span of
truss in mm or ±10
mm whichever is less
- Lateral shift in location of truss from its true position. ±10mm
- Lateral shift in location of purlin from true position. ±5mm

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- Deviation in difference of bearing levels of truss from the true level

±1/1200 of span of truss in
mm or 20mm whichever is
less.
(c) Gantry girders and Rails
- Shift in the centre line of crane rail with respect to centre line of web of gantry
girder ± [ web thickness of girder(mm) +2mm]
2
- Shift of alignment of crane rail (in plan) with respect to true axis of crane rail
at any point ± 5 mm
- Deviation in crane track gauge with respect to true gauge.
i) For track gauge upto and ± 5 mm

including 15 m
ii) For track gauge more than 15m ± [5+0.25(S-15)] subject to

maximum ±10mm, where S in
metres is true gauge.
- Deviation in the crane rail level at ±10 mm

any point from true level
- Difference in level between crane track rails (across the bay) at
i) Supports of gantry girders 15 mm
ii) Mid span of gantry girders 20 mm
- Relative shift of crane rail surfaces 2 mm

(at a joining) in plan and elevation
6.1.10 Construction of all other items of works shall conform to relevant Indian Standards and
sound engineering practices.
6.1.11 The Contractor shall be responsible for the complete safety pertaining to all
construction works.
7.1 GENERAL
7.1.1 Apart from the conditions mentioned in the Design requirements given in the
document, the following shall be strictly adhered to.
7.1.2 Cable/pipe trenches & precast slab covers shall be designed to withstand the load of
hydra-crane. Seating surface of the slab shall be at least 100mm wide with structural
ISA50x50x6 edge protection embedded through out the length of the trench.
7.1.3 Only steel shuttering shall be used for civil construction.

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7.1.4 Contractor shall make necessary arrangement for placing the anchor bolts in position
before concreting. Whenever there are more than four foundation bolts, these shall be
fixed by using template. In case bolts are not available at site at the time of casting of
foundation, proper pockets shall be left as per direction of the Engineer-in-charge.
7.1.5 Contractor to ensure isolation of structures/equipments with difference of temperature

for free expansion while providing interconnecting platform and for connection to the
stair structure.
7.1.6 Contractor shall ensure lateral stability by providing box/built up sections for columns
wherever it is not feasible to provide vertical bracing in either direction.
7.1.7 Sub-station building shall be provided with anti termite treatment.
7.1.8 All designs, detailing & construction shall strictly conform to enclosed standards,
specifications & drawings. However drawings marked “Issued for Information only” are
for only guidance to the contractor.
7.1.9 Contractor shall furnish the BULK MTO for cement and High Strength Deformed TMT
bars (diameter wise) and Structural Steel (section wise) within 45 days from the date of
receipt of LOI/TOI. It shall also be updated at 50% & 90% stages of engineering
progress and shall be submitted to owner/owner’s representative for information.
7.1.10 Sequence of construction is to be shown on the AFC drawings by indicating

construction joints wherever required.
7.1.11 The minimum diameter of reinforcement bar for slabs, beam stirrups and column ties
shall be 8 mm and for footing slabs and vertical walls it shall be 10 mm. The maximum
spacing of these bars shall be restricted to 300 mm c/c.
7.1.12 No equipment shall be directly supported on suspended floor slab. Suitable

arrangement of beams shall be provided underneath to support the equipments.
7.1.13 The foundation design shall be based on approved Geotechnical investigation

recommendations. Geotechnical investigation shall be in scope of the bidder. However,
boreholes of nearby areas are enclosed for reference only for the bidder.
7.1.14 Contractor shall depute his concerned Civil-Structural design engineer to

owner/owner’s representative review office as and when required for review of his
documents. During such reviews involving computer aided analysis/design/drafting of
structures, the Contractor shall make his own arrangement of Personal Computer (PC)
in the form of Lap-top in the premises of owner/owner’s representative review office.
This is required to expeditiously resolve all the comments including those involving the
use of PC by Contractor in his submission. The Contractor shall ensure that these PC's
are fully operational along with necessary software already loaded including the
input/output/drawing files of the structures being reviewed. The Contractor shall revise
and re-submit the analysis/design and drawings as required during review.
7.2 PAINTING OF STRUCTURAL STEEL WORKS
7.2.1 Painting on structural steel shall be as per specification enclosed elsewhere.

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7.3 REVIEW OF DESIGN AND APPROVED FOR CONSTRUCTION (AFC) DRAWINGS
7.3.1 Complete structural design and AFC drawings for the following structures shall be got
reviewed by owner/owner’s representative in detail before taking up any construction
activity at the work site:
a) Design Basis/Geotechnical investigation report/Foundation recommendations.

b) Gas Turbine Generators/HRSG/Steam Turbine Generator/Utility Boiler foundations
c) Chimney for Utility Boilers (Typ.)
d) Bypass stacks for GTG & HRSG foundation (Typ.)
e) Control room building (Blast proof)
f) Substation building (Typ.)
g) Shed for GTG & STG with EOT crane (Typ.)
h) FD & ID fan foundations (Typ.)
i) Pipe Racks (Typ.)
For all other works/buildings/structures, requisite number of prints (as mentioned

elsewhere) of design calculations and AFC drawings shall be sent simultaneously to
owner/owner’s representative for information and to site for construction.
Submission of typical review category documents shall be taken up prior to

corresponding information category documents. Owner/owner’s representative
comments on typical review category documents shall be duly taken care in
information category documents as well before issuing them for construction.
7.3.2 The contractor shall furnish the quantities of different grades of concrete, reinforcement
and structural steel in the respective AFC drawings. Bar Bending schedule for all RCC
drawings shall be submitted by the contractor along with the AFC drawings.

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ENCLOSURE I
FACTORS OF SAFETY FOR FOUNDATION DESIGN
Minimum Factor Of Minimum Factor Of

Safety Against Safety Against % Weight Of
Type Of Overturning Sliding Overburden Over
Structure With Wind Without With Without Projected Plan
Or Wind Or Wind Or Wind Or Area Of Footing
Seismic Seismic Seismic Seismic
All Buildings/
Structures/Eqpts. 1.5 2.0 1.5 1.5 100
in Units
Pipe Rack
1.5 2.0 1.5 1.5 50$
(Offsite)
Flood Light Mast 1.5 - 1.5 - 50$
Retaining Wall 1.5 2.0 1.5 1.75 100
Tall
1.5 2.0 1.5 1.5 100
vessels/columns
Transmission
Tower/Switch 1.5 2.0 1.5 1.75 50$
yard structures
Blast Resistant
1.5 2.0/1.2# 1.5 1.5/1.5# 100
Structures
# With blast pressure

$ In case area is paved, overburden shall be based on NGL (for area under filling) or
600mm below HPP whichever is lower. In case of unpaved area, it shall be w.r.t.
FGL.
Minimum Factor of safety against UPLIFT shall be 1.2 for all structures. (Note: In case of
sumps, lining weight shall not be included).

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CONTENTS
1.1 BUILDING REQUIREMENT

1.2 SPECIFICATION OF ARCHITECTURAL FINISHES

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1.1 BUILDING REQUIREMENT
The Buildings shall be designed on the basis of basic requirements furnished in this clause
(including attached drawings referred in the clause) and Design Basis elaborated
elsewhere in the bid package.
Provisions for LAN (Local Area Networking cabling) shall be considered for the building as
per the Owner requirements. Necessary detailing for concealed conduiting through
flooring, wall panels/walls, ceiling/ false-ceiling etc. shall be provided during the detail
engineering.
Provisions for proper and aesthetically pleasing landscaping shall be considered for all the
buildings as per the Owner requirements.
In case of conflict or contradictions between building requirement & design basis,

provisions of the former shall override. The Buildings shall be sized in accordance with the
Owner/ PMC approved GA drawings prepared on the basis of functional, maintenance,
safety & statutory requirements as given in the drawings attached with Tender.
1.2 SPECIFICATION OF ARCHITECTURAL FINISHES
1.2.1 GENERAL
(a) For any aspect of item not covered in the document, the contractor shall follow
instructions of the engineer-in-charge and execute the work as per relevant IS
codes/ recommendations of approved manufacturer/ good engineering practice
without any cost or time implication to Owner/PMC. Contractor shall refer only to
the relevant part of the specifications given below as per the Building
Finishes described before.
(b) All materials shall be of first quality conforming to the specifications & IS or
equivalent with IS marks and shall be obtained from the approved Manufacturer.
The Contractor shall get the materials approved by the Engineer - In - Charge
before ordering & procurement. The Contractor shall furnish necessary certificates
etc. as asked by the Engineer - In - Charge. Further to that he shall get the
materials tested from approved test house if asked by the Engineers - In - Charge
& submit the test certificate at his own cost for which no extra payment shall be
made to him. The Engineer - In - Charge shall have the right to reject all or any of
the materials intended to be used and such materials shall be immediately
removed from the site by the Contractor at his own cost without any claim for
compensation etc. due to such rejection.
(c) Workmanship shall be to the satisfaction of the Engineer- In- Charge. The
contractor shall follow the specifications, relevant Codes & Manufacturer's
guidelines for achieving desired level of workmanship as per specification & good
engineering practice. Any executed work not conforming to the specification or not
to the satisfaction of the Engineer -In-Charge shall be rectified by the Contractor as
directed by the Engineer -In-Charge. No extra payment shall be made to the
Contractor for such rectification. The contractor shall use only first quality approved
material for all items.
(d) All specifications of various finishing items include construction supervision; supply
of all materials, labours, tools tackles, scaffoldings etc. and are applicable for all
heights, locations etc.
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(e) For specifications of construction water, sand, cement, bricks/ stone, aggregates
etc. reference shall be made to the Civil/ Structural specifications attached in the
bid document.
(f) All specialised items of work (e.g. Aluminium Doors and Windows, Waterproofing,
Overdeck Insulation, Precoated roof sheeting/ cladding, False ceiling, False
Flooring, Partitioning and Panelling, Expansion joint sealing etc.) shall be got
executed by the Contractor only through authorised applicators/ sub contractors of
approved manufacturer/ vendor. The contractor shall submit list of such authorised
applicators/ sub contractors for approval before execution of such items.
1.2.2 FLOOR FINISHING
Reference shall be made to the following Indian Standards for any further information etc.
not covered in the specification. In case of any conflict/contradiction, provision of
specification shall override.
IS: 4971 Recommendations for selection of Industrial floor finishes.

IS: 1237 Specification for Cement concrete flooring tiles.
IS: 777 Specification for glazed earthenware wall tiles.
IS: 2571 Code of practice for laying in situ cement concrete flooring.
IS: 4631 Code of practice for laying of epoxy resin floor toppings.
IS: 5491 Code of practice for laying in situ granolithic concrete floor topping.
IS: 4441 Code of practice for use of silicate type Chemical resistant mortars.
IS: 4443 Code of practice for use of resin type chemical resistant mortar.
(A) Cement Concrete Flooring
Cement concrete flooring shall be laid in average 25mm thickness over sub base
(as per structural drawings/ specifications) and shall generally conform to IS: 2571.
The flooring shall be laid in panels and shall consist of:
(a) 25 mm thick base course of M-15 grade cement concrete (with 6mm and
down size stone aggregate) laid on the sub-base in panels (each panel not
exceeding 1 Sq. Mtr. in area) in desired shape and pattern. The panels shall
be bound by 3x20mm PVC strips panel dividers; fixed in position with their
top at proper level maintaining the required levels, slopes, linearity etc. as
required. Base course shall be laid in alternate panels. Before laying the
base course, neat cement slurry @ 2.75Kg. of cement per Sq. Mtr. of area
shall be applied (brushed) over the prepared sub base surface. Cement
concrete shall be placed in position and beaten with trowel, including
tamping and finishing smooth. Finishing of the surface shall follow
immediately after completion of laying of base. The bed for flooring shall be
prepared either level or sloped as per drawings and as instructed by
Engineer-in-charge.
(b) Neat cement @ 2.75Kg. per Sq. Mtr. mixed with water to form a thick slurry
applied over the base course (when the concrete is green), spread over the
surface, pressed twice by means of iron floats; once when the slurry is
applied and second time when the cement starts setting. The junction of
floor with wall plaster, cladding, skirting shall be rounded off uniformly upto
a radius of 25mm unless otherwise mentioned.

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Each finished portion of floor, on completion shall be kept wet with ponding for a
minimum period of 7 days.
(B) Cement Concrete Granolithic Flooring
Cement concrete granolithic flooring shall be laid in overall 40mm thickness over
sub base (as per structural drawings/ specifications) and shall generally conform to
IS:5491 in workmanship. The flooring shall be laid in panels and shall consist of:-
(a) 25mm base Course (Under layer) of M-15 grade Concrete (shall generally
conform to Civil structural specifications) laid over sub base in panels (each
panel not exceeding 1 Sq. Mtr. in area) in desired shape and pattern. The
panels shall be bound by 3x30 PVC strips panel dividers; fixed in position
with their top at proper level maintaining the required levels, slopes, linearity
etc. as required. Base course shall be laid in alternate panels. Before laying
the base course, neat cement slurry @ 2.75Kg. of cement per Sq. Mtr. of
area shall be applied (brushed) over the prepared sub base surface. The
borders of the panels shall have mitred joints at the corners of the room and
intermediate joints shall be in straight line with panel joints. Cement
concrete shall be placed in position and beaten with trowel and finished
smooth. Beating shall cease as soon as surface is found covered with
cream of mortar. Necessary slope shall be provided.
(b) 15mm thick Wearing top layer of cement mortar 1:3 (1 cement: 3 course
sand by volume) which shall be laid within 15 minutes of laying the first
layer. The cement and aggregates for the top layer shall be mixed dry. After
mixing, sufficient quantity of washed sand and water shall be added to
make the mix plastic but not flowing. The top and bottom layer shall firmly
grip together. The base course shall be free of excessive moisture before
starting the floor finishing. Use of dry cement, cement sand mixture
sprinkled on the surface to stiffen the concrete or absorb excessive
moisture shall not be permitted.
(c) While the concrete is still green, cement @ 2.75 kg per Sq.M of floor area
shall be mixed with water to form a thick slurry and spread over the surface.
It shall be pressed twice by means of iron floats, once when the slurry is
applied and second time when the cement starts setting. The junction of
floor with wall plaster, cladding, skirting shall be rounded off uniformly upto
a radius of 25mm unless otherwise mentioned.
(C) Heavy Duty Cement Concrete Flooring
Heavy duty Cement concrete flooring shall be laid in overall 50mm thickness over
sub base (as per structural drawings/ specifications); shall generally conform to IS:
5491 in workmanship. The flooring shall be laid in panels and shall consist of:-
(a) Base Course (Under layer) 35mm thick of cement concrete (1 cement: 1.5
coarse sand: 3.5 stone aggregates of 10mm to 6mm size by volume) laid
over sub base in panels (each panel not exceeding 1 Sq. Mtr. in area) in
desired shape and pattern. The panels shall be bound by 3x40mm PVC
strips panel dividers; fixed in position with their top at proper level
maintaining the required levels, slopes, linearity etc. as required. Base
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course shall be laid in alternate panels. Before laying the base course, neat
cement slurry @ 2.75Kg. of cement per Sq. Mtr. of area shall be applied
(brushed) over the prepared sub base surface. The borders of the panels
shall have mitred joints at the corners of the room and intermediate joints
shall be in straight line with panel joints. Cement concrete shall be placed in
position and beaten with trowel and finished smooth. Beating shall cease as
soon as surface is found covered with cream of mortar. Necessary slope
shall be provided.
(b) Wearing Top layer/ Finishing layer shall be of cement, hardener and stone
aggregate mix of 15mm thickness laid over the base course. Unless
otherwise mentioned, one part of approved quality hardener and four parts
of cement by weight shall be mixed dry. This dry mixture shall be mixed with
stone grit of 6mm and down size in the ratio of 1 hardener and cement
mixture : 2 stone grit by volume. Just enough water shall then be added to
the mix.
The mixture so obtained shall then be laid on the base course within 2 to 4 hours of
latter's laying. It shall be firmly pressed into bottom concrete so as to have a good
bond with it. After the starting of initial setting, the surface shall be finished smooth
and true with steel floats.
(D) Cement Plaster Skirting
Cement plaster skirting shall be laid with cement mortar (1 cement:3 coarse sand
by volume) shall be of 18mm thickness. The surface on which the skirting is to be
applied shall be prepared and skirting shall be laid. The junction between flooring
and wall shall be rounded off to a radius of 25mm if not otherwise mentioned.
While the mortar is still green, cement @ 2.75Kg per square metre shall be mixed
with water to form a thick slurry and applied over the mortar. It shall be pressed
twice by means of iron floats, once when the slurry is applied and second time
when the cement starts setting. The flooring shall be cured for 7 days.
(E) Tile Work (Glazed/ Ceramic/Vitrified Porcelain)
Glazed vitreous tiles shall conform to IS: 777. Ceramic tiles for flooring shall be
matt finished and non slip type. All tiles shall be decorative type of approved shade,
pattern, texture and design and of approved manufacturer. . The sizes of the
ceramic tiles shall generally be 300x300x8mm for flooring and 100x200x6mm or
300x200x6mm for walls (dado). Pigments to be admixed with mortar for grouting
the joints shall conform to Table -1 of IS: 2114. The tiles shall be laid over a coating
of approved neoprene based adhesive (as per manufacturer’s specification) laid on
base floor/ wall plaster. The joints of the tiles shall be flush pointed with cement
paste (white cement and pigment conforming to IS:2114, Table-l) matching the
shade of colours. The tile work shall be suitably cured.
(F) Acid Resistant Tiles Flooring
The tiles shall be vitrified ceramic tiles of approved size as per approved
manufacturer’s specification and shall be homogeneous having following
properties:-
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S.No. Property Values Norms

1 Water Absorptions ±0.5% ASTM C 373
2 Scratch Resistance >6 ASTM C 373
3 Chemical Resistance Unaffected ASTM C 650
4 Abrasion Resistance > 100 ASTM C 501
5 Breaking strength 1400 kg/sq.cm ASTM C 648
6 Density > 2.0 Gm/CC
The base course for flooring shall be Cement Concrete flooring/ Cement Concrete
granolithic flooring and for skirting/ dado it shall be Cement plaster and background
surface shall be prepared as per clause no. 5.2 and IS:4443.
Tiles shall be fixed on the prepared surface over a bitumen priming layer, bitumen
mastic layer and resin type chemical resistant mortar. The bitumen shall conform to
IS:702 and laying of bitumen mastic shall conform to 1S:1196.
Joints shall be allowed to set for 24 hours. The floor shall then be washed as per
manufacturer's specifications to totally remove all marks from tile surface.
(G) Decorative vitrified porcelain flooring
The tiles shall be vitrified porcelain tiles, mirror polished, of approved size as per
approved manufacturer’s specification and shall be homogeneous having
properties similar to vitrified ceramic acid resistant tiles. The fixing of tiles shall be
similar to ceramic tiles.
(H) Kota Stone Floor Finish
Kota Stone Flooring shall be laid in minimum 40mm overall thickness over sub
base (as per structural drawings/ specifications). The Kota Stone slabs shall be of
selected quality and shade, hard, sound, dense, homogenous in texture, free from
cracks, decay, weathering and flakes. These shall be machine cut to the requisite
size and thickness and chisel dressed. For flooring and skirting/ dado/ riser the
thickness of the stone slabs shall be 25mm and 18mm respectively. Skirting shall
normally be 125mm high unless specified otherwise.
The slabs shall have smooth top (exposed) face before being laid. Before starting
the work, the contractor shall get the samples of slabs approved by Engineer-in-
charge. Each slab shall be machine cut to the required size and shape and fine
chisel dressed at all edges to full depth and machine rubbed to a smooth surface
finish. All angles and edges of the slabs shall be true square and free from
chippings giving a plane and smooth surface.
Preparation of base shall include making it rough, cleaning thoroughly and applying
neat cement slurry @ 2.75 kg of cement per Sq.M. of area to receive the mortar.
Cement mortar shall be 15mm thick !:6 (1 cement: 6 Coarse sand by volume) for
flooring and 12mm thick 1:3 (1 cement: 6 Coarse sand by volume) for skirting. The
mortar shall be laid for fixing one slab at a time. The slab shall be washed clean
before laying. It shall be laid over cement mortar bedding on top, pressed, tapped
gently to bring it in level. It shall be then lifted and laid aside. Top surface of the
mortar then shall be corrected by adding fresh mortar at hollows and depressions.
The mortar then shall be allowed to harden and cement slurry of honey like
consistency @ 4.4.kg of cement per Sq. M shall be spread over the mortar. The
edges of the slabs shall be buttered with white cement (with necessary pigment)
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grout to match the shade of the slabs. The slabs shall then be gently placed in
position and tapped with wooden mallets till it is properly bedded in level. The joints
shall be as fine as possible. Surplus cement on the surface of the slab shall be
removed. The slabs in flooring shall continue for not less than 10 mm under the
plaster/skirting. The finished surface shall be true to levels and slopes as instructed
by the Engineer-in-Charge. The slabs shall be laid in patterns as per drawings and
size shall not be less than 400 x 275mm, which shall be uniform. Cut size may be
used along periphery as required. Curing, as required shall be done.
Grinding shall be commenced when the joints are properly set. Unevenness at the
meeting edges of slabs shall be removed by fine chiselling. Grinding shall be done
by machines except for skirting and small areas. First grinding shall be done with
Carborundum stones of 48 to 60 grade grit fitted in the machine. Water shall be
properly used during grinding. When the floor has been uniformly rubbed, it shall be
cleaned with water baring all pin holes. It shall then be covered with a thin coat of
cement mixed with pigments to match with colour of the Kota stone. This grout
shall be kept moist for a week. Thereafter the second grinding shall be started with
Carborundum stone of 120 grit. Grinding and curing shall follow again. Final
grinding shall be with Carborundum of grade 220 to 350 grit using water in
abundance. The floor shall be washed clean with water, oxalic acid powder shall
then be dusted at 35 gms/sq. m. on the surface rubbed with machine fitted hessian
bobs or rubbed hard with woollen rags. The floor shall then be washed clean and
dried with a soft cloth or linen. If any stone slab is disturbed or damaged, it shall be
refitted or replaced and properly jointed and polished.
1.2.3 DOORS AND WINDOWS
(A) Aluminium Glazed Doors, Windows And Ventilators
Aluminium glazed doors/ windows/ ventilators shall be made of extruded tubular

electrostatically powder coated (min. 30 microns)/anodised Aluminium sections
conforming to IS : 733 and IS : 1285 of ‘INDAL’ or approved equivalent
manufacturer with 6.3mm laminated safety glass conforming to I.S.: 2553 fixed with
rubber lining or EPDM gasket and extruded anodised aluminium beading.
Extruded aluminium sections used for various application shall have minimum
weights as under.
a. Doors
1. For fixed frames

i) Sides & Top members : 1.975 Kg/RM
ii) Lock rail 1.594 Kg/RM
iii) Bottom rail : 3.495 Kg/RM
2. For shutter frame 1.202 Kg/RM
3. Glazing clips (beading) : 0.182 Kg/RM
b. Window/Ventilator
1. For fixed frames : 0.639 Kg/RM

2. For shutter frame : 0.636 Kg/RM
3. Glazing clips ( beading ) : 0.165 Kg/RM
4. Coupling bars : 0.933 Kg/RM
5. Member for fixing the frame : 0.463 Kg/RM
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The frames shall be fixed to masonry by means of Aluminium lugs fixed to the
frame by counter sunk brass machine screws and grouted with M-15 grade
concrete in minimum 150 x 150 x 50 mm sized hole in the masonry. In case of
RCC, the frames shall be fixed with 12mm dia dash fasteners in case of concrete.
Any steel item coming in contact with Aluminium shall be galvanised.
Aluminium glazed doors shall be provided with cup pivots (of aluminium alloy
conforming to IS designation NS-4 of IS 737 and IS designation of A-5-M of IS :
617) riveted to outer and inner frames to permit to swing through an angle of 85
degree.
Following hardware shall be provided for the doors.
1. Heavy duty & hydraulically operated double or single action adjustable door
closer conforming to IS : 6315
2. 250mm and 150mm long, 10mm dia Aluminium tower bolts as per IS: 204 one
each for each shutter.
3. Brass body 6 lever mortise lock as per IS : 2209
4. Aluminium door handle for each shutter for each side.
(Note: All Aluminium fittings/ fixtures shall be of same finish as that of doorframe &
shutter)
Side hung window shutters shall be fixed to the frame with Aluminium alloy friction
hinges and shall be complete in all respects including accessories, fittings fixtures
of same finish as that of window frame & shutter, handles of cast aluminium
conforming to IS designation A-5-M of IS : 617 mounted on a handle plate riveted
to opening frames, Aluminium Tower bolts, peg stays for ventilators etc. Wherever
specified, decorative aluminium safety grills of approved design shall be provided
which shall be screwed to the main frame.
(B) Steel Doors
Steel doors shall consist of :
(a) Pressed steel door frame of overall 125x 65mm size conforming to IS :
4351 and made of 16 SWG pressed steel sheet bent to required shape
using bending machine to form solid/ true mitred edges/ corners, stiffened
with 50 x 5mm thick MS flat spacers welded to the frame facing the wall/
column @ 600mm c/c maximum vertical spacing. The frame shall be fixed
to the masonry by means of 300 x 25 x 6 mm thick MS hold fast welded to
the spacer and grouted with M-15 concrete in minimum 350 x 100 x 100
mm sized hole in the masonry. In case of concrete, the frames shall be
fixed by 96mm long, 12 mm dia metallic counter sunk type dash fasteners
through the frame & spacers. Provision for hinges, locking arrangement and
other hardware shall be provided in the frame by machine cutting of
required size cutouts in the frame and welding/ screwing to 3 mm thick MS
pad plates already welded over the cutout from behind. The frame shall be
thoroughly cleaned of rust, mill scale, dirt, oil etc. and then finished with 2 or
more coats of approved quality synthetic enamel paint of approved shade
over a priming coat of approved red oxide zinc chromate primer. The hollow
frame shall be packed with PCC to fill the cavity without gap.
(b) Pressed steel door shutter shall be made with 18 gauge steel sheets
formed by machine bending in the form of hollow box (overall 40mm thick)
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welded at meeting of the sheets with pad plate of 3mm thick MS flat all
along the perimeter. The shutter shall be braced with channel shaped
35mm wide horizontal stiffeners by folding 16 gauge MS sheets @ 500mm
c/c fixed by flush riveting. 3mm thick MS pad plates shall be welded inside
at required locations for fixing of hardware. The cavity inside shall be
packed with rigid PU foam/ phenolic foam or glass wool insulation to fill into
the box cavity without gap.
For double shutters, an MS angle (25x 45x 3mm thick) shall be welded to one of
the shutter providing a minimum 25mm wide rebate for the other shutter at the
meeting point.
The shutters shall be fixed to the door frame by means of heavy duty MS butt
hinges of 150mm size conforming to IS : 1341 @ 500mm c/c maximum.
Each door shutter shall have following accessories.
1. Spring loaded pressure die cast zinc alloy door stopper.
2. Heavy duty, MS aldrop 400mm long for double shutter & 300mm long for
single shutter.
3. 12mm dia, 300mm long pressure die cast zinc alloy handles on both sides.
4. 12mm dia, 250mm long MS tower bolt at top and 12 mm dia 150mm long at
bottom.
5. 3- way spring loaded locking & latching system.
6. 150mm x 300mm Vision panel with 16 gauge MS beading bent to ‘Z’ shape
& 4mm thick plain glass conforming to IS : 2853.
The entire shutter including all accessories, fittings & fixtures etc. shall be painted
with 2 or more coats of approved quality synthetic enamel paint of approved shade
over a coat of approved quality red oxide zinc chromate primer.
(C) Wooden Flush Doors
Flush doors shall consist of:-
(a) Pressed steel door frame of overall 125x 65mm size conforming to IS :
4351 and made of 16 SWG pressed steel sheet bent to required shape
using bending machine to form solid/ true mitred edges/ corners, stiffened
with 50 x 5mm thick MS flat spacers welded to the frame facing the
wall/column @ 600mm c/c maximum vertical spacing. The frame shall be
fixed to the masonry by means of 300 x 25 x 6 mm thick MS hold fast
welded to the spacer and grouted with M-15 concrete in minimum 350 x 100
x 100 mm sized hole in the masonry. In case of concrete, the frames shall
be fixed by 96mm long, 12 mm dia metallic counter sunk type dash
fasteners through the frame & spacers. Provision for hinges, locking
arrangement and other hardware shall be provided in the frame by machine
cutting of required size cut outs in the frame and welding/ screwing to 3 mm
thick MS pad plates already welded over the cut out from behind. The frame
shall be thoroughly cleaned of rust, mill scale, dirt, oil etc. and then finished
with 2 or more coats of approved quality synthetic enamel paint of approved
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shade over a priming coat of approved red oxide zinc chromate primer).
The hollow frame shall be packed with PCC to fill the cavity without gap.
(b) Flush door shutters shall be factory made and overall 35mm thick consisting
of solid core block board bonded with phenol formaldehyde synthetic resin
conforming to IS : 848. The shutters shall be faced on both sides with 3 mm
thick commercial plywood finished with 1 mm thick laminate of approved
shade & make. 35 x 20mm second class Teakwood lipping shall be
provided all around the shutter by means of approved quality neoprene
based adhesive and nailing @ 300mm (maximum). Teakwood lipping shall
be French polished (lacquer finish) as per specifications. The shutters shall
be fixed to the frame by means of 125mm long MS butt hinges conforming
to IS: 1341 @ 600mm c/c maximum.
Teakwood used for lipping etc. shall be second class Indian teakwood (conforming
to IS : 4021) of good quality, well seasoned and free from defects such as cracks,
dead knots, sapwood etc. and shall be with no individual hard & sound knots more
than 15 Sq.cm in area and the aggregate area of such knots not exceeding 2% of
area of the piece. The wood shall be fairly closed grains having not less than 2
growth rings per Cm. Width in cross section.
Following hardware of approved quality and shade shall be provided in each

shutter:-
1. Heavy duty, overhead hydraulically operated door closer conforming to IS:

3564.
2. Anodised aluminium tower bolts as per IS : 204, 10mm dia 250mm long (at
top) and 150mm long (at bottom), one each for each shutter on either side.
3. Brass body 6 lever mortise lock as per IS : 2209 including pair of handles of
pressure die cast zinc alloy (satin finished )
4. 3mm thick plastic kick/push plate (150mm high at bottom for entire width &
200mm x 100mm at handle location).
5. Zinc alloy pressure die cast chromium plated spring loaded door stopper
with heavy duty rubber shoes.
6. 150mm x 300mm Vision panel with of 4mm thick plain glass conforming to
IS: 2853 fixed with second class Teakwood beading (not for toilet doors).
(D) Steel Windows and ventilators
Steel windows, ventilators shall in general conform to IS:1038 and IS:7452. Rolled
steel sections for the fabrication of steel windows, ventilators shall conform to
IS:7452. Glass panels for glazing purpose shall be 4mm thick (wt. 7.2 kg/ Sq.M)
The profile and type of windows, ventilators (glazed, partly glazed/ 1ouvred, side
hung/ top hung/ fixed shutter, composite) shall be as per approved drawings.
The frames shall be constructed of sections cut to size and mitred. Corners shall be
welded to form a fused welded joint. Process of welding shall be flash butt welding.
The welded joints shall be grinded to square and flat edges.
Where larger units are to be formed by coupling individual units, the mullions,
transoms shall be bedded in mastic to ensure weather tightness. Mastic shall be
applied liberally to the channels of the outside frame sections before assembly, and
the two units being coupled shall be drawn together tight with clamps, the mastic

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being squeezed out and cut off neatly when the units shall be screwed together
tight.
Where fixed glazing units are placed over openable units a push fit weather bar
shall be provided.
Before glazing, all opening parts shall be checked for their operational smoothness.
The frame shall be completely cleaned and bedding putty shall be placed in the
rebate before glazing. Glass then shall be cushioned into the bedding and shall be
fronted with front putty in a manner so as to enable the painting to be done upto the
sight line. The back putty oozing out over the glazing rebate shall be cut off square
and smoothed down.
For panels exceeding 600 x 300 mm in size, glass shall be secured by special
glazing clips inserted in holes already provided in the steel sections, before
applying the front putty.
For glazing of very large areas, rust proof steel beading with mitred corners shall
be provided with screws @ 10 cm. from each corner and @ 20 cm. apart from each
other. Putty shall be provided to the face of the bead in contact with glass, in
addition to back putty.
Side hung shutters shall be connected to the frame by means of friction hinges.
The handle for side hung shutters shall be of pressed brass mounted on a steel
handle plate welded to the opening shutter frame and shall not be removable easily
after glazing. The handle shall have a two point nose, which shall engage with a
brass striking plate on the fixed frame in a slightly open as well as in a fixed
position.
In case of fixing with masonry, holes for fixing the lugs/hold fasts shall be cut at
required locations. In case of concrete or stone, the frames shall be fixed by means
of dash fasteners. In case of masonry, the lugs shall be grouted in the holes with
cement concrete, M-15 Grade when fixing to steel work, mastic shall be applied to
the sill of the opening and the unit shall be placed on it with the jambs and head
buttered with mastic and the unit shall be fixed with special fixing dips or with nuts
and bolts.
All the steel surfaces shall be thoroughly cleaned free of rust, mill scale, dirt, oil etc.
by sand and shot blasting and then painted with 2 or more coats of approved
quality & shade synthetic enamel paint over a coat of approved quality red oxide
zinc chromate primer.
12mm M.S. square safety bars (welded to fixed frame horizontally @ 100mm c/c)
shall be provided wherever specified.
(E) Steel Rolling Shutter
MS rolling shutters shall conform to IS: 6248 and shall be constructed with
interlocking lath sections formed out of cold rolled 0.9mm thick, 80mm wide steel
strips for shutter width upto 3.5 M, or 1.25mm thick, 80mm wide steel strips for
shutter width beyond 3.5 M, jointless MS channel section of 3.15mm thickness for
guide, MS girders & bottom rail, shutter suspension stud with pully & cage, top
rolling springs, locking arrangement etc. all complete as per manufacturers
approved drawings. The entire shutter including all accessories shall be painted
with 2 or more coats of approved quality & shade synthetic enamel paint over a

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coat of approved quality red oxide zinc chromate primer. All the damaged surfaces
of wall, columns, plastering etc. shall be made good.
Rolling shutters shall be mechanically operated type, when the size of the shutter
exceeds 9 Sq. M and shall be complete with all accessories for mechanical
operation as per approved manufacturers design & drawings.
Wherever specified the Rolling shutters shall be electrically operated; complete

with all accessories, electrical motor, cabling etc. as per approved manufacturers
design and drawings
Wherever specified the Rolling shutters shall be grill type or partly grill & partly solid
type or fully solid type depending on ventilation requirement.
1.2.4 PLASTERING
(A) Plain Cement Plaster
Plain Cement plaster shall be provided in following thickness:
a. 12mm thick in 1:6 cement mortar for all plumb of the internal masonry walls
& RCC Columns coming in line (flush) with this side of wall.
b. 15mm thick in 1:6 cement mortar for rough side of internal masonry walls
RCC Columns coming in line (flush) with this side of wall.
c. The external plastering shall be with waterproof compound (cement mortar

mixed with approved acrylic waterproof compound @ 1 Kg. per 50 Kg. of
cement) 18mm thick cement plaster in 1:6 cement mortar for all external
surfaces as indicated.
d. 6mm thick in 1:4 cement mortar for all RCC ceiling, beam etc. However if
the undulation in ceiling is beyond 6mm thick plaster, extra thickness of
plaster shall be applied without any extra cost to give a smooth and fair
surface to the satisfaction of Engineer-In-Charge.
e. Sand face plaster wherever required as per architectural treatment.
The plastering work shall include preparation of background surface which shall
consist of cleaning of all dust, loose mortar droppings, traces of algae,
efflorescence or any other foreign matter by water or by brushing, roughening up of
smooth surfaces by wire brushing or hacking, trimming of projections whenever
necessary. The surface shall be washed off and well wetted before applying the
plaster.
For external plaster, the plastering shall be started from top floor and carried
downwards. Internal plastering shall start with ceiling. Plastering shall be applied
evenly in specified thickness. The entire surface shall be finished smooth by means
of trowel or wooden float.
All the brick/stone masonry and RCC joints shall be provided with 20 gauge
chicken wire mesh stretched tight and fixed with G.I. type nails before plastering.

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20mm x 10mm grooves (horizontal and vertical) shall be provided in perfect straight
line & plumb in plastering as per drawings and instructions of Engineer- In -
Charge.
Curing shall be started 24 hours after finishing the plaster. The plaster shall be kept
wet for a period of 7 days. During this period the plaster shall be suitably protected
from all damages at the contractor's expense by such means as approved by the
Engineer-in-charge. The date of execution of plastering shall be marked on the
plastering to ensure the proper duration of curing.
The plastering shall include all scaffolding, damage rectification etc. complete.
(B) Sand Face Plaster
Sand face plaster shall consist of 13mm thick 1:4 cement mortar (1 cement: 4
coarse sand by volume) under layer and top layer of 7mm thick 1:2 cement mortar
(1 cement: 2 coarse sand by volume)
Preparation of background surface, workmanship, curing etc. shall be same as

plain cement plaster.
The first layer shall be started from top floor and carried downwards. Before the
first layer hardens, surface of it shall be roughened up by edges of wooden tapers
and close dents shall be made on the surface. The subsequent layer shall be
applied over the first layer after the first layer has been allowed to set for 3-5 days
depending on weather conditions. The surface shall not be allowed to dry during
this period.
All the brick/stone masonry and RCC joints shall be provided with 20 gauge
chicken wire mesh stretched tight and fixed with G.I. (U) type nails before
plastering.
20mm x 10mm grooves (horizontal/ vertical) shall be provided in perfect straight

line & plumb in plastering as per drawings and instructions of Engineer- In -
Charge.
Curing shall be started 24 hours after finishing the plaster. The plaster shall be kept
wet for a period of 7 days. During this period the plaster shall be suitably protected
from all damages at the contractor's expense by such means as approved by the
Engineer-in-charge. The date of execution of plastering shall be marked on the
plastering to ensure the proper duration of curing.
The plastering shall include all scaffolding, damage rectification etc. complete.
1.2.5 ROOF TREATMENT/ WATERPROOF COATING
(A) APP Bituminous membrane Water proofing
Material:
The water proofing membrane shall have a non-woven polyester membrane coated
on both side with APP (Atactic polypropylene) modified bitumen. It shall have a
Black finish with a very thin polyethylene foil on both sides It shall be in rolls of
1x10m for continuous laying on large lengths. When installed, it shall form an
impervious, flexible blanket, which accepts normal structural movement without
breaking or cracking.
JOB SPECIFICATIONS
CAPTIVE POWER PLANT
Workmanship:
a) Preparation of surface:
The roof surface (or screed) shall be thoroughly cleaned with a wire brush and
all foreign matter etc. shall be removed. Well-defined cracks on the surfaces
shall be cut to a ‘V’ section, cleaned and filled up flush with a paste of filling
compound and cement in the ratio of 1:2. The finished surface shall be perfectly
dry and any dampness should be allowed to evaporate.
b) Laying:
The membrane shall be laid on the perfectly dry prepared surface by torching-
on method with a gas torch. All joints shall have an overlap of 75mm which
shall be torch sealed. The overlap shall be done in a manner, which does not
hinder water flow along the roof slope. The membrane shall be finished with
bituminous base aluminium paint.
The waterproofing shall be continued up to the parapet/wall for a minimum of
600mm over the finished roof surface. It shall be continued into rain water pipes
by at least 100mm.
c) Cement Screed:
Plain cement concrete (1:2:4) of 25mm min. thickness with 24 SWG chicken
wire mesh shall be laid to slope in panels not exceeding 6 m.sq. area per panel
over the roof slab. The joints between panels shall be raked out neatly (after
stipulated curing period) to a min. 6mm x 6mm V-groove and filled up with an
approved quality sealant compound. Drain outlet shall be provided for all
spouts/ rain water pipes by suitable rounding, filling and sloping of PCC. At the
junction of the roof and parapet or any other vertical surface, a fillet of 75mm
radius shall be formed in cement mortar (1 cement: 4 coarse sand).
The finished work shall be measured in M.Sq of area for the purpose of payment.
A guarantee of 10 years shall be provided by the manufacturer against the
performance of the finished waterproof coating.
1.2.6 WHITE/ COLOUR WASHING, PAINTING, POLISHING ETC.
Reference shall be made to the following Indian Standards for further information etc. not
covered in the specification. In case of conflict/ contradictions provisions of the
IS : 6278 : Code of practice for white washing and colour washing.

IS : 2395 : Code of practice for painting concrete, masonry and plaster surfaces.
IS : 712 : Specification for building limes.
IS : 55 : Specification for Ultramarine blue for paints.
IS : 63 : Specification for whiting for paint and putty.
IS : 5411: Specification for plastic Emulsion paint for interior use.
IS : 2338: Code of practice for finishing of wood, and wood based materials.
IS : 5410: Cement paint, colour as required.
IS : 384: Brushes, paints and varnishes, flat.
IS : 486: Brushes, sash, tool, for paints and varnishes.
IS : 110: Ready mixed paint, brushing, grey filler enamels for use over primers.
IS : 426: Paste filler for colour coats.
IS : 345: Wood filler, transparent liquid.
JOB SPECIFICATIONS
CAPTIVE POWER PLANT
IS : 3585: Ready mixed paint, alum. brushing priming water resistant for woodwork
IS : 426: Paste filler for colour coats.
IS : 106: Ready mixed paint, brushing, priming for enamels, for use on metals.
All materials required for the execution of painting work shall be obtained direct from
approved manufacturers and shall be brought to the site in makers drums, bags etc. with
seals unbroken.
In case of ready mixed paints, thinning if necessary, the brand of thinner shall be as per
recommendations of the manufacturer.
Paint shall be applied by brushing or spraying. Spray machine used may be of high
pressure type or low pressure depending on the nature and location of work. The paint
containers, when not used shall be kept close and free from air.
After the finishing of work, the adjacent surfaces not intended to be washed/
distempered/painted/polished, shall be thoroughly cleaned of all paint patches and shall be
finished in accordance with surface finishing of such surfaces.
(A) White/ Colour Washing
White washing in general shall conform to IS:6278. Scaffolding shall be erected for
white washing in such a way that no part of the scaffolding shall rest against the
surface to be white/ colour washed. The surface shall be thoroughly cleaned of all
dirt, dust, mortar dropping and other foreign matter before white wash is to be
applied. Surfaces already white/colour washed shall be broomed down to remove
all dust, dirt, loose scales of lime wash or other foreign matters.
All damaged portions of the surface plaster shall be removed to full depth of plaster
in rectangular patches and plastered again after raking the joints in masonry
properly. Such portions shall be wetted and allowed to dry before any operation. All
holes, cracks, patches etc. not exceeding 0.1 sq. m. in area shall be made good
with material similar to that of the surface. Surfaces affected by efflorescence,
moss, fungi, algae, lichen etc. shall be treated in accordance with IS: 2395.
The fat lime conforming to IS: 712 shall be slaked at site and shall be mixed and
stirred with about 5 litres of water for 1 kg. of unslaked lime to make thin cream.
This shall be allowed to stand for a period of 24 hours and then shall be screened
through a clean coarse cloth. 4 kg of gum dissolved in hot water shall be added to
each cubic metre of lime cream. Approved quality ultramarine blue (for white wash)
conforming to IS: 55 @ 3 gram per kg. of lime shall be added to the solution. The
whole solution shall be stirred thoroughly before use.
For colour washing sufficient quantity of colour wash enough for the complete job
shall be prepared in one operation to avoid any difference in colour. Mineral colours
of approved shade and quality not affected by lime shall be added to the white
wash solution in proportions as directed by Engineer-in-charge. Solid lumps etc. in
the colour powder shall be ground to fine powder, sieved and mixed evenly and
thoroughly to the white wash solution.
White/ colour wash shall be applied with "MOONJ" brush to the in minimum 3
number of coats. The operation for each coat shall consist of stroke of the brush
from the top to down wards, another from the down to upwards over the first stroke,
similarly one stroke horizontally from right and another stroke from the left. Each

JOB SPECIFICATIONS
CAPTIVE POWER PLANT
coat shall be allowed to dry before the next coat is applied. The white washing on
ceiling should be done prior to that on walls.
Surfaces of doors, windows, floors etc. shall be protected from being splashed
upon. Such surfaces shall be cleaned of white/ colour wash splashes.
(B) Oil Bound Distempering
The oil bound distempering work shall consist of:-

(a) Preparation of surface:-
The surface shall be thoroughly brushed free from dust, dirt, grease, mortar
droppings, other foreign matter and shall be made smooth by sand
papering. In case of distempering over existing distempered surface, the
existing distempering shall be scrapped by steel scrapers leaving a clean
surface. All nails shall be removed. Pitting in plaster shall be made good
with plaster of Paris mixed with distemper of colour to be used. The surface
then shall be rubbed down again with a fine grade sand paper and made
smooth. A coat of distemper shall be applied over the patches. The surface
shall be allowed to dry thoroughly. The surface affected by moss, fungus,
algae, efflorescence shall be treated in accordance with IS: 2395. Any
unevenness shall be made good by applying putty made of plaster of Paris
mixed with water including filling up the undulation and then sand papering
the same after it is dry. Scaffolding wherever required shall be erected in
such a way that no part of the scaffolding shall rest against the surface to
be painted.
(b) The primer coat:-
The primer coat shall be alkali resistant primer or distemper primer and
shall be of the same manufacture as oil bound distemper.
(c) Base preparation:-
After the Primer coat, the base preparation shall include applying two or
more coatings of oil based putty in paste form made from chalk powder
mixed with linseed oil, white zinc, varnish etc. as per manufacturers
recommendations. After each coat of putty, sandpapering of the surfaces
shall be done.
(d) Application of Distemper:-
After the base preparation coats have dried, the surface shall be lightly
sand papered and dusted off avoiding rubbing off of the primer coat. The
distemper shall conform to IS: 428 and shall be diluted with water or any
other prescribed thinner recommended by the manufacturer. Minimum two
coats of distemper shall be applied with brushes in horizontal strokes
followed by immediate vertical strokes, which together shall constitute one
coat. The subsequent coats shall be applied after at least 24 hours between
consecutive coats to permit proper drying of the preceding coat. The
finished surface shall be even and uniform without patches, brush marks
drops etc. Application of a coat in each room shall be finished in one
operation.14 cm double bristled distemper brushes shall be used. After
each days work brushes shall be thoroughly washed in hot water with soap
solution and hung down to dry.
JOB SPECIFICATIONS
CAPTIVE POWER PLANT
Surfaces of doors, windows, floors etc. shall be protected from being

splashed upon. Such surfaces shall be cleaned of distemper splashes.
(C) Plastic Emulsion Paint
The Plastic Emulsion paint work shall consist of:-

(a) Preparation of surface:-
The surface shall be thoroughly brushed free from dust, dirt, grease, mortar
droppings, other foreign matter and shall be made smooth by sand
papering. In case of plastic emulsion paintwork over existing distempered/
emulsioned surface, the existing distempering/ emulsion shall be scraped
by steel scrapers leaving a clean surface. All nails shall be removed. Pitting
in plaster shall be made good with plaster of Paris mixed with plastic
emulsion of colour to be used. The surface then shall be rubbed down again
with a fine grade sand paper and made smooth. A coat of plastic emulsion
shall be applied over the patches. The surface shall be allowed to dry
thoroughly. The surface affected by moss, fungus, algae, efflorescence
shall be treated in accordance with IS: 2395. Any unevenness shall be
made good by applying putty made of plaster of Paris mixed with water
including filling up the undulation and then sand papering the same after it
is dry. Scaffolding wherever required shall be erected in such a way that no
part of the scaffolding shall rest against the surface to be painted.
(b) The primer coat:-
The primer coat shall be alkali resistant primer or emulsion primer and shall
be of the same manufacture as plastic emulsion paint.
(c) Base preparation:-
After the Primer coat, the base preparation shall include applying two or
more coatings of oil based putty in paste form made from chalk powder
mixed with linseed oil, white zinc, varnish etc. as per manufacturers
recommendations. After each coat of putty, sandpapering of the surfaces
shall be done.
(d) Application of Plastic Emulsion Paint :-
After the base preparation coats have dried, the surface shall be lightly
sand papered and dusted off avoiding rubbing off of the primer coat. The
plastic emulsion paint shall conform to IS: 5411 (Part- I) and shall be diluted
prescribed thinner recommended by the manufacturer. Minimum two coats
of plastic emulsion paint shall be applied with brushes in horizontal strokes
followed by immediate vertical strokes, which together shall constitute one
coat. The subsequent coats shall be applied after at least 24 hours between
consecutive coats to permit proper drying of the preceding coat. The
finished surface shall be even and uniform without patches, brush marks
drops etc. Application of a coat in each room shall be finished in one
operation. 14 cm double bristled distemper brushes shall be used. After
each days work brushes shall be thoroughly washed in hot water with soap
solution and hung down to dry.

JOB SPECIFICATIONS
CAPTIVE POWER PLANT
Surfaces of doors, windows, floors etc. shall be protected from being

splashed upon. Such surfaces shall be cleaned of splashes.
(D) Plaster Of Paris Punning
Plaster of Paris punning shall be applied over roughened plastered surfaces.

Superior quality Plaster of Paris of approved make shall be mixed with water to
obtain paste like consistency and shall be applied on walls, ceiling etc. in sufficient
thickness to give an absolutely smooth, plumb and straight surfaces.
(E) Waterproof Cement Paint
Scaffolding shall be erected for white washing. The surface shall be thoroughly
cleaned of all dirt, dust, mortar dropping and other foreign matter before white wash
is to be applied. Surfaces already white/colour washed shall be broomed down to
remove all dust, dirt, loose scales of lime wash or other foreign matters.
Scaffolding, Preparation of Surface shall be same as white wash. The surface so

prepared shall be thoroughly wetted with clean water before the paint is applied.
Waterproof cement paint of approved make shall be mixed with water and stirred to
obtain a thick paste, which shall then be diluted to brushable consistency. The
proportion of mixture shall be as per manufacturer's recommendation. The paint
shall be mixed in such quantity, which can be used up within an hour of mixing to
avoid setting and thickening of the paint.
The surface shall be treated with minimum two coats of waterproof cement paint.
No less than 24 hours shall be allowed between two coats and subsequent coats
shall be applied only after the preceding coat has become hard to resist marking by
subsequent brushing. The finished surface shall be even and uniform in shade
without patches, brush marks, paint drops etc. Cement paints shall be applied with
a brush with relatively short stiff hog or fibre bristles.
Curing shall be started after the paint has hardened. Curing shall be done by
sprinkling with water two or three times a day. This shall be done between coats
and for at least two days following the final coat.
(F) Painting of Steel and Other Metal Surface
Reference shall be made to IS :2524 and IS:1447.
The surface, before painting, shall be cleaned of all rust, scale, dirt and other
foreign matter with wire brushes, steel wool, scrappers, sand paper etc. The
surface shall then be wiped finally with mineral turpentine, which shall then be
removed of grease etc. The surface then shall be allowed to dry.
In case of GI surface, surface so prepared shall be treated with Mordant solution (5

litre for about 100 sq.m.) by rubbing the solution generously with brush. After about
half an hour, the surface if required shall be retouched and washed down
thoroughly with clean cold water and allowed to dry.
Approved quality primer and paint in specified numbers of coats shall be applied as
per manufacturer's recommendations either by brushing or spraying. Each
subsequent coat shall be applied only after the preceding coat has dried.
JOB SPECIFICATIONS
CAPTIVE POWER PLANT
1.2.7 ROOFING
Reference shall be made to the following Indian Standards for information etc. not covered
in the specification. In case of any conflict/contradiction, provisions of specification shall
override.
IS 1230: Cast iron rainwater pipes & fittings.
The roof slope shall be as specified and in general not pitched flatter then 1:5. The normal
pitch if not specified shall be 1:2. Materials shall be supplied by approved manufacturer.
The items supplied shall be free from cracks, chipped edges or corners or other damages.
Storage and safety precautions shall be taken to avoid damage to the accessories.
A) C.I. Rain Water Pipes
C.I. rain water pipes shall be 100mm dia or 150mm dia (as specified/ indicated in
drawings); shall conform to I.S:1729. The pipes shall be provided complete with
necessary clamps, connections, bends, Tees, other accessories (as per approved
manufacturers specifications) and shall be jointed with spurn yarn and cement
mortar 1:2 (1 cement: 2 fine sand by volume). Embedded rain water pipes shall be
suitably embedded/ encased in masonry/ cement concrete (M-15) with nominal
reinforcement.
(B) Precoated Galvanised Steel Sheet Roofing/ Cladding
The base metal of the roofing shall be Cold rolled in high tensile Galvalume Steel of
550 MPA yield stress conforming to IS:513, IS:14246 and ASTM A446 Grade E.
The substrate shall have hot dip metallic coating of aluminium- zinc alloy (150
grams per sq. mtr. total on both sides, coating class AZ150 as per per ASTM
A792). The bottom unexposed surface shall then be coated with alkyd backer of
minimum 7 microns. Top exposed surface shall have SMP (Silicon Modified
Polyester) paint system Minimum 20 microns top coat applied over 5 microns
primer. The top coat shall be in specified colour.
The precoated galvalume steel sheets shall meet the following performance
standards
Pencil Hardness: F minimum
Formability: 2-3 t
Specular Glass (60 deg): 20- 35%
(ASTM D523)
Impact Resistance: Greater than 10J
Salt spray test: 750 hours
QUV-Wealterometer Test: 1000 light hours
Humidity Test: 1000 hours
Temperature Resistance: 100 C
Fire performance: Class I
The SMP coated steel sheet in standard colour under normal well washed
conditions of exposure shall not show any cracking, flaking or peeling of paint film
for at least 10 years. Colour change during service, determined according to ASTM
D2244 should not exceed 5E hunter lab units on light colours.

JOB SPECIFICATIONS
CAPTIVE POWER PLANT
The profiles shall have a depth of not less than 28mm and pitch of 190mm. Overall
sheet thickness shall be minimum 0.50mm. Minimum weight of the sheet shall be
5.2 kg/ Sq.M
All roofing accessories like ridge, gutters, north light curves etc. shall be fabricated
out of precoated sheet of same thickness (as for roof sheeting) and as per
manufacturer’s specifications. Metallic Fasteners and Fixing accessories shall be
corrosion proof (polyester polymer coated). Self drilling screws/ fasteners with
integral washers and EPDM seals, and nylon colour caps and joint sealants shall
be provided for fixing of sheets as per approved manufacturer’s specifications. Non
metallic fasteners shall be of neoprene. Sealants shall be natural cure type and of
cold setting variety.
Wind ties shall be of 40 mm x 6 mm flat iron section and other size as specified.
These shall be fixed at the two eaves end of the sheet. Fixing shall be done with
the same loose bolts which secure sheets to the purlins. Slot holes shall be cut in
the wind ties to allow for temperature variations. The wind ties shall be painted with
two or more coats of synthetic enamel paint of same shade as that of sheeting over
a coat of approved primer.
1.2.8 SANITARY FITTINGS AND FIXTURES
Reference shall be made to the following Indian Standards for any further information etc.
not covered in the specification. In case of any conflict/ contradiction provisions of
IS-2556: Specification for Vitreous Sanitary appliances (Vitreous-China, Part 1-15).

IS-774 : Specification for Flushing Cistern for Water Closets and Urinals.
IS-781: Specification for Cast copper alloy screw down bib taps and stop valves for water
services.
IS-2064: Code of Practice for Selection, Installation and Maintenance of Sanitary
appliances.
All glazed earthen ware shall be of approved make, colour and of one piece construction.
All metallic fixtures like taps, stop cocks, soap holders etc. shall be CP brass and approved
make. All wall fittings shall be fixed with nylon sleeve and CP brass screws and washers.
(A) Indian Type Water Closet
Squatting Pan shall be 550mm x 440mm Orissa Pan conforming to IS: 2556 Part-III
with integrated footrests. The closet shall be fixed in the floor with 150 mm thick
sand cushion and shall be connected with 100 mm dia CI `S' or `P' trap. The closet
shall also be fitted with 10 litres valve less syphonic type glazed earthenware
flushing cistern, conforming to IS: 774, and complete with all accessories like 15
mm dia. PVC inlet connection pipe 450mm long (with 15mm dia CP Brass stop
cock and brass union), PVC ball valves, C.P Brass handle, telescopic 32 mm dia
GI telescopic flushing pipe with union, 15 mm dia GI overflow pipe with mosquito
proof net and fixed with glazed earthenware cover.
The cistern shall be fixed on MS brackets at a minimum height of 2150 mm from

top of pan. All exposed metallic surface shall be painted with two coats of synthetic
enamel paint of approved quality over a coat of red oxide zinc chromate primer
(primer is not required for GI pipes).

JOB SPECIFICATIONS
CAPTIVE POWER PLANT
One number heavy grade approved quality CP Brass bib cock conforming to IS:
781 (with necessary connections) shall be provided with each WC.
The work shall include providing and fixing water-closet and flushing cistern with all
accessories, breaking wall and floors and making good the same, all inlet and
outlet connections of cistern and water closet, finishing of solder joints, painting and
testing of all connections etc. complete.
(B) Wash Down (European) Type Water Closet
Wash down water closet shall be of pattern-1 conforming to IS:2556 Part-II. Water
Closet shall be of one piece construction, double trap syphonic type. This shall be
fixed with plastic seat and cover as per IS:2548 of approved make and colour, fixed
with CP brass hinges and rubber buffers and an integral 100 mm dia 'S' or 'P' trap
with antisyphonage vent horn.
A low level earthenware cistern conforming to IS:774 of about 10 litres capacity,

with 15mm dia PVC inlet pipe (with 15mm dia CP Brass stop cock) and brass union
with wiped solder joint, internal overflow arrangement, 40 mm dia CP brass flushing
pipe. CI or MS supporting brackets shall be fixed with the water closet. The closet
shall be fixed firmly in the floor with matching cement mortar. All exposed metallic
surfaces shall be painted with two coats of synthetic enamel paint of approved
quality over a coat of red oxide zinc chromate primer. The clearance between top
of pan and bottom of cistern shall not exceed 300 mm.
One number heavy grade approved quality CP Brass bib cock conforming to IS:
781 (with necessary connections); one number approved quality CP Brass Toilet
paper holder (fixed to wall with wooden cleats, CP Brass screws) shall be provided
with each WC.
The work shall include providing and fixing of all fittings, breaking floors and wall,
making good the same, making inlet and outlet connection to the cistern and the
closet, testing of joints, painting the exposed metallic surface with two coats of
synthetic enamel paint over a coat of primer etc. complete.
(C) Urinals
Half stall type urinal shall be of size 610mm x 400mm x 380mm and conforming to
IS:2556 Part VI. Urinals shall be of single piece construction with integral flushing
box rim. These shall be mounted on walls. The flushing inlet pipe shall be of CP
brass 15 mm dia and waste pipe 32 mm dia GI, 750 mm long shall be embedded in
wall. Necessary unions and CP bottle trap shall be provided in the waste line.
Rawl plugs with CP brass screws shall be used for fixing the urinal. Fixing shall
ensure that no liquid is left over in the pan after flushing. Unless otherwise
indicated height above finished floors shall be 600 mm.
Urinals shall be connected to glazed earthenware automatic flushing glazed

earthenware cisterns either individually, or in groups. Where individually connected
to flushing cistern, the cistern capacity shall be 5 litres. For two urinals, one cistern
of 10 litres capacity and for three urinals, one cistern of 15 litres, capacity shall be
provided.
Cistern inlet shall be 15 mm dia PVC pipe with brass union. Outlet pipe from cistern
shall be 25mm CP brass main, with 15 mm CP distributor pipe of sufficient lengths
JOB SPECIFICATIONS
CAPTIVE POWER PLANT
to reach each bowl. Where individual cisterns are provided the outlet shall be of 15
mm CP brass.
The work shall include urinals inlet and outlet pipes, flushing cistern, breaking and
making good the walls and flooring, making inlet and outlet connections including
all related G.I. piping work (embedded in wall), painting exposed brackets and
exposed metallic parts with two coats of synthetic enamel paint of approved quality
over a coat of red oxide zinc chromate primer etc. all complete.
All The Urinals shall be separated by Marble partitions (of minimum 19mm thick
White Makrana marble slabs; each partition in one piece) of minimum size 1000mm
x 600mm. These partitions shall be inserted upto 100mm depth in the wall and
fixed with cement mortar 1:3 (1 cement: 3 coarse sand by volume) and suitable
sized M.S. Channel (embedded in wall with grouting) at bottom. The M.S. Channel
at bottom shall be finished with two coats of synthetic enamel paint of approved
quality over a coat of red oxide zinc chromate primer.
(D) Wash Basins
This shall be flat back wash basin (with require number of tap holes and
conforming to IS: 2556 Part-IV) with anti splash rims on three sides, of size 550mm
x 400mm size. Wash basins shall be of one piece construction including a
combined overflow having an area of not less than 5 Sq. cm. shall be provided in
the front or back of the bowl and it shall be so designed as to facilitate cleaning of
the overflow. This shall be fitted on CI or MS brackets. Brackets shall conform to
IS: 775. The brackets shall be given two coats of synthetic enamel paint or
aluminium paint, over a coat of approved primer. Each wash basin shall be
provided with 15mm dia CP brass pillar cock of approved make, rubber plug with
CP brass chain, 32mm CP Waste fitting of standard pattern with 32mm dia G.I.
pipe, CP Brass bottle trap, CP Brass 15mm dia stop cock etc. complete with all
related accessories, fittings and fixtures. The wall side shall be fixed well flushed
with the plaster or wall and the joint if any, shall be properly stopped with an
elastomeric sealant. The top of rim of the wash basin shall be fixed at 800 mm
above finished floor level, unless otherwise specified.
The work shall include provision and fixing of wash basin with all accessories,
providing stop cocks and pillar cocks, breaking and making good walls, fixing and
making inlet and outlet connections for stop cock, pillar cock and waste pipe,
providing & fixing MS brackets painted with two coats of synthetic enamel paint of
approved quality over a coat of red oxide zinc chromate primer etc. complete.
Following fixtures of approved quality shall be provided for each Wash Basin.
1. Mirror : Round edged Mirror of 5.5mm thick (minimum size of

400mm x 550mm)plain glass with 6mm thick AC
sheet backing, beveled edged.
2. Glass Shelf : 600mm x 120mm x 4mm thick Glass shelf with CP

brass bracket & guard rails ; fixed on wall.
3. Towel Rail : Chromium plated brass towel rail of 20mm dia,

600mm length & 1.25mm thickness.
4. Liquid soap container :Chromium plated Liquid soap container.

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All the fixtures shall be fixed to the wall at identified locations with wooden cleats
and CP Brass screws including cutting walls, making good the same etc. complete.
(E) Glazed Chinaware Sink
This shall be white glazed vitreous china Lab sink/kitchen sink of 610mm x 450mm
x 250mm size conforming to IS : 2556, Part-V. It shall be fixed with approved
quality M.S./C.I. brackets conforming to IS : 775. One 15mm dia CP brass bibcock,
15mm dia PVC connection, C.P. brass chain with 40mm dia GI pipe connected to
floor trap with unions shall be provided. All exposed metallic surfaces shall be
painted with 2 coats of approved shade and quality synthetic enamel paint (ICI or
approved equivalent) over a priming coat of approved quality red oxide zinc
chromate. All necessary cutting of floor, walls, counter etc. shall be made and then
finished etc. all complete.
(F) Stainless Steel Sink
The stainless steel Kitchen/Laboratory sink shall be of approx. size 610mm x

450mm 200mm and made of min. 1mm thick stainless steel sheet of `Salem Steel'
or equivalent. It shall be supported on M.S. brackets conforming to IS: 775. One
15mm dia C.P brass long body bib cock (if fixed to wall) or swivel type pillar cock (if
fixed to counter) shall be provided. 15mm dia PVC/ G.I. connections to floor trap
with unions shall be provided. All exposed metallic surfaces shall be painted with
min. 2 coats of synthetic enamel paint of approved make and shade over a coat of
red oxide zinc chromate primer. All necessary cutting of floor, walls, counter etc.
shall be made and then finished etc. all complete.
1.2.9 FALSE CEILING, FALSE FLOORING. UNDERDECK INSULATION ETC.
A) Aluminium Lineal False Ceiling
Aluminium lineal false ceiling shall consist of:-
(a) Panel Carriers:-
These shall be roll- formed out of coated steel/ 0.95mm thick aluminium alloy;
32mm wide and 39mm deep with cut-outs to hold panels in a module of 90mm/
100mm; all complete as per manufacturer’s standard details and specifications.
When two or more carriers are to be joined, they shall be joined together by means
of carrier splices which will clip on to holes in the sides of the carriers and hold
them firmly in place while maintaining the required module. The carriers shall be
suspended from roof by 4mm dia. galvanised steel wire rod hangers, with height
adjustment springs of stainless steel. Hangers shall be fixed to roof by “J” hooks
and nylon inserts. Edge profiles shall be “L” shaped roll- formed out of 0.6mm
aluminium alloy with coating.
(b) Panels:-
Panels shall be 84mm wide, 16mm deep, roll formed out of 0.5mm aluminium alloy
5050 or 3005. The aluminium panels shall be chromatised and stove enamelled
(coil coated) on both sides in approved shade. Panels shall be factory cut in
lengths upto 5 metres to suit site dimensions. As per air- conditioning requirements,
JOB SPECIFICATIONS
CAPTIVE POWER PLANT
for return air, (wherever required) perforated panels shall be used, which shall have
2mm dia holes at 5mm centre to centre staggered in uniform pattern and
symmetrically located in the middle of the panel face.
The ceiling shall be erected in continuous manner as per approved manufacturer’s

recommendations, specifications etc. The false ceiling shall have perfect levels,
linearity etc. as required. Necessary cut outs for Electrical, AC and other fixtures
shall be provided as per drawing and in co- ordination with relevant construction
activities.
(B) Cavity (False) Flooring (with Particle Board)
The False flooring system shall consist of
(a) Pedestal base plate made of galvanised Mild steel and shall be of 100 mm
x 100mm size and 8mm thick.
(b) Pedestal stud 30 mm dia made of galvanised mild steel seamless pipe and
having threads at top and bottom for attaching the top head attachment and
fixing to base plate.
(c) Top head attachments made of pressure die cast aluminium alloy of shape
and thickness as per drawing; and shall be provided with check nuts at
bottom portion for attaching the top head threads in the stud allowing for
adjustment upto 25mm up & down.
(d) Channel stringers made of galvanised, machine cut, cold rolled mild steel
channels of size 40 mm x 40 mm and 3.15 mm thickness.
(e) Floor panels of size 610 mm x 610 mm in general and of 35 mm thickness;
made of unveneered, 3 layer flat pressed, teakwood particle board
(conforming to IS :3087 bonded with BWP type phenol formaldehyde
synthetic resin conforming IS: 848 and categorised as class-I for `Surfaces
of very low flame spread' as per IS-1642); finished on the underneath side
with 0.05mm thick Aluminium foil turned up and extended by minimum
12mm along the perimeter; finished on top with 2mm thick high pressure
laminate and along four sides with hard PVC lipping as per drawing. 12mm
x 12mm x 75mm long, 2mm thick Aluminium channel cleats shall be
provided on middle of four sides of the panels for lateral stability.
False flooring pattern shall be as per approved drawing. Pedestal base plates
shall be fixed to the base floor by 6mm dia, 40mm long dash fasteners as per
the grid.
The pedestal stud locations shall ensure the grid work as per flooring pattern
which in general shall be of 610 mm x 610 mm dimension. The length of the
pedestal studs shall be such that clear cavity between false flooring and base
flooring is of desired depth.
The top head attachments shall be inserted into the studs and shall be adjusted
to obtain proper level of the finished floor panels by means of the adjustment
nuts.
Stringer channels then shall be fitted onto the top heads in position to form the
supporting grid work for the floor panels checking the level once again by
adjusting the nut position if necessary. Now the check nut shall be finally
tightened to secure the final level. Floor panels as specified shall be placed
over the stringer channels.

JOB SPECIFICATIONS
CAPTIVE POWER PLANT
Each floor panel shall be marked with positional numbering on the underneath.
The finished floor panels shall be perfectly leveled, aligned without any gaps in
between the panels.
Each individual panel shall be removable maintenance purpose.
Necessary cut-outs shall be made in the panels for cable routing, control panel
fixation etc. as per drawing.
Necessary ramps, slopes, steps etc. shall be also provided for as per drawing.
Around a control panel/ rack, the residual space left out shall be filled up with
cut panels of uniform size as required to fully close the gap between the
adjacent full panel and the control panel base channel. In this case the part
floor panel shall extend upto the full width of the base channel and the cut size
shall be determined accordingly. An additional row of jack pedestals shall be
provided along the cut out on which the edge of the floor panel shall rest and
over which the base channel of control panel shall be placed. It shall not
directly rest on the jack head pedestal or grid channels.
The cavity between false flooring and base floor shall be properly cleaned and
made dust free. The floor shall be finally coated with polyurethane based
coating
The finished false flooring shall be able to serve for a distributed load of 1250
kg/Sq.M.
(C) Underdeck Insulation
a) Phenolic Foam Underdeck Insulation:-
Phenolic Foam Underdeck insulation shall be of rigid slab of 25mm

thickness and approx. 1000mm x 500mm size as specified and shall
conform to IS: 13204. It shall have density of 32 kg /Cu. Mtr. and K Value of
0.034 w/mk at 53 deg. mean temperature. The insulation shall be classified
as ` Non Combustible ' as per BS 476, part 5 and >Class I= for surface
spread of flame as per BS 476 ,part 7. It shall be prelaminated on both
sides with kraft paper.
The entire soffit of slab and beams shall be thoroughly cleaned. Bituminous
primer or zinc chromate primer shall be applied evenly @ 0.5 kg/m2 over the
entire surface. Hot bitumen or CPRX adhesive shall then be applied on the
insulation panel @ 1.5 kg/Sq.M. The panels shall be pressed in position
and further secured by dash fasteners.
The underdeck insulation shall be fixed only after all fixtures like hooks,
clamps, cleats etc. for light fixtures, ducts etc. have been fixed in the ceiling.
b) Polyisocyanurate Foam Underdeck Insulation
Polyisocyanurate foam (PIR) shall be rigid slabs of size 1000 x 1500mm

and thickness of 30mm conforming to IS:12436 having density not less than
32 kg./ Cu. M., thermal conductivity (K- value) not more than 0.023 w/mk
measured at 10 deg. C. The slabs shall be covered on one side with glass
fibre tissue/ Aluminium foil having 50mm overlap. The insulation shall be

JOB SPECIFICATIONS
CAPTIVE POWER PLANT
classified as >Non Combustible= as per BS 476, part 5 and >Class I= for

surface spread of flame as per BS 476, part 7.
First, holes in R.C.C. slab/ beam shall be drilled and nylon rawl plugs of size
8 x 25mm shall be inserted (5 nos. for each slab- One each at 4 corners
and one at center). Entire R.C.C surface shall be thoroughly cleaned of all
dust, dirt and loose particles by wire brushing. Then a coat of bituminous
primer @ 0.5 Litres/ Sq.M. shall be applied to bare R.C.C.surface and
allowed it to dry. After the primer has dried, hot blow grade bitumen of 85/25
grade or cold adhesive CPRX shall be applied on R.C.C.surface and to the
two surface of each PIR panel and shall be pressed in position while the
bitumen is still tacky. The PIR panels shall be secured in position with the
help of G.I. screws (No. 8 x 75mm long) fixed into rawl plugs and G.I
washers 25mm dia. Facing side of the panels shall be the one covered with
fibre tissue/ Aluminium foil. The overlaps shall be covered with approved
quality sealing compound (MAS-94 or equivalent). Chicken wire mesh 24G
x 19mm shall then be fixed to G.I screws and tightened with lacing wire.
The underdeck insulation shall be fixed only after all fixtures like hooks,
clamps, cleats etc. for light fixtures, ducts etc. have been fixed in the ceiling.
1.2.10. MISCLLENEOUS ITEMS
(A) Plinth Protection (Without Drain)
The plinth protection (all round the buildings- without drain) shall consist of a layer
(150mm thick) of compacted sand and over that 100mm thick M-15 grade concrete
top layer laid to slope. The top concrete layer shall be trowel finished, cured etc.
complete. The work also includes carrying out the necessary excavation, disposal
of surplus earthwork etc.
(B) Cinder Filling
All the sunk R.C.C slabs shall be provided with cinder filling comprising of:-
(a) Plastering the R.C.C. slab top, sides etc. with 18mm thick cement plaster
1:6 (1 cement: 6 sand by volume) mixed with approved waterproof
compound @3% of cement by weight and finishing with a floating coat of
neat cement slurry @ 2.75 kg. per sq. Mtr, finishing, curing etc. The work
includes preparation of base surface as described in Plastering item.
(b) Filling with Cinder concrete 1:10 (1 cement : 10 cinder of 12mm and down
grade) including consolidating, finishing, curing etc. complete.
(C) Sealing of Expansion Joints
All expansion joints (25mm wide) of the building shall be sealed with premium
grade Silicon sealant (SILPRUF of GE Silicons or equivalent) consisting of the
following:-
(a) The surfaces over which it is to be applied shall be totally dried and cleaned
of all dirt, oils, mortar droppings, all loose material etc. by vigorous wire
brushing and wherever necessary by grinding and blast cleaning (sand or
water).

JOB SPECIFICATIONS
CAPTIVE POWER PLANT
(b) A backup material or joint filler tapes (as per approved manufacturers
specifications) shall be fixed in the expansion joint.
(c) A coat of primer as per approved manufacturers specifications (specially

developed for use with Silicon sealant material) shall then be applied over
the surface.
(d) Silicon sealant shall be applied by means of cartridge- type caul gun, either
hand or air pressure activated. The sealant shall be applied in a continuous
operation, horizontally in one direction and vertically from bottom to top of
joint opening. The sealant shall be applied in excess so that a positive
pressure adequate to properly fill and seal the joint is created. The sealant
shall be struck with light pressure to spread the material against the back up
material and the joint surfaces properly. The sealant shall be tooled to
slightly conclave surface. As the work progresses, the excessive sealant
shall be removed. The masking tape shall be removed immediately after
tooling. The sealant shall be cured as per approved manufacturers
recommendations.
Entire work shall be carried out as per as per approved manufacturers

specifications and recommendations.

STANDARD SPECIFICATIONS SECTION: E-1
GENERAL CIVIL
CAPTIVE POWER PLANT
E STANDARD SPECIFICATIONS
E-1 GENERAL CIVIL
CAPTIVE POWER PLANT
JOB NO. : 6782
A 28-11-2006 ISSUED WITH BIDS

Date Purpose
No by by by

GENERAL CIVIL
CAPTIVE POWER PLANT
STANDARD SPECIFICATIONS
(GENERAL CIVIL)
Revision Sheets/
S. No. Description Specification no. pages
no.
1 Standard Specification for Site Grading & Rock 6-65-0017 3 12
Cutting for Site Grading
2 Standard specification for Roads & Flexible 6-65-0018 5 9
Pavement (upto WBM layer)
3 Standard Specification for Concrete Pavements 6-65-1019 2 10
4 Standard Specification for Flexible Pavement with 6-65-0020 1 8
Bitumen Premix Carpet
5 Standard Specification for RCC Pipe Culvert & 6-65-0021 2 6
ERC / IRC crossing etc.
6 Standard specification for U/G and A/G GI 6-65-0027 2 4
pipeline system (water services)
7 Standard specification for fabrication and laying of 6-65-0030 2 11
piping
8 Standard specification for misc. civil and structural 6-65-0035 1 6
works for U/G piping & other civil works
9 Standard specification for U/G CI piping system 6-65-0036 2 8
10 Standard specification for under ground sewer 6-65-0042 2 7
system – pre cast RCC pipes
11 Specification for under ground sewer system – 6-65-0044 1 6
HDPE pipes
12 Standard specification for plumbing & building 6-65-0053 1 10
drainage
13 Standard specification for acid / alkali proof lining 6-65-0061 1 4
with bitumen mastic
14 Standard specification for acid proof tile lining 6-65-0062 2 5
15 Standard specification for cooling water treatment 6-65-0071 1 8
plant
16 Standard Specification for Portable CO2 Type 6-66-0003 1 3
Extinguisher
17 Standard Specification for Portable DCP Type 6-66-0006 1 4
Extinguisher
18 Standard Specification for rubber lined or 6-66-0011 1 3
rubberized fabric lined woven Jacketed Hose
19 Standard Specification for Stand Post Type Fire 6-66-0012 2 5
Hydrant
20 Standard Specification for Foam Branch Pipe 6-66-0016 1 4
21 Standard Specification for First Aid Hose Reel 6-66-0018 2 5
22 Standard Specification for Stand Post Type water 6-66-0021 2 5
Monitor
23 Standard Specification for Water cum Foam 6-66-0027 2 6
Monitor
GENERAL CIVIL
CAPTIVE POWER PLANT
24 Standard Specification for Landing Valve 6-66-0035 2 4

25 Standard specification for safety shower and eye 6-66-0038 2 5
wash
26 Standard Specification for Tower Mounted Foam / 6-66-0042 1 5
Water Monitor
27 Standard Specification for Water Spray Nozzle 6-66-0046 1 5
Assembly
28 Standard Specification for Hose Cabinet 6-66-0047 1 4
29 Standard Specification for Deluge Valve 6-66-0048 1 8
30 Standard Specification for 50 Kg and 75 Kg 6-66-0061 1 4
Capacity DCP Extinguisher
31 Specification for corrosion protection tape coating 6-79-0011 0 14
of underground steel pipelines (Refer subsection
C-3.12)
ADDENDUM TO STANDARD SPECIFICATIONS (GENERAL CIVIL):
Following Addendum to General Civil standard specifications is enclosed herewith. The

standard specification shall be read in conjunction with the following addendums.
i. For concrete works, all specification shall be modified to the extent as given in
IS456:2000.
ii. Brick-work used for General Civil work and minimum brick class designation
shall be as specified in Structural document.
iii. For reinforcement, all specification shall be modified to the extent as given
below:
High strength deformed (HSD) / TMT steel bars of minimum grade Fe 415,
conforming to IS:1786 shall be used.
iv. EIL STD. Specification no. 6-65-0017: The degree of earth compaction shall be
modified to the following extent: Site Grading/ Micro-grading: The earth shall be
compacted to 95% of Standard Proctor Dry Density as per IS: 2720 Part VII.
v. EIL STD. SPECIFICATION NO. 6-65-0035 Rev. 0

(Std. specification for miscellaneous civil & structural work for U/G piping and
other civil works - for LSTK package)
Clause no. 9.0: Replace “1:3:6 grade cement concrete” by “M-20 grade plain
cement concrete suitable for severe exposure condition conforming to IS
456:2000”.
Replace “1:2:4 grade cement concrete “ by M30 grade plain cement concrete
suitable for severe exposure condition conforming to IS 456:2000”.
vi. EIL STD. SPECIFICATION NO. 6-65-0044 Rev. 0

(Std. specification for U/G sewer system-HDPE pipes for LSTK package)
Clause no. 5.1: First line and third line – Delete “1:5:10”. Add at the end of
fourth line:
”Plain Cement Concrete shall be of grade M20 suitable for severe exposure
condition conforming to IS 456:2000”
vii. SPECIFIC REQUIREMENTS TO STANDARD SPECIFICATIONS

All payment clauses shall be deleted for all standard specifications attached with
the bid document.

STRUCTURAL & ARCHITECTURE
CAPTIVE POWER PLANT
E STANDARD SPECIFICATIONS
E-2 STRUCTURAL & ARCHITECTURE
CAPTIVE POWER PLANT
JOB NO. : 6782

Date Purpose
No by by by

CAPTIVE POWER PLANT
STANDARD SPECIFICATIONS
(Structural & Architecture)
Revision Sheets/
S. No. Description Specification no. pages
no.
Standard Specification For Fire Proofing Of
1 6-68-0033 5 12
Steel Structures
2 Standard Specification For RCC & Steel
6-68-0053 1 27
Chimneys for Turnkey Packages
3 Standard Specification For Guniting 6-68-0055 2 9

ENGINEERING INSTALLATION SECTION: F-1
STANDARDS
GENERAL CIVIL
CAPTIVE POWER PLANT Page 1 of 4
PHASE-III REFINERY PROJECT, MRPL
F INSTALLATION STANDARDS
F-1 GENERAL CIVIL
CAPTIVE POWER PLANT
JOB NO. : 6782

Date Purpose
No by by by

STANDARDS
GENERAL CIVIL
STANDARDS
(GENERAL CIVIL)
Revision Sheets/
S. No. Description Standard no. no. pages
1 Abbreviations and Legends 7-65-0001 2 4
2 Cable Crossings Under Road (PVC Pipes) 7-65-0006 2 1
3 Pipe Sleeves Detail 7-65-0008 1 1
4 Road Curves & Crossings 7-65-0010 3 1
5 Pipe Culvert for Storm Water Drainage 7-65-0103 1 3
6 Box Culvert Type-I, II, III & IV 7-65-0104 2 1
7 Grating detail for catch basin (for both steel & 7-65-0206 2 1
galvanized material)
8 Valve Pit (RCC)Type-V 7-65-0207 1 1
9 Valve Pit (RCC)Type-VI 7-65-0208 1 1
10 Valve Pit (RCC)Type-VII 7-65-0209 1 1
11 Details of rungs for manhole, valve chamber, 7-65-0211 2 1
tank, etc.
12 Standard miscellaneous details for manholes. 7-65-0212 1 1
13 Conc. Bedding and encasement for pipes. 7-65-0213 2 1
14 Gully trap chamber 7-65-0214 3 1
15 Inspection chamber 7-65-0215 2 1
16 Vents for manholes. 7-65-0219 2 1
17 Valve pit type-I for dia. ≤ 1.5” 7-65-0220 3 1
18 Valve pit type-II for dia. 2” to 6” valve 7-65-0221 3 1
19 Chequered plate details 7-65-0224 0 1
(for masonry valve pit type-I, type-II, type-III &
type-IV)
20 Typical detail of bend pipe for manholes 7-65-0230 2 1
21 Manhole type-1 for depth 7-65-0251 3 1
≤ 1 M, (φ ≤ 300)
22 Manhole type-2 for depth 7-65-0252 3 1
≤ 2 M, (φ ≤ 500)
23 Manhole Type-6 7-65-0256 2 1
24 Manhole Type-7 7-65-0257 2 1
25 Manhole Type-8 7-65-0258 2 1
26 Manhole Type-9 7-65-0259 2 1
27 Manhole Type-10 7-65-0260 2 1
28 Manhole Type-11 7-65-0261 2 1
29 Manhole Type-12 7-65-0262 2 1
30 Manhole Type-13 7-65-0263 2 1
31 Manhole Type-14 7-65-0264 2 1
32 Unit drainage details (catch pit type-3) 7-65-0265 2 1
33 Unit drainage details (equipment drain 7-65-0266 2 1
funnels)

STANDARDS
GENERAL CIVIL
34 Unit drainage details (OWS manhole type-15) 7-65-0267 2 1

35 Unit drainage details (OWS manhole type-16) 7-65-0268 2 1
36 Unit drainage details (CBD & ABD header 7-65-0269 2 1
laying detail)
37 Unit drainage details (clean out for CBD 7-65-0270 2 1
header)
38 Unit drainage details (typical branch 7-65-0271 1 1
connection for CBD / OWS)
39 Unit Drainage Details (Rectangular Ditch 7-65-0272 2 1
details)
40 Unit drainage details (manhole combined with 7-65-0273 2 1
double valve pits)
41 Details of neutralization pit 7-65-0310 1 1
42 RCC pavement details 7-65-0404 2 1
43 Typical details of Acid/ Alkali Proof Lining 7-65-0412 1 1
44 Installation Details of Fire Hydrant, Water 7-65-0420 1 1
Monitor, Foam/ Water Monitor
45 Installation Details of Water Monitor 7-65-0421 0 1
ADDENDUM TO EIL STANDARDS (GENERAL CIVIL):
Following Addendum to General Civil standards is enclosed herewith. The standards shall be
read in conjunction with the following addendums.
Sl Std. No. Rev. Title Existing Revised Description

No No. Description
1 7-65-0103 1 Pipe Culvert for Storm PCC M10 PCC M15
Water Drainage
2 7-65-0104 2 Box Culvert Type-I, II, Lean conc. 1:5:10Lean conc. 1:5:10
III & IV PCC 1:4:8 PCC M15
RCC M20 RCC M30
3 7-65-0212 1 Std. Misc. Details for Precast cover
With Cover of 45mm,
Manholes thickness 70mm thickness of section
B-B shall be 120mm
4 7-65-0213 2 Concrete Bedding and PCC M10 PCC M15
Encasement of Pipes PCC M15 PCC M15
RCC M15 RCC M25
5 7-65-0251 3 Manhole type-1 Lean Con. 1:5:10 Lean Concrete 1:5:10
RCC M15 RCC M30
PCC M15 PCC M20
Cover to R/f Cover to R/f 45mm
Footing thickness Footing thickness 120
100
6 7-65-0252 3 Manhole type-2 Lean Con. 1:5:10 Lean Concrete 1:5:10
RCC M15 RCC M30
PCC M15 PCC M20
Cover to R/f Cover to R/f 45mm
7 7-65-0256/ 2 Manhole Type- Lean Con. 1:5:10 Lean Concrete 1:5:10
0258/ 0259/ 6/7/8/9/10/11/12/13/14 RCC M15 RCC M30
0260/ 0261/ Cover to R/f 45mm
STANDARDS
GENERAL CIVIL
0262/ 0263/ Puddle flange shall be

0264 provided for
connection between
pipe and manhole.
8 7-65-0265 2 Unit drainage details PCC 1:5:10 Lean Concrete 1:5:10
(catch pit type-3) RCC M15 RCC M30
Cover to R/f 45mm
9 7-65-0272 2 Unit Drainage Details PCC 1:5:10 Lean Concrete 1:5:10
(rectangular ditch RCC M15/20 RCC M25/ M30
details) Same as pavement Same as pavement
10 7-65-0273 2 Unit Drainage Details PCC 1:5:10 Lean Concrete 1:5:10
(manhole combined RCC M15 RCC M30
with double valve pit)
11 7-65-0310 1 Detail of neutralization Lean conc. 1:5:10 Lean Concrete 1:5:10
pit Conc. M15 RCC M30
12 7-65-0420 1 Installation Details of PCC 1:5:10 Lean Conc. 1:5:10
Fire Hydrant & PCC 1:2:4 (FOR PCC M20 (FOR
Monitors PLTF) PLTF)
13 7-65-0421 0 Installation Details of PCC 1:5:10 Lean Conc. 1:5:10
Water Monitor PCC 1:2:4 (FOR PCC M20 (FOR
PLTF) PLTF)
For reinforcement, all standards shall be modified to the extent as given below:
High strength deformed (HSD) / TMT steel bars of minimum grade Fe 415, conforming to IS: 1786
shall be used.
Brickwork used for General Civil work and minimum brick class designation shall be as specified in
Structural document.

STANDARDS
F INSTALLATION STANDARDS
F-2 STRUCTURAL & ARCHITECTURE
CAPTIVE POWER PLANT
JOB NO. : 6782

Date Purpose
No by by by

STANDARDS
STANDARDS
(Structural & Architecture)
Revision Sheets/
S. No. Description Standard no. no. pages
1 Pedestal for stair / ladder 7-67-0008 5 1
2 Handrail fixing to RCC structure 7-68-0061 4 1
3 Typical grating support 7-68-0202 4 1
4 Typical chequered plate supports 7-68-0203 4 1
5 Welded Column Splice (Unequal Joist
7-68-0207 2 2
Section)
6 Splicing Details For Rolled Sections 7-68-0208 3 7
7 Rigid Frame Details 7-68-0209 3 1
8 Crane Bracket Details 7-68-0210 3 2
9 Beam To Beam And Beam To Column
7-68-0211 3 1
Connection Details
10 M.S. Anchor Bolt Assembly 7-68-0417 4 7
11 Handrails. 7-68-0501 5 10
12 Steel stairs 7-68-0506 4 6
13 Details of steel ladder 7-68-0507 5 3
14 Steel ladder joint details 7-68-0509 4 4
15 Standard grating detail type - I to type – III 7-68-0561 3 6
16 Details Of Moment Connection For Boxed MC
7-68-0654 1 2
Column To Boxed MC Beam
17 Shear Connection – Welded Type Beam To
7-68-0689 0 4
Beam
18 Skirting Detail (With Brick Wall) 7-75-0002 3 1
19 Skirting Detail (With RCC Column) 7-75-0003 3 1
20 Dado Detail With Bk. Wall/ RCC Column 7-75-0004 3 1
21 Steel Door Single Shutter Air Tight 7-75-0008 3 1
22 Steel Door Double Shutter Air Tight 7-75-0009 3 1
23 Wooden Flush Door With Steel Frame 7-75-0011 3 1
24 Aluminium Glazing Details 7-75-0014 3 1
25 Glazed Aluminium Window 7-75-0015 3 1
26 Steel windows general specifications 7-75-0027 3 1
27 Steel windows use of sections 7-75-0028 3 1
28 Steel windows section details 7-75-0029 3 1
29 Steel windows with louvers 7-75-0031 3 1
30 Steel windows fittings and fixtures 7-75-0032 3 1
31 Pipe Handrail 7-75-0037 3 1
32 False Ceiling Details With Aluminium Grid 7-75-0041 3 1
33 Aluminium panel false ceiling (84C system) 7-75-0042 3 1
34 False Flooring Detail (Channel Type) 7-75-0047 3 1
35 False Flooring 7-75-0048 3 3

STANDARDS
36 Transformer Gate Details (Upto 6mtr.) 7-75-0051 3 1

37 Transformer Gate Det.(From 6m-12m) 7-75-0052 2 1
38 Orissa Pan W.C. Fixing Details 7-75-0060 3 1
39 European Type W.C. Fixing Details 7-75-0062 3 1
40 Urinals Fixing Details 7-75-0063 3 1
41 Wash Basin Fixing Details 7-75-0064 3 1
42 Roof Drainage & Water Proofing 7-75-0068 3 3
43 Steel Door (Pressed Steel) Single Shutter 7-75-0070 3 1
44 Steel Door (Pressed Steel) Double Shutter 7-75-0071 3 1

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TENDER SPECIFICATION

BHEL PSSR SCT 1367

Fabrication & Erection of Structural steel in GTG Hall,

PHASE III REFINERY PROJECT FOR MRPL-CPP,

BHARAT HEAVY ELECTRICALS LIMITED

Mangalore refinery and petrochemicals limited (MRPL), is setting up a

4.0 Key Features of Project Site

4.1 Project site : Mangalore, Karnataka.

4.2 Nearest town : Mangalore

Evening North west to South East.

4.12 Elevation above mean sea : Min – 5.5m

C-1 SCOPE OF WORK/ SUPPLY

C-1.3 GENERAL CIVIL

CAPTIVE POWER PLANT

PROJECT : PHASE-III REFINERY PROJECT

OWNER : MANGALORE REFINERY AND PETROCHEMICALS LTD

PMC : ENGINEERS INDIA LTD.

JOB NO. : 6782

MRPL COMMENTS INCORPORATED & ISSUED FOR

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

1.0 SCOPE OF WORK

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

2.0 DETAILED SCOPE OF WORK

2.1 SITE GRADING AND STORM WATER DRAINS

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

2.3 DRINKING WATER SYSTEM

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

2.7 FIRE PROOFING

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

2.12 HARD STAND

- Cooling water treatment plant consisting of side stream filters, antiscalant,

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

2.14.4 COOLING WATER SUMP AND PUMP HOUSE

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

2.14.6 COOLING WATER TREATMENT AND DOSING SYSTEM

The scope of work shall also include following

COUNTER FLOW TOWERS

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

3.0 DRAWINGS/ DOCUMENTS REQUIRED FROM CONTRACTOR

3.1 WITH OFFER

3.2 AFTER AWARD OF THE CONTRACT

5.1 OWNER’S SCOPE OF SUPPLY

5.2 CONTRACTOR’S SCOPE OF SUPPLY

- All items consumables/non consumables required to complete the job.

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

C-1 SCOPE OF WORK/ SUPPLY

C-1.4 STRUCTURAL & ARCHITECTURAL

CAPTIVE POWER PLANT

PROJECT : PHASE-III REFINERY PROJECT

OWNER : MANGALORE REFINERY AND PETROCHEMICALS

PMC : ENGINEERS INDIA LTD.

JOB NO. : 6782

REVISED AS / OWNER’S COMMENT & REISSUED FOR S.

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

SUB SECTION DESCRIPTION

1.0 SCOPE OF WORK

2.0 SCOPE OF SUPPLY

3.0 LIST OF ATTACHMENTS

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

1.0 SCOPE OF WORK

Design and construction/installation of all foundations (including installation,